RX290B PDF

SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Maintenance And Repair ..................................... 0B-2 Maintenance And Lubrication ............................... 0B-2 Normal Vehicle Use ............................................. 0B-2 Explanation Of Scheduled Maintenance Services ....................................... 0B-2 Owner Inspections And Services ......................... 0B-3 While Operating the Vehicle ................................. 0B-3 At Each Fuel Fill ................................................... 0B-3 At Least Twice a Month ....................................... 0B-3 At Least Monthly ................................................. 0B-3 At Least Twice a Year .......................................... 0B-3 Each Time The Oil is Changed ............................. 0B-4 At Least Annually ................................................ 0B-4 Standard Bolts Specifications .............................. 0B-5 Basic Specification ............................................... 0B-6 Dimension ........................................................... 0B-6 Specifications ...................................................... 0B-7 Recommended Fluids And Lubricants .................. 0B-9 Vehicle Identification Number System .............. 0B-10 Vehicle Identification Number (Vin) ..................... 0B-10 ManufacturerS Plate ........................................... 0B-11 Engine Number .................................................. 0B-12 Vehicle Lifting Procedures .................................. 0B-14
0B-2 GENERAL INFORMATION
MAINTENANCE AND REPAIR MAINTENANCE AND LUBRICATION

NORMAL VEHICLE USE
The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to Tire and Wheel in section 2E. To be driven on reasonable road surfaces and within legal operating limits. Replace the air cleaner element every. Gasoline Engine : 60,000 km (36,000 miles) Diesel Engine : 30,000 km (18,000 miles) Replace the air cleaner more often under dusty conditions.
Fuel Filter Replacement

Replace the engine fuel filter every. Gasoline Engine : 60,000 km (36,000 miles) Diesel Engine : 45,000 km (24,000 miles)
Spark Plug Replacement

Replace spark plugs with same type. Type : BOSCH : F8DC4 BERU : 14F-8DU4
EXPLANATION OF SCHEDULED MAINTENANCE SERVICES

The services listed in the maintenance schedule are further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants.
Champion : C11YCC Gap : 0.8 0.1 mm
Spark Plug Wire Replacement

Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed.
Brake System Service

Check the disc brake pads or the drum brake linings. Check the pad and the lining thickness carefully.
Engine Oil and Oil Filter Change

Always use above the API SH grade or recommended engine oil.
Tire and Wheel Inspection and Rotation

Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type)
Engine Oil Viscosity

Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage.
Cooling System Service

Drain, flush and refill the system with new coolant. Refer to Recommended Fluids And Lubricants in this section.
Air Cleaner Element Replacement

Clean the air cleaner element every. Gasoline Engine : 15,000 km (10,000 miles) Diesel Engine : 10,000 km (6,000 miles)
YAA0B010
SSANGYONG Y200
GENERAL INFORMATION 0B-3
OWNER INSPECTIONS AND SERVICES

WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check all the button locations. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level reading.
Engine Coolant Level and Condition

Check the coolant level in the coolant reservoir tank and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.
Brake System Operation

Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking. Also, if the brake warning light goes on, or flashes, something may be wrong with part of the brake system.
Windshield Washer Fluid Level

Check the washer fluid level in the reservoir. Add fluid if necessary.
Exhaust System Operation

Be alert to any changes in the sound of the system or the smell of the fumes. These are signs that the system may be leaking or overheating. Have the system inspected and repaired immediately.
AT LEAST TWICE A MONTH

Tire And Wheel Inspection and Pressure Check
Check the tire for abnormal wear or damage. Also check for damaged wheels. Check the tire pressure when the tires are cold (check the spare also, unless it is a stow-away). Maintain the recommended pressures. Refer to Tire and Wheel is in section 0B.
Tires, Wheels and Alignment Operation

Be alert to any vibration of the steering wheel or the seats at normal highway speeds. This may mean a wheel needs to be balanced. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or a wheel alignment.
Steering System Operation

Be alert to changes in the steering action. An inspection is needed when the steering wheel is hard to turn or has too much free play, or is unusual sounds are noticed when turning or parking.
AT LEAST MONTHLY
Lamp Operation
Check the operation of the license plate lamp, the headlamps (including the high beams), the parking lamps, the fog lamps, the taillamp, the brake lamps, the turn signals, the backup lamps and the hazard warning flasher.
Headlamp Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.
Fluid Leak Check

Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once.
AT EACH FUEL FILL

A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately.
Engine Oil Level

Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm. 1. After stopping the engine, wait a few minutes for the oil to drain back to the oil pan. 2. Pull out the oil level indicator (dip stick). 3. Wipe it clean, and push the oil level indicator back down all the way. 4. Pull out the oil level indicator and look at the oil level on it. 5. Add oil, if needed, to keep the oil level above the lower mark. Avoid overfilling the engine, since this may cause engine damage. 6. Push the indicator all the way back down into the engine after taking the reading.
SSANGYONG Y200
AT LEAST TWICE A YEAR

Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 6A, Power Steering System.
Brake Master Cylinder Reservoir Level

Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced. Check the breather hole in the reservoir cover to be free from dirt and check for an open pas-sage.
Weather-Strip Lubrication
Apply a thin film silicone grease using a clean cloth.
EACH TIME THE OIL IS CHANGED

Brake System Inspection
This inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect the disc brake pads for wear. Inspect the rotors for surface condition. Inspect other brake parts, the parking brake, etc., at the same time. Inspect the brakes more often if habit or conditions result in frequent braking.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and Operation
Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors.
Movable Head Restraint Operation

On vehicles with movable head restraints, the restraints must stay in the desired position.
Steering, Suspension and Front Drive Axle Boot And Seal Inspection
Inspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears or leakage. Replace the seals if necessary.
Spare Tire and Jack Storage

Be alert to rattles in the rear of the vehicle. The spare tire, all the jacking equipment, and the tools must be securely stowed at all times. Oil the jack ratchet or the screw mechanism after each use.
Key Lock Service

Lubricate the key lock cylinder.
Body Lubrication Service

Lubricate all the body door hinges including the hood, the fuel door, the rear compartment hinges and the latches, the glove box and the console doors, and any folding seat hardware.
Exhaust System Inspection

Inspect the complete system (including the catalytic converter if equipped). Inspect the body near the exhaust system. Look for broken, damaged, missing, or out-of-position parts as well as open seams, holes, loose connections, or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment.
Underbody Flushing
Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control. At least every spring clean the underbody. First, loosen the sediment packed in closed areas of the vehicle. Then flush the underbody with plain water.
Throttle Linkage Inspection

Inspect the throttle linkage for interference or binding, damaged, or missing parts. Lubricate all linkage joints and throttle cable joints, the intermediate throttle shaft bearing, the return spring at throttle valve assembly, and the accelerator pedal sliding face with suitable grease. Check the throttle cable for free movements.
Engine Cooling System

Inspect the coolant and freeze protection fluid. If the fluid is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the proper mixture in order to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help en-sure proper operation.
Engine Drive Belts

Inspect all belts for cracks, fraying, wear and proper tension. Adjust or replace the belts as needed.
Hood Latch Operation

When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly.
SSANGYONG Y200
STANDARD BOLTS SPECIFICATIONS

Torque (Nm / Ib-in) Bolt* M3 0.5 M4 0.7 M5 0.8 M6 1.0 M8 1.25 M10 1.25 M10 1.5 M12 1.25 M12 1.75 M14 1.5 M16 1.5 M18 1.5 M20 1.5 M22 0.5 M24 1.5 M24 2.0 4T 0.5 Nm (4.5 lb-in) 1.2 Nm (11 lb-in) 2.4 Nm (22 lb-in) 4.0 Nm (36 lb-in) 8.6 Nm (77 lb-in) 18.6 Nm (14 lb-in) 18.6 Nm (14 lb-in) 34.3 Nm (25lb-in) 32.3 Nm (24 lb-in) 54.0 Nm (40 lb-in) 81.3 Nm (60 lb-in) 117.6 Nm (87 lb-in) 166.6Nm (123 lb-in) 225.4Nm (167 lb-in) 284.2 Nm (210 lb-in) 274.4 Nm (203 lb-in) *Diameter X pitch in millimeters Standard 7T 0.9 Nm (8 lb-in) 2.0 Nm (18 lb-in) 4.0 Nm (36 lb-in) 6.7 Nm (60 lb-in) 15.7 Nm (12 lb-in) 32.3 Nm (24 lb-in) 30.4 Nm (22 lb-in) 56.8 Nm (42 lb-in) 53.9 Nm (40 lb-in) 89.2 Nm (66 lb-in) 107.8 Nm (80 lb-in) 196.0 Nm (145 lb-in) 274.4 Nm (203 lb-in) 372.4 Nm (276 lb-in) 480.2 Nm (355 lb-in) 460.6 Nm (341 lb-in) 9T 1.3 Nm (12 lb-in) 3.0 Nm (27 lb-in) 5.6 Nm (50 lb-in) 9.7 Nm (87 lb-in) 22.5 Nm (17 lb-in) 46.0 Nm (34 lb-in) 44.1 Nm (33 lb-in) 82.3 Nm (61 lb-in) 77.4 Nm (57 lb-in) 127.4 Nm (94 lb-in) 196.0 Nm (145 lb-in) 284.2 Nm (210 lb-in) 392.0 Nm (290 lb-in) 529.2 Nm (392 lb-in) 686.0 Nm (508 lb-in) 666.4 Nm (493 lb-in) 4T 0.7 Nm (6.3 lb-in) 1.6 Nm (14 lb-in) 3.1 Nm (28 lb-in) 5.4 Nm (49 lb-in) 12.7 Nm (9 lb-in) 25.5 Nm (19 lb-in) 24.5 Nm (18 lb-in) 45.0 Nm (33 lb-in) 43.1 Nm (32 lb-in) 71.6 Nm (53 lb-in) 107.8 Nm (80 lb-in) 156.8 Nm (116 lb-in) 215.6 Nm (160 lb-in) 294.0 Nm (218 lb-in) 382.2 Nm (283 lb-in) 372.4 Nm (276 lb-in) Limit 7T 1.2 Nm (11 lb-in) 2.6 Nm (23 lb-in) 5.2 Nm (47 lb-in) 9.0 Nm (81 lb-in) 20.6 Nm (15.2 lb-in) 42.1 Nm (31 lb-in) 41.2 Nm (30 lb-in) 75.5 Nm (56 lb-in) 71.5 Nm (53 lb-in) 117.6 Nm (87 lb-in) 186.2 Nm (138 lb-in) 264.6 Nm (196 lb-in) 362.6 Nm (268 lb-in) 490.0 Nm (362 lb-in) 637.0 Nm (471 lb-in) 617.4 Nm (457 lb-in) 9T 17 Nm (15 lb-in) 4.0 Nm (36 lb-in) 7.6 Nm (68 lb-in) 12.7 Nm (114 lb-in) 30.4 Nm (22 lb-in) 60.8 Nm (31 lb-in) 58.8 Nm (44 lb-in) 107.8 Nm (80 lb-in) 98.0 Nm (73 lb-in) 166.6 Nm (123 lb-in) 264.6 Nm (196 lb-in) 372.4 Nm (276 lb-in) 519.4 Nm (384 lb-in) 705.6 Nm (522 lb-in) 921.2 Nm (682 lb-in) 891.8 Nm (660 lb-in)
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SSANGYONG Y200
BASIC SPECIFICATION
DIMENSION
* ( ): Gasoline engine equipped vehicle
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SSANGYONG Y200
SPECIFICATIONS
Systems General Items Overall length (mm) Overall width (mm) Overall height (mm) Gross vehicle weight (kg) Curb weight (kg) Min. turning radius (m) Ground clearance (mm) Fuel Fuel tank capacity Engine Model No. of cyl./Compression ratio Total displacement Camshaft arrangement Max. power Max. torque Injection timing Idle speed Cooling system Coolant capacity Lubrication Max. oil capacity Turbo charger and cooling type Manual transmission Gear ratio 1st 2
nd rd th th
Diesel 4,270 1,870 1,760 AT : 2405, MT : 2365 AT : 1950, MT : 1910 5.6 200 Diesel 80 L OM662LA 5 / 22 : 1 2,874 cc SOHC 120 ps / 4,000 rpm 25.5 kg.m / 2,400 rpm BTDC 18 1.0 770 50 rpm Water-cooled/forced circulation 10.5 L ~ 11 L Gear pump, forced circulation 8.9 L Turbo charger, air-cooled Remote control, floor change type 3.969 2.341 1.457 1.000 0.851 3.705 Electronic Floor change type 1 2 3
st
Gasoline G32D (G23D) 4,745 1,780 2415 Gasoline M162 (M161) 6 / 10 : 1 3,199 cc DOHC 220 ps / 6,000 rpm 31.9 kg.m / 3,000 rpm BTDC 8 770 50 rpm 11.3 L ~ 11.5 L 9.8 L
Type
4 5 Automatic transmission Gear ratio Model Type
Rev.
2.742 1.508 1.000 0.708 2.429
nd rd th
Rev.
SSANGYONG Y200
SPECIFICATIONS (Contd)
Systems Transfercase Gear ratio Clutch Type Disc type Items Model Type High Low Diesel Part-time Planetary gear type 1.000 : 1 2.483 : 1 Hydraulic [A/T: Torque converter] Dry single diaphragm type [A/T: 3 elements 1 stage 2 phases] Power steering Front axle Rear axle Brake Type Steering angle Inner Outer Drive shaft type Axle housing type Drive shaft type Axle housing type Master cylinder type Booster type Type Suspension Parking brake Front Rear Air conditioner Electrical Refrigerant Compressor type Battery type/Capacity (V-AH) Starter capacity (V-kW) Alternator capacity (V-A) Front Rear Rack and pinion 3617 3240 Ball joint type Build-up type Semi-floating type Build-up type Tandem type Vacuum booster Disc Drum (Disc) Cable type (internal expansion) Wishbone + Coil spring 5-link + Coil spring R134a Vane type MF / 12 - 90 12 - 2.2 12 - 75 (12 - 90) Disc (Drum) MF / 112 - 75 12 - 1.8 12 - 115 3 elements 1 stage 2 phases Gasoline G32D (G23D) Full-time (Part-Time) Torque converter
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RECOMMENDED FLUIDS AND LUBRICANTS

Usage Engine Oil D29ST Specification Approved by MB Sheet 229.1 or 229.3 Viscosity: See MB Sheet 224.1 G32D G23D Automatic Transmission Fluid* Manual Transmission Fluid Clutch Fluid (For Manual Transmission) Transfer Case Fluid Full-time Brake Fluid Front and Rear Front Axle Axle Fluid Rear Axle Power Steering Fluid Coolant D29ST G23D G32D Air Cleaner Fuel filter Diesel Gasoline Diesel Gasoline Clean every 10,000 km, Replace every 30,000 km Clean every 15,000 km, Replace every 60,000 km Replace every 45,000 km Replace every 60,000 km Part-time ATF DEXRON II, III, ATF S-2, S-3, S-4, TOTAL FLUID ATX ATF DEXRON II,III, ATF S-2, S-3, S-4, TOTAL FLUID ATX DOT4 API GL-5 or SAE 80W/90 API GL-5 or SAE 80W/90 (ATF DEXRON II) Approved by MB Sheet 229.1 or 229.3 Viscosity: See MB Sheet 224.1 CASTROL TQ95 (ATF DEXRON II or III) (DOT 4) Service interval Initial change: 1,000 km, Change every 10,000 km or 12 months (But, every 5,000 km or 6 months under severe conditions) Initial change: max. 1,000 km, Change every 15,000 km or 12 months (But, every 7,500 km or 6 months under severe conditions) Inspect every 30,000 km or 12 months (But, change every 60,000 km under severe conditions) Initially change at 12,000 km, and Inspect every 50,000 km Inspect frequently, Change every 40,000 km or 2 years Inspect every 10,000 ~ 15,000 km Change every 60,000 km Inspect every 10,000 ~ 15,000 km Change every 60,000 km Change every 40,000 km or 2 years (Inspect frequently) Inspect frequently Change every 38,000 km Inspect frequently Change every 38,000 km Check and replenish as necessary. 1.9 L Approx. 1.1 L 10.5~11.0 L 10.0~10.5 L 11.0~11.5 L Approx. 3.4 L As required 1.2 L 1.4 L As required 1.4 L Approx. 9.5 L 7.0 ~ 9.0 5.5 ~ 7.5 6.0 ~ 8.0 Capacity (L)
Change every 3 years. And, inspect and replenish as necessary.
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VEHICLE IDENTIFICATION NUMBER SYSTEM

VEHICLE IDENTIFICATION NUMBER (VIN)
Vehicle Identification Number (VIN) is on the right front axle upper frame.
YAA0B040
* K P T G 0 B 1 9 S 1 P 000000
12~17. Production Serial Number : 000001- 999999 11. Plant Code P : PyongTaek Plant 10. Model Year 2 : 2002 3 : 2003 9. Check Digit S : All area except North America 8. Engine Type 6 : 2295cc, In-line 4Cylinder, Gasoline (E23) 9 : 3199cc, In-line 6Cylinder, Gasoline (E32) D : 2874cc, In-line 5Cylinder, Diesel (662LA) 7. Restraint System 1 : 3-Point Seat Belts, 2 : 2-Point Seat Belts 6. Trim Level A : Standard, B : Deluxe, C: Super Deluxe 5. Body Type 0 : 5-Door 1 : 4-Door 2 : 3-Door 4. Line Models G: Rexton (LHD) H : Rexton (RHD) 3. Vehicle Type T : Passengr Cars, A : Truck 2. Maker Identification : P 1. Nation : K *. Symbol according to No.
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MANUFACTURERS PLATE
1 Type Approval No. 2 Vehicle Identification No.
YAA0B050
Manufacturers Plate Location

Gasoline Engine
YAA0B060
Diesel Engine
YAA0B070
SSANGYONG Y200
ENGINE NUMBER
Diesel Engine
662 920 1 0 012345
Serial Number 0 : Manual T/M 1 : Hydr - Auto Coupling 2 : Automatic T/M

YAA0B080
The engine number is stamped on the cylinder block in front of injection pump.
0 : Common 1 : Left - Hand Drive 2 : Right - Hand Drive 5 : REXTON 910 :Non-Intercooler Engine 920 :Intercooler Engine 661 : 2299cc 662 : 2874cc
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SSANGYONG Y200
GENERAL INFORMATION 0B-13 Gasolind Engine (3.2L DOHC)
162 990 1 0 012345
Serial Number 0 : Manual T/M 1 : Hydr - Auto Coupling 2 : Automatic T/M

YAA0B100
The engine number is stamped on the lower rear side of the alternator.
0 : Common 1 : Left - Hand Drive 2 : Right - Hand Drive 5 : REXTON 99 : 3.2L 97 : 2.3L ENGINE TYPE
YAA0B120
Gasolind Engine (2.3L DOHC)
YAA0B110
The engine number is stamped on the upper rear left-hand side of the cylinder block.
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VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the lifting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle. If any other hoist method is used, take special care to avoid damaging the fuel tank, the filter neck, the exhaust system, or the underbody.
Using Floor Jack

Front Side Rear Side
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YAA0B140
Using Jack
YAA0B150
YAA0B160
Rearward of Front Tire
Forward of Rear Tire
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DIESEL ENGINE MECHANICAL 1B3-133
TDC (TDC SENSOR BRACKET) SETTING

Preceding Work: Removal of No.1 cylinder prechamber
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1 Measuring Device 2 Dial Gauge
3 Cylinder Head 4 Piston ................................................ Set at TDC
Notice: The TDC sensor bracket must be adjusted in case of followings.
When replacing the TDC sensor bracket. When replacing the crankshaft, the hub or the vibration damper. When replacing or installing the timing case cover. After engine overhauling.
If the cylinder head is removed, the measuring pin of the dial gauge can be positioned on the piston crown. This is done by placing the magnetic dial holder on the mating surface of the crankcase.
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1B3-134 DIESEL ENGINE MECHANICAL

Tools Required 001 589 32 21 00 Dial Gauge 601 589 07 21 00 Measuring Device 667 589 01 21 00 Fixing Device
Setting (With Cylinder Head Installed)

1. Remove the prechamber of No. 1 cylinder. 2. Position the piston of No.1 cylinder at BTDC 10 .
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3. Install the measuring device 601 589 07 21 00 into the prechamber bore and position the dial gauge 001 589 53 21 00 with a preload of 5mm. 4. Slowly rotate the crankshaft in the direction of engine rotation until the large pointer on the dial gauge 001 589 53 21 00 stops (TDC position). Notice: The position of TDC is when the large pointer on the dial gauge is stopped before moving back. 5. Remove the reinstall the measuring device and position the dial gauge 001 589 53 21 00 scale at 0. 6. Slowly rotate the crankshaft in the direction of engine rotation until the dial gauge 001 589 53 21 00 has moved back (counterclockwise) by 3.65 mm.
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7. Insert fixing device into the sensor bracket. Notice: The pin (6) on the vibration damper must engage into the slot of the fixing device 667 589 01 21 00 (7). 8. If the pin does not engage, adjust the setting of the sensor bracket by removing and tightening of the sensor bracket bolts. Installation Notice Tightening Torque
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10 N m (89 lb-in)
The timing mark on the damper must be positioned at ATDC 20 .
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MACHINING OF FLYWHEEL
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1 Flywheel
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Machining of Flywheel
Notice: Flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding or precision-turning. If the scores or cracks are severe than permissible specifications, replace the flywheel. Distance a Distance b Max. axial runout
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19.3 - 19.5 mm New Repair up to 16.6 mm 15.6 mm 0.05 mm
When machining the clutch surface A, the mounting surface (B) for the clutch pressure plate should also be machined in accordance with A to keep the distance a . Do not machine under b value. When machining, fix the flywheel exactly not to exceed the standard runout.
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HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK
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1 Cylinder Head Cover 2 Bolt ........................................... 10 N m (89 lb-in) 3 Gasket.................................................... Replace
4 Valve Tappet 5 Cylinder Head
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Checking
Notice: The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it does not need to be repaired. Determine the malfunctions in valve clearance compensation device with noise through following tests. If defective, replace as respectively. 1. Run the engine at more than 3000rpm for approx. 4 minutes. 2. Stop the engine. After 5minutes, check the engine oil level and adjust if necessary. 3. Remove the cylinder head cover. 4. Check the valve tappets at TDC position of each cylinders. 5. Using a drift, lightly press the valve tappet and measure clearance between the cam and valve tappet. Notice: If the clearance exceeds 0.4mm, replace the valve tappet. 6. If a valve tappet moves down too far in comparison to the others, replace the valve tappet. 7. Rotate the engine and check the remaining valve tappets. Notice: Unnecessary rotation of the engine will damage the valve tappets. Do not rotate the engine by using the camshaft sprocket bolt or to the opposite direction of the engine rotation.
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SSANGYONG Y200
VALVE SPRINGS CHECK

Preceding Work : Removal of valve spring
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1 Valve Spring
2 Spring Scale
Service Data
At preloaded Outer diameter 33.1 mm Wire diameter 4.20 mm Free length 50.0 mm Length 27 mm Tension (new) 680 - 740 N Limit 612 N
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CHECK AND MACHINING OF VALVES

Preceding Works: Removal of cylinder head Removal of the vale spring Removal of the valve
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I Valve Length w Camshaft Cam Basic Diameter x Distance (Camshaft Basic Bore - Valve Stem)
y Half Camshaft Basic Bore Diameter z Distance (Cylinder Head Cover Parting Surface - Valve Stem)
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Intake Valve
Exhaust Valve
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Item Valve Disc Diameter d Valve Disc Height h Setting Angle o r Machining the Valve Valve Stem Diameter d1 Valve Length I Standard Repair Max. Permissible Runout at Valve Stem and Valve Seat
Intake Valve 37.90 - 38.10 mm 1.7 mm 45 7.955 - 7.970 mm 106.20 - 106.60 mm 105.30 - 105.70 0.03 mm
Exhaust Valve 34.90 - 35.10 mm 1.7 mm 45 9.945 - 8.960 mm 106.20 - 106.60 mm 105.30 - 105.70 mm 0.03 mm
Matching Valves
Camshaft Cam Basic Dia. W = 38.0 0.2 mm Camshaft Cam Basic Dia. W = 36.6 0.2 mm 19.5 - 20.1 mm Valve to be used Use machined valve, Size (x) 19.5 - 20.3 mm if needed new repair valve I = 105.5 0.2 mm Size (x) Size (x) 20.4 - 21.4 mm 21.4 - 21.97 mm 20.2 - 21.2 mm 21.2 - 21.97 mm Reuse valve Use standard size valve I = 106.4 0.2 mm
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Tools Required 001 589 32 21 00 Dial Gauge Commercial Tool Valve corn grinding machine
Checking and Machining Procedure

1. Clean the valves and do visual check. Notice: Valves with wobbled valve disc, with worn or scored valve stem should be replaced. 2. Measure valve disc height h .
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Service data
Intake Exhaust
1.7 0.15 mm 1.7 0.15 mm
3. Machine the valve. Notice: Pay attention to setting angle .
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4. Measure radial runout between valve stem and valve seat with a dial gauge 001 589 32 21 00. Limit Max. 0.03 mm
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SSANGYONG Y200

5. Clean the vales, valve seats and valve guides. 6. Coat the valve stem with oil and insert it into valve guide.
YAD1BJR0
7. Insert the valves (1) into the valve guides according to marking. 8. Measure amount by which the valve arrears a . Arrears a 0.1 - 0.7 mm
Notice: If out of standard, replace the valve seat ring.
YAD1BJS0
9. Measure camshaft cam basic diameter (w). Diameter w 38 0.2 mm or 37.6 0.2 mm
YAD1BJT0
10. Measure distance z (cylinder head cover parting surface - valve stem).
YAD1BJU0
SSANGYONG Y200

11. The distance x (camshaft basic bore - valve stem).
x = z - y. Determine the valve to use according to this measurement (See matching valves )
Example) Measured value w = 38.2 mm Measured value z = 36.5 mm Value y = 15.5 mm
x = 36.5 - 15.5 = 21.0 mm In this case according to Matching valves table, the installed valve may be used.
SSANGYONG Y200
MACHINING OF VALVE SEAT

Preceding Work: Removal of prechamber Removal and inspection of valve, replace if necessary Inspection of valve guide, replace if necessary
YAD1BJV0
1 2 3 4
Valve Valve Seat Ring Cylinder Head Valve Guide
a b
Valve Arreare Valve Seat Width Valve Seat Angle Valve Seat Free Angle
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-145 Service Data

Item Valve Arrears a Valve Seat Width b Valve Seat Angle Valve Seat Free Angle Permissible Radial Runout Valve Length I Standard Repair Intake 0.1 - 0.7 mm 1.2 - 1.7 mm 45 65 0.03 mm 106.20 - 106.60 mm 105.30 - 105.70 mm Exhaust 0.1 - 0.7 mm 1.5 - 2.0 mm 45 65 0.03 mm 106.20 - 106.60 mm 105.30 - 105.70 mm
Matching Valves
Camshaft Cam Basic Dia. w = 38.0 0.2 mm 19.5 - 20.3 mm Camshaft Cam Basic Dia. w = 37.6 0.2 mm 19.5 - 20.1 mm Valve to be Used Use machined valve, Size (x) if needed use pair valve 1 = 105.5 0.2 mm Size (x) Size (x) 20.4 - 21.4 mm 21.4 - 21.97 mm 20.2 - 21.2 mm 21.2 - 21.97 mm Reuse valve Use standard size valve I = 106.4 0.2 mm
Commercial Tools
Cylinder Head Clamping Devie Hunger D-8000 Mnchen 70 Type Ventilknecht K2000 Order No. 221 00 100 Valve Seat Turning Tool Hunger D-8000 Mnchen 70 Type VDS 1A Order No. 236 03 308 Test Sat for Valves Hunger D-8000 Mnchen 70 Order No. 217 93 601
SSANGYONG Y200
1B3-146 DIESEL ENGINE MECHANICAL Machining Procedure

Valve machining is required : - When the valve is leaking. - When replacing the valve. - When replacing the valve guide. - When replacing the valve seat or valve seatring. 1. Machine the valve seat ( =45 ).
YAD1BJW0
2. Measure valve seat width b . Valve seat width b Intake Exhaust 1.2 - 1.7 mm 1.5 - 2.0 mm
YAD1BJX0
3. If the specification is exceeded, the valve seat width has to be corrected at the lower free angle of =65 .
YAD1BJY0
4. Measure radial runout. Runout Max. 0.03 mm
YAD1BJZ0
SSANGYONG Y200

5. Insert the valve (1) into the valve guide according to marking and measure amount by which the valve arrears a . Arrears a 0.1 - 0.7 mm
YAD1BJS0
6. Measure camshaft cam basic circle diameter (w). Diameter w 38 0.2 mm or 37.6 0.2 mm
YAD1BJT0
7. Measure distance z (cylinder head cover parting surface - valve stem).
YAD1BJU0
SSANGYONG Y200
YAD1BJK0
I Length of Valve w Camshaft Cam Basic Circle Diameter x Distance (Camshaft Basic Bore - Valve Stem)
y Half Camshaft Basic Bore Diameter z Distance (CylinderHead Cover Parting Surface Valve Stem)
8. Measure x (Camshaft basic bore - valve stem). x = z - y 9. Determine the valve to be used. (See Matching valves ) Example) Measured value w = 38.2 mm Measured value z = 36.5 mm Value y = 15.5 mm x = 36.5 - 15.5 = 21.0 mm In the case of a camshaft cam basic circle diameter w = 38.2 mm and a distance x = 21.0 mm, the installed valve may be used.
SSANGYONG Y200
CAMSHAFT TIMING TEST

Preceding Work: Removal of glow plug
YAD1BK00
1 Cylinder Head Cover 2 Bolt ........................................... 10 N m (89 lb-in) 3 Gasket.................................................... Replace
4 Valve Tappet 5 Cylinder Head
Timing
Condition of camshaft New After approx. 20,000km
*
Intake valve Open ATDC 11.33 ATDC 12 Close ABDC 17 ABDC 18 Open
Exhaust valve Close BTDC 15.25 BTDC 14 BBDC 28 BBDC 27
At 2mm of valve lifting stroke.
SSANGYONG Y200

Tools Required 001 589 53 21 00 Dial Gauge
363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension
Measurement Procedure
1. Remove the cylinder head cover. 2. Rotate the engine in the direction of engine rotation until the intake valve of no. 1 cylinder is completely closed. The cam lobe faces up (arrow).
YAD1BK10
Notice: Do not rotate the engine at the bolt of the crankshaft sprocket. Do not rotate the engine in the opposite direction of engine rotation. If do, this will cause serious measuring errors. 3. Install the dial gauge holder 363 589 02 21 00 and dial gauge 001 589 53 21 00 (7) with the extension 366 589 00 21 05 (8) to the cylinder head and position the tracer pin (9) onto the valve tappet (intake valve of cylinder no.1) with a preload of min. 3mm. Notice: The tracer pin should be positioned exactly vertical.
YAD1BK20
4. Set the dial gauge to 0 . 5. Rotate the engine further in direction of rotation until the dial gauge has moved back by 2 mm (valve lift) to 1mm. 6. Check the timing.
New After approx.
ATDC 11.33 ATDC 12
YAD1BC10
Notice: If timing is out of standard, the camshaft should be checked for wear and the timing chain for stretch. If a difference of more than 4 exists, the timing chain should be replaced. 7. Replace the gasket and install the cylinder head cover. Installation Notice Tightening Torque 10 N m (89 lb-in)
SSANGYONG Y200
CYLINDER HEAD PRESSURE LEAKAGE TEST

Preceding Work: Removal of the cylinder head Removal of the exhaust manifold Removal of the valve
YAD1BK30
1 2 3 4 5 6 7
Feed Pipe Bolt Return Connection Gasket.................................................................. Replace Coolant Gallery .................................................... Sealing Pressure Measuring Plate ................................... Completely tight to the cylinder head Cylinder Head ...................................................... Immerse with pressure measuring plate into warm water of approx. 60C (140 F) and pressurize with compressed air of 2 bar.
Notice: If air bubbles are seen, replace the cylinder head.
Tools Required 115 589 34 63 00 Mounting Device 601 589 00 25 00 Pressure Testing Device
SSANGYONG Y200
FACING CYLINDER HEAD MATING SURFACE

Preceding Work: Removal of prechamber Cylinder head pressure leakage test
YAD1BK40
1 2 3 A
Valve Cylinder Head Prechamber Height of Cylinder Head
B C a b
Longitudinal Direction Transverse Direction Valve Arrears Prechamber Protrusion
Service Data
Height A (Cylinder Head Surface - Cylinder Head Cover Surface) Minimum Height After Machining Permissible Unevenness of Parting Surface Permissible Variation of Parallelism (Longitud. direction) Peak-to-Valley Height Valve Arrears a Prechamber Protrusion c Intake Valve Exhaust Valve In Longitudinal Direction In Transverse Direction 142.5 mm 0.08 mm 0.0 mm Max. 0.1 mm 0.0017 mm 0.1 - 0.7 mm 0.1 - 0.7 mm 7.6 - 8.1 mm 142.9 - 143.1 mm
SSANGYONG Y200

Measurement Procedure
1. Measure height A . Limit 142.5 mm
Notice: If the height is less than 142.5 mm, replace the cylinder head.
YAD1BK50
2. Insert the valve (1) and measure valve arrears a. Valve Arrears a 0.1 - 0.7 mm
Notice: If out of standard, machine the valve seat.
YAD1BJS0
3. Install the prechamber and measure protrusion c Protrusion c 7.6 - 8.1 mm
4. Assemble the engine and check the valve timing.
YAD1BK60
SSANGYONG Y200
REPLACEMENT OF CRANKCASE CORE PLUG

Core Plug
YAD1BK70
Service Data
Left Right Front Rear
34 mm
3 EA
34 mm
3 EA
17 mm
1 EA
34 mm
1 EA
SSANGYONG Y200

Tools Required 102 589 00 15 00 102 589 12 15 00 Drift Drift
Replacement Procedure
1. Completely drain the coolant. 2. Remove any parts which impede access. (Example : transmission, injection pump) 3. Place the screwdriver to the deepdrawn edge of the core plug and pull forward and then rotate 90.
YAD1B3Z0
4. Pull out the core plug with pliers.
YAD1B4B0
5. Thoroughly clean the sealing surface and apply Loctite 241. 6. Install the new core plug by using a drift. 7. Install the removed parts and fill the coolant. Notice: The adhesive must be allowed to harden for about 45 minutes before filling of coolant. 8. Warm up the engine and check the coolant for leaks.
YAD1BK80
SSANGYONG Y200
FACING CRANKCASE CONTACTING SURFACE
YAD1BK90
1 Crankcase 2 Crankcase Contacting Surface Y Height (crankcase upper surface - crankcase lower surface)
B Longitudinal Direction C Transverse Direction
Service Data
Height Y Permissible unevenness of contacting surface Permissible roughness upper contacting surface Permissible variation of parallelism of crankcase upper surface to lower surface in longitudinal direction Piston protrusion at TDC to crankcase upper surface Max. Min. 0.965 mm 0.735 mm In longitudinal direction (B) In transverse direction (C) Min. 299.62 mm 0.06 mm 0.06 mm 0.0006 - 0.0016 mm 0.05 mm
SSANGYONG Y200
CYLINDER BORE MEASUREMENT
YAD1BKA0
1 Crankcase Contacting Surface 2 TDC of 1 st Piston Ring 3 BDC of Ring
a Longitudinal Direction b Transverse Direction c,d,e Measuring Point
Service Data
Standard size Code letter A Code letter X Code letter B Wear limit in direction of travel and in transverse direction Permissible deviation of cylinder shape Honing angle When new Wear limit 89.000 - 89.006 mm 89.006 - 89.012 mm 89.012 - 89.018 mm Max. 0.20 mm 0.01 mm 0.05 mm 50 10
SSANGYONG Y200
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application 12-Sided Stretch Bolt (Flywheel) Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt Chain Tensioner Connecting Rod Bearing Cap Bolt Cooling Fan Belt Pulley Bolt Cooling Fan Shroud Bolt Crankshaft Bearing Cap Bolt Crankshaft Belt Pulley Bolt Cylinder Head Bolt 1st Step 2nd Step Torque Angel Wait For Torque Angel Cylinder Head Cover Bolt Damper Bolt Drain Plug (Cylinder Head) End Cover Bolt Engine Mounting Bolt Exhaust Manifold Nut Fuel Filter Pipe Bolt Fuel Line (to Injection Pump) Fuel Pipe (to Injection Nozzle) Fuel Pipe (to Injection Pump) Generator Bracket Bolt Generator Mounting Bolt Guide Pulley Bolt Guide Pulley Bracket Bolt Hub Bolt Idle Pulley Bolt Injection Nozzle Injection Pump Mounting Bolt Intake Manifold Nut Oil Dipstick Tube Bracket Bolt Oil Filter Housing Bolt Oil Filter Housing Cap Upper Lower Nm 45 + 90 25 25 + 90 80 35 + 90 10 3-7 55 + 90 23 10 35 90 10 min 90 10 21 30 10 50 - 75 25 25 13 18 18 25 25 45 23 9 200 + 90 23 40 23 25 10 25 25 Lb-Ft 33 + 90 18 18 + 90 59 26+ 90 41 + 90 17 26 90 10 min 90 15 22 37 - 55 18 18 10 13 13 18 18 33 17 148 + 90 17 30 17 18 18 18 Lb-In 89 27 - 62 89 89 89 80 89 -
SSANGYONG Y200
FASTENER TIGHTENING SPECIFICATIONS (Contd)

Application Oil Pan Bolt Socket Bolt M6 M8 Oil Pan Drain Plug Oil Pump Mounting Bolt Oil Pump Sprocket Bolt Oil Pump Screw Plug Oil Spray Nozzle Bolt Power Steering Dump Pulley Bolt Prechamber Threaded Ring Skid Plate Bolt Socket Bolt Stud Bolt TDC Sensor Bracket Bolt Tensioning Lever Nut Tensioning Pulley Bolt Timing Case Cover Bolt Transmission Mounting Bolt Turbo Charger to Exhaust Pipe Bolt Vacuum Pump Mounting Bolt Nm 10 10 25 25 25 25 50 10 32 130 28 - 47 25 12 10 21 29 10 54 - 68 30 10 Lb-Ft 18 18 18 18 37 24 96 21 - 35 18 15 21 40 - 50 22 Lb-In 89 89 89 106 89 89 89
SSANGYONG Y200
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE
000 589 04 14 00 Tensioning Strap
000 589 25 33 00 Internal Extractor
YAD1BKW0
YAD1BKS0
000 589 10 53 00 Reamer (for Exhaust)
000 589 33 33 00 Counter Support
YAD1BLC0
YAD1BKR0
000 589 10 68 00 Cylinder Brush
000 589 58 43 00 Chain Assembling Device
YAD1BL60
YAD1B1W0
000 589 21 53 00 Reamer (for Intake)
001 589 32 21 00 Dial Gauge
YAD1BLD0
YAD1BLG0
SSANGYONG Y200
SPECIAL TOOLS TABLE (Contd)
001 589 53 21 00 Dial Gauge
102 589 05 33 00 Puller
YAD1BKJ0
YAD1BKU0
102 589 00 15 00 ( 34) Drift
102 589 12 15 00 ( 17) Drift
YAD1B3Y0
YAD1B1A0
102 589 00 23 00 Go/No Go Gauge (for Intake)
103 589 00 33 00 Puller
YAD1BLF0
YAD1BKM0
102 589 03 40 00 Magnetic Bar
103 589 02 15 00 Drift (for Exhaust)
YAD1BKX0
YAD1BL80
SSANGYONG Y200
SPECIAL TOOLS TABLE (Contd)
104 589 00 37 00 Pliers
116 589 03 07 00 T Type Socket Wrench
YAD1BL40
YAD1BKF0
105 589 03 15 00 Drift (for Intake)
116 589 06 63 00 Magnetic Finger
YAD1BL70
YAD1BL10
115 589 34 63 00 Mounting Device
116 589 07 15 00 Drift
YAD1BKG0
YAD1BKV0
116 589 02 34 00 Thread Bolt
116 589 20 33 00 Sliding Hammer
YAD1BLH0
YAD1B580
SSANGYONG Y200
SPECIAL TOOLS TABLE (Cont d)
117 589 03 23 00 Go/No Go Gauge (for Exhaust)
601 589 00 25 00 Pressure Testing Device
YAD1BLE0
YAD1BKH0
346 589 00 63 00 Super Cooling Box
601 589 00 66 00 Counter Sink
YAD1BL90
YAD1BKD0
363 589 02 21 00 Dial Gauge Holder
601 589 01 59 00 Assembling Board
YAD1BKQ0
YAD1BKY0
366 589 00 21 05 Extension
601 589 02 43 00 Drift
YAD1BKP0
YAD1BL50
SSANGYONG Y200
601 589 02 59 00 Supporting Bridge
601 589 06 15 00 Drift (for Exhaust)
YAD1BKZ0
YAD1BLB0
601 589 03 14 00 Sleeve
601 589 07 21 00 Measuring Device
YAD1B790
YAD1BKK0
601 589 03 43 00 Oil Seal Assembler
602 589 00 40 00 Engine Lock
YAD1BKN0
YAD1B720
601 589 05 15 00 Drift (for Intake)
603 589 00 09 00 Serration Wrench
YAD1BLA0
YAD1BKB0
SSANGYONG Y200
603 589 00 40 00 Counter Holder
667 589 00 31 00 Press Lever
YAD1B4K0
YAD1BL00
603 589 01 40 00 Holding Wheel
667 589 01 21 00 Fixing Device
YAD1BL20
YAD1BKL0
667 589 02 63 00 Supporting Bar
YAD1BKC0
YAD1BL30
667 589 00 23 00 Height Gauge
YAD1BKE0
SSANGYONG Y200
SECTION 1D
ENGINE COOLING
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
Description and Operation ................................... 1D-2 General Description ............................................. 1D-2 Radiator .............................................................. 1D-2 Coolant Reservoir ................................................ 1D-2 Water Pump ........................................................ 1D-2 Thermostat .......................................................... 1D-2 Electric Cooling Fan ............................................. 1D-2 Engine Coolant Temperature Sensor ..................... 1D-3 Coolant Temperature Guage ................................. 1D-3 Component Locator ............................................. 1D-4 Gasoline Engine .................................................. 1D-4 Diesel Engine ...................................................... 1D-5 Diagnostic Information and Procedure ............... 1D-6 Cooling System Diagnosis ................................... 1D-6 System Leakage Test .......................................... 1D-7 Thermostat Test ................................................... 1D-7 Repair Instructions ................................................ 1D-8 On-Vehicle Service ................................................. 1D-8 Coolant Drain and Fill Up ...................................... 1D-8 Coolant Connection Fitting (M162 Engine) ........... 1D-11 Water Pump (M162 Engine) ............................... 1D-13 Water Pump (M161 Engine) ............................... 1D-15 Water Pump (Diesel Engine) ............................... 1D-17 Oil Cooler Pipe Line (M162 Engine) .................... 1D-19 Thermostat (M162 Engine) ................................. 1D-20 Thermostat and Thermostat Housing Assembly (M161 Engine) ............................................... 1D-21 Thermostat and Water Pump Housing (Diesel Engine) ............................................... 1D-23 Cooling Fan and Viscous Clutch (M162 Engine) .. 1D-25 Cooling Fan and Viscous Clutch (M161 Engine) .. 1D-27 Cooling Fan and Viscous Clutch (Diesel Engine) . 1D-29 Cooling Fan Shroud (Gasoline Engine) ................ 1D-31 Cooling Fan Shroud (Diesel Engine) .................... 1D-33 Radiator (Gasoline Engine) ................................. 1D-34 Radiator (Diesel Engine) .................................... 1D-36 Specifications ..................................................... 1D-38 General Specifications ....................................... 1D-38 Fastener Tightening Specifications ..................... 1D-39 Special Tools and Equipment ............................ 1D-40 Special Tools Table ............................................ 1D-40
1D-2 ENGINE COOLING
DESCRIPTION AND OPERATION

GENERAL DESCRIPTION
The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly. The cooling system includes a radiator and recovery subsystem, cooling fans, a thermostat and housing, a water pump, and a water pump drive belt. The timing belt drives the water pump. All components must function properly for the cooling system to operation. The water pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head. When the coolant reaches the operating temperature of the thermostat, the thermostat opens. The coolant then goes back to the radiator where it cools. This system directs some coolant through the hoses to the heat core. This provides for heating and defrosting. The coolant reservoir is connected to the radiator to recover the coolant displaced by expansion from the high temperatures. The coolant reservoir maintains the correct coolant level. The cooling system for this vehicle has no radiator cap or filler neck. The coolant is added to the cooling system through the coolant reservoir. Maintain the coolant level between the MIN and MAX marks on the coolant reservoir when the system is cold.
WATER PUMP
The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and, therefore, cannot be disassembled.
THERMOSTAT
A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. The thermostat is mounted in the thermostat housing to the front of the cylinder head. The thermostat stops the flow of the engine coolant from the engine to the radiator to provide faster warmup, and to regulate the coolant temperature. The thermostat remains closed while the engine coolant is cold, preventing circulation of the engine coolant through the radiator. At this point, the engine coolant is allowed to circulate only throughout the heater core to warm it quickly and evenly. As the engine warms, the thermostat opens. This allows the engine coolant to flow through the radiator where the heat is dissipated. This opening and closing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits. The wax pellet in the thermostat is hermetically sealed in a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled. As the vehicle is driven and the engine warms, the engine coolant temperature increases. When the engine coolant reaches a specified temperature, the wax pellet element in the thermostat expands and exerts pressure against the metal case, forcing the valve open. This allows the engine coolant to flow through the engine cooling system and cool the engine. As the wax pellet cools, the contraction allows a spring to close the valve. The thermostat begins to open at 82 C (180 F) and is fully open at 95 C (203 F). The thermostat closes at 80 C (176 F).
RADIATOR
This vehicle has a lightweight tube-and-fin aluminum radiator. Plastic tanks are mounted on the upper and the lower sides of the radiator core. On vehicles equipped with automatic transaxles, the transaxle fluid cooler lines run through the radiator tank. A radiator drain plug is on this radiator. To drain the cooling system, open the drain plug.
COOLANT RESERVOIR
The coolant reservoir is a transparent plastic reservoir, similar to the windshield washer reservoir. The coolant reservoir is connected to the radiator by a hose and to the engine cooling system by another hose. As the vehicle is driven, the engine coolant heats and expands. The portion of the engine coolant displaced by this expansion flows from the radiator and the engine into the coolant reservoir. The air trapped in the radiator and the engine is degassed into the coolant reservoir. When the engine stops, the engine coolant cools and contracts. The displaced engine coolant is then drawn back into the radiator and the engine. This keeps the radiator filled with the coolant to the desired level at all times and increases the cooling efficiency.
ELECTRIC COOLING FAN

Caution: Keep hands, tools, and clothing away from the engine cooling fans to help prevent personal injury. This fan is electric and can turn on even when the engine is not running.
SSANGYONG Y200
ENGINE COOLING 1D-3

Caution: If a fan blade is bent or damaged in any way, no attempt should be made to repair or reuse the damaged part. A bent or damaged fan assembly should always be replaced with a new one to prevent possible injury. The cooling fans are mounted behind the radiator in the engine compartment. The electric cooling fans increase the flow of air across the radiator fins and across the condenser on air conditioned (A/C)equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds. All models have two fans. The main fan is 320 mm (12.6 inches) in diameter with seven blades to aid the airflow through the radiator and the condenser. An electric motor attached to the radiator support drives the fan. The auxiliary fan is 320 mm (12.6 inches) in diameter.
The ECM will change the cooling fans from high peed to low speed at 100 C (212 F) and will turn the cooling fans off at 90 C (194 F).
A/C On
The ECM will turn the cooling fans on at low speed when the A/C system is on. The ECM will change to high speed when the high side A/C pressure reaches 1860 kPa (269.8 psi). The cooling fans will return to low speed when the high side A/C pressure reaches 1378 kPa (199.8 psi).
ENGINE COOLANT TEMPERATURE SENSOR

The Engine Coolant Temperature (ECT) sensor uses a temperature to control the signal voltage to the Engine Control Module (ECM).
A/C Off or Non-AC Model
The cooling fans are actuated by the engine control module (ECM) using a low-speed cooling fan relay, a high-speed cooling fan relay and a cooling fan motor relay. The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 C (203 F) and at high speed when the coolant temperature reaches 105 C (221 F).
COOLANT TEMPERATURE GAUGE

The coolant temperature gauge controls the instrument panel temperature indicator. The coolant temperature gauge is located with ECT sensor.
SSANGYONG Y200
1D-4 ENGINE COOLING
COMPONENT LOCATOR
GASOLINE ENGINE
YAD1D010
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Radiator Electric Fan Shroud Deaeration Tube Clamp Deaeration Hose (Radiator) Electric Fan Mounting Bracket Bolt (M6, 8 pieces) Bolt (M6, 4 pieces) Bolt (M6, 4 pieces) Upper Radiator Insulator Lower Radiator Insulator Plate Clip
15 16 17 18 19 20 21 22 23 24 25 26 27
Inlet Hose Outlet Hose 3 way Hose Deaeration Hose (Reserver Tank) Clamp Clamp Make Up Hose Holder Reserver Tank Bolt (M6, 2 piece) Cooling Fan Viscous Clutch Bolt (M6, 1 piece) Bolt (M6, 3 piece)
SSANGYONG Y200
ENGINE COOLING 1D-5
DIESEL ENGINE
YAD1D01A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Radiator Electric Fan Shroud Deaeration Tube Clip Deaeration Hose (Radiator) Deaeration Hose (Reserver Tank) Clip Bolt (M6, 2 pieces) Reserver Cap Reserver Tank Clamp 3 way Hose Clamp Clamp Connector
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Outlet Hose Intlet Hose Bolt Cooling Fan Bolt Viscous Clutch Upper Radiator Insulator Bolt Lower Radiator Insulator Plate Clip Intercooler Intercooler Outlet Duct Intercooler Inlet Duct Clamp Electric Fan Mounting Bracket
SSANGYONG Y200
1D-6 ENGINE COOLING
DIAGNOSTIC INFORMATION AND PROCEDURE

COOLING SYSTEM DIAGNOSIS
Engine Overheats
Checks Check for a loss of the coolant Check for a weak coolant solution. Check the front of the radiator for any dirt, any leaves, or any insects. Check for leakage from the hoses, the water pump, the heater, the thermostat housing, the radiator, the core plugs, or the head gasket. Check for a faulty thermostat. Check for retarded ignition timing. Check for an improperly operating electric cooling fan. Check for radiator hoses that are plugged or rotted. Check for a faulty water pump. Check for a faulty coolant reservoir cap. Check for a cylinder head or an engine block that is cracked or plugged. Add the coolant. Confirm that the coolant solution is a 50/50 mixture of ethylene glycol and water. Clean the front of the radiator. Replace any damaged components. Action
Replace a damaged thermostat. Perform an ECM code diagnosis. Confirm the integrity of the timing chain. Replace the electric cooling fan. Replace any damaged radiator hoses. Replace a faulty water pump. Replace a faulty coolant reservoir cap. Repair the damaged cylinder head or the damage engine block.
Loss of Coolant
Checks Check for a leak in the radiator. Check for a leak in the following locations: Coolant reservoir. Hose. Check for loose or damaged radiator hoses, heater hoses, and connections. Check for leaks in the water pump seal. Check for leaks in the water pump gasket. Check for an improper cylinder head torque. Check for leaks in the following locations: Intake manifold. Cylinder head gasket. Cylinder block plug. Heater core. Radiator drain plug. Action Replace a damaged radiator. Replace the following parts, as needed. Coolant reservoir. Hose. Reseat the hoses. Replace the hoses or the clamps. Replace the water pump seal. Replace the water pump gasket. Tighten the cylinder head bolts to specifications. Replace the cylinder head gasket, if needed. Repair or replace any components, as needed, to correct the leak.
Engine Fails to Reach Normal Operating Temperature or Cool Air from the Heater
Checks Check to determine if the thermostat is stuck open or is the wrong type of thermostat. Check the coolant level to determine if it is below the LOW mark on the coolant reservoir. Action Install a new thermostat of the correct type and heat range. Add sufficient coolant to raise the fluid to the specified mark on the coolant reservoir.
SSANGYONG Y200
ENGINE COOLING 1D-7
;;;;; ;;;;; ;;;;; ;;;;;
SYSTEM LEAKAGE TEST

Tools Required 124 589 15 21 00 Leakage Tester
Test Procedure
1. Loosen the cap a little and release pressure and remove the cap. Notice : For the risk of scalding, cap must not be opened unless the coolant temperature is below 90 C (194 F).
YAD1D030
2. Fill coolant up to upper edge (arrow) of reservoir. 3. Connect the leakage tester 124 589 15 21 00 to the reservoir filler cap and apply 1.4 bar of pressure. 4. If the pressure on the tester drops, check leakage at the all coolant hoses and pipes and each connections. Replace or retighten if necessary.
YAD1D040
THERMOSTAT TEST
Test Procedure
1. Remove the thermostat from the vehicle. Refer to Thermostat in this section. 2. Make sure the valve spring is tight when the thermostat is closed. If the spring is not tight, replace the thermostat. 3. Suspend the thermostat and a thermometer in a pan of 50/50 mixture of ethylene glycol and water. Do not let the thermostat or the thermometer rest on the bottom of the pan. The uneven concentration of heat on the bottom could result in inaccurate temperature measurements. 4. Heat the pan on a burner. 5. Use the thermometer to measure the temperature of the heated solution. 6. The thermostat should begin to open at 82 C (180 F) and it should be fully be fully open at 95 C (203 F). If it does not open at these temperatures, replace the thermostat.
YAD1D050
SSANGYONG Y200
1D-8 ENGINE COOLING
REPAIR INSTRUCTIONS ON-VEHICLE SERVICE

COOLANT DRAIN AND FILL UP
Draining & Filling up Procedure (Gasoline Engine)
1. Loosen the cap a little and release pressure and remove the cap. Notice : For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 C (194 F).
YAD1D060
2. Loosen the radiator lower drain cock and drain the coolant. Notice : Collect coolant by using a proper container.
YAD1B480
3. Drain the coolant from the crankcase by inserting a hose (dia. 14 mm) onto the drain bolt on the side of crankcase (exhaust manifold) and by loosening the plug. Notice: Just loosen the drain plug to drain the coolant and do not remove the plug completely. Collect coolant by using proper container. 4. After complete draining of the coolant, remove the hose connector to drain plug and reinstall the drain plug.
YAD1D080
Installation Notice Tightening Torque 30 Nm (22 lb-ft)
5. Tighten the radiator lower drain cock.
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ENGINE COOLING 1D-9

6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose. 7. Fill up the coolant through the coolant reservoir tank. Notice: Match the anti-freeze and the water ratio to 50 : 50.
Supplement the coolant until the coolant overflows to the de-aeration hose.
YAD1D090
8. Insert the de-aeration hose and completely tighten the clamp. 9. Check the coolant level in the coolant reservoir tank. 10. Warm up (until thermostat is opened) the engine and recheck the coolant level in the reservoir tank and fill up the coolant if necessary.
Draining & Filling up Procedure (Diesel Engine)

1. Loosen the pressure cap of reservoir by 1 notch and remove pressure and then loosen the cap. Notice: For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 C (194 F).
YAD1D100
2. Open the drain plug and drain the coolant. Notice: Collect the coolant by using a proper container.
YAD1D070
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1D-10 ENGINE COOLING

3. Remove the drain plug (1) and seal (2) of cylinder block and drain the coolant. 4. Replace the seal to new one and tighten the drain plug. Installation Notice Tightening Torque 30 Nm (22 lb-ft)
5. Tighten the drain plug of the lower radiator. 6. Fill the coolant through coolant reservoir-tank.
YAD1D110
Notice: Match the anti-freeze and the water ratio to 50 : 50. 7. Warm up (until thermostat is opened) the engine and recheck the coolant level in the reservoir tank and fill up the coolant if necessary.
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ENGINE COOLING 1D-11
COOLANT CONNECTION FITTING (M162 ENGINE)

Preceding Work : Removal of cooling fan shroud
YAD1D120
1 Bolt (M8 X 100, 2 pieces).......... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 2 Engine Hanger Bracket 3 Coolant Outlet Port
4 O-ring 5 Hose Mounting Clamp 6 Hose
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Removal & Installation Procedure

1. Drain coolant from the radiator. 2. Remove the hose mounting clamp (5) and disconnect the coolant hose (6). 3. Remove the two bolts (1), the engine hanger bracket (2) and coolant outlet port (3). Installation Notice Tightening Torque 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
Replace the O-ring with new one.

YAD1D130
4. Installation should follow the removal procedure in the reverse order. 5. Fill up the coolant as specified. 6. Check the leaks in the cooling system.
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WATER PUMP (M162 ENGINE)

Preceding Work : Removal of V-belt Removal of air admission housing
YAD1D140
1 2 3 4 5 6 7
Air Admission Housing Oil Cooler Pipe Line Seal ........................................................ Replace Bolt .............................. 9 - 11 Nm (80 - 97 lb-in) Coolant Hose Coolant Hose Outlet Coolant Hose
8 9 10 11 12 13
Coolant Hose Inlet Coolant Hose Water Pump Bolt ................ 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) Dowel Sleeve Seal ........................................................ Replace
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1. Drain the coolant. 2. Disconnect the water pump wire connector. 3. Loosen the hose clip and disconnect all hoses from the water pump 4. Remove the coolant line bolts (4) and then remove the coolant line (2). Installation Notice Tightening Torque
YAD1D150
9 - 11 Nm (80 - 97 lb-in)
Replace the seal (3). 5. Remove the mounting bolts (11) and carefully pull out water pump (10). Installation Notice Tightening Torque Replace the seal (13). 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
YAD1D160
6. Installation should follow the removal procedure in the reverse order. 7. Fill up coolant. 8. Do coolant system leakage test.
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WATER PUMP (M161 ENGINE)

Preceding Work : Removal of viscous clutch
YAD1D170
1 Bolt (M6 X 45, 1 pieces) .................................... 9 - 11 Nm (80 - 97 lb-in) 2 Bolt (M6 X 95, 1 pieces) .................................... 9 - 11 Nm (80 - 97 lb-in) 3 Bolt (M6 X 25, 4 pieces) .................................... 9 - 11 Nm (80 - 97 lb-in) 4 Bolt (M6 X 85, 2 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
5 Water Pump Housing 6 Bolt (M6 X 16, 4 pieces) .................................... 9 - 11 Nm (80 - 97 lb-in) 7 Water Pump Pulley 8 Coolant Inlet Hose 9 Heater Hose 10 Coolant Bypass Hose 11 Gasket
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Tools Required 603 589 00 40 00 Fan Clutch Holder

1. Drain the coolant. 2. Disconnect the coolant hoses (8, 9, 10). 3. Tak off the drive belt. 4. Unscrew the four bolts (6) from water pump pulley and remove the pulley (7). Installation Notice
YAD1D180
Tightening Torque
9 - 11 Nm (80 - 97 lb-in)
Hold the pulley with fan clutch holder 603 589 00 40 00 while removing the pulley.
5. Unscrew the bolts (1, 2, 3, 4) from water pump housing (5) and remove the water pump. Installation Notice Tightening Torque (1, 2, 3) (4) 9 - 11 Nm (80 - 97 lb-in) 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
6. Clean the sealing surface. 7. Replace the gasket with new one.
YAD1D190
Notice: Apply the sealant when the sealing surface of water pump housing and coolant mounting area is clean. 8. Installation should follow the removal procedure in the reverse order. 9. Check for leaks by starting the engine.
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WATER PUMP (DIESEL ENGINE)

Preceding Work : Removal of cooling fan Removal of V-belt
YAD1D200
1 Tensioning Lever 2 Gasket ................................................... Replace 3 Bolt .............................. 9 - 11 Nm (80 - 97 lb-in)
4 Water Pump Pulley 5 Bolt .............................. 9 - 11 Nm (80 - 97 lb-in) 6 Water Pump
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1. Loose the bolts (5) and remove the pulley (4). Installation Notice Tightening Torque 9 - 11 Nm (80 - 97 lb-in)
YAD1D210
2. Loose the bolts (3). Installation Notice Tightening Torque 9 - 11 Nm (80 - 97 lb-in)
3. Pull the tensioning lever (1) to the arrow direction. 4. Remove the water pump (6). Notice: Clean gasket residues on the sealing surface of water pump and replace the gasket. 5. Installation should follow the removal procedure in the reverse order.
YAD1D220
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OIL COOLER PIPE LINE (M162 ENGINE)

Preceding Work : Removal of upper intake manifold
YAD1D230
1 Bolt (M6 X 35, 1 piece) .................................... 9 - 11 Nm (80 - 97 lb-in) 2 Bolt (M6 X 16, 2 pieces) .................................... 9 - 11 Nm (80 - 97 lb-in)
3 Oil Cooler Pipe Line 4 O-ring ..................................................... Replace

1. Drain the coolant. 2. Unscrew the bolts (1, 2) and remove the oil cooler pipe line (3). Installation Notice Tightening Torque 9 - 11 Nm (80 - 97 lb-in)
Replace the O-ring with new one. 3. Installation should follow the removal procedure in the reverse order. 4. Fill up the coolant as specified. 5. Check the leaks in the cooling system.
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THERMOSTAT (M162 ENGINE)
YAD1D240
1 2 3 4
Thermostat Cover Thermostat O-ring Thermostat Cover Bracket
5 Bolt (M6 X 25, 3 pieces) .................................... 9 - 11 Nm (80 - 97 lb-in) 6 Hose Mounting Clamp 7 Heater Hose

1. Drain the coolant from the radiator. 2. Loosen the hose mounting clamp (6) and remove the heater hose (7). 3. Unscrew the three bolts (5) and remove the thermostat cover bracket, thermostat cover and the thermostat in order. Installation Notice Tightening Torque 9 - 11 Nm (80 - 97 lb-in)
Do not separate the thermostat cover and thermostat. 4. Replace the O-ring if necessary. 5. Check the leakage in the cooling system.
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THERMOSTAT AND THERMOSTAT HOUSING ASSEMBLY (M161 ENGINE)

Preceding Work : Removal of viscous clutch
YAD1D250
1 Bolt (M6 X 25, 3 pieces) ...................................... 9 - 11 Nm (80-97 lb-in) 2 Thermostat Cover 3 De-aeration Hose 4 Coolant Outlet Hose 5 Thermostat 6 O-ring 7 Tensioning Device Shock Absorber 8 Engine Hanger Bracket 9 Thermostat Housing Assembly
10 O-ring 11 Coolant Bypass Hose a Bolt (M6 X 95, 2 pieces) ..................................... 9 -11 Nm (80 - 97 lb-in) b Bolt (M8 X 75, 2 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) c Bolt (M8 X 35, 1 piece) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
SSANGYONG Y200
1D-22 ENGINE COOLING Removal & Installation Procedure

1. Drain the coolant. 2. Remove the de-aeration hose (3), coolant outlet hose (4) and coolant bypass hose (11). 3. Disconnect the engine coolant temperature sensor connector and coolant temperature gauge connector. 4. Unscrew the three bolts (1) and remove the thermostat cover assembly from thermostat housing. Installation Notice Tightening Torque 9 - 11 Nm (80 - 97 lb-in)
Do not separate the thermostat cover and thermostat. 5. Replace the O-ring if necessary. 6. Unscrew the bolt (c) and pry off the tensioning device shock absorber (7). Installation Notice Tightening Torque 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
7. Unscrew the bolts (a, b) and remove the engine hanger bracket and thermostat housing. Installation Notice Tightening Torque (a) (b) 9 - 11 Nm (80 - 97 lb-in) 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
8. Replace the O-ring with new one. 9. Installation should follow the removal procedure in the reverse order. 10. Check for leaks in cooling system.
SSANGYONG Y200
THERMOSTAT AND WATER PUMP HOUSING (DIESEL ENGINE)

Preceding Work : Removal of coolant pump Removal of thermostat Removal of alternator
YAD1D260
1 2 3 4 5
Gasket ................................................... Replace Water Pump Housing Connector Bolt .............................. 9 - 11 Nm (80 - 97 lb-in) Thermostat
6 7 8 9
Seal ........................................................ Replace Coolant Hose Coolant Temperature Guage Thermostat Housing Cover
Notice: The bolt on the arrow should be installed last.
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1. Drain the coolant completely. 2. Disconnect the coolant hose (7) from the thermostat housing cover (9).
YAD1D270
3. Remove the bolts (4) and then remove the thermostat (5) and housing cover (9). Installation Notice Align the groove on thermostat and the housing cover rib (arrow). Tightening Torque Replace the seal (6). 9 - 11 N m (80 - 97 lb-in)
YAD1D280
4. Disconnect the coolant temperature guage connector (3). 5. Separate the coolant hose (a) and return pipe (b).
YAD1D290
6. Remove the water pump housing bolts. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
Clean gasket residues on the sealing surface of water pump and replace the gasket. 7. Remove he water pump housing (2). 8. Installation should follow the removal procedure in the reverse order.
YAD1D300
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COOLING FAN AND VISCOUS CLUTCH (M162 ENGINE)

YAD1D310
1 Cooling Fan Pulley 2 Viscous Clutch 3 Cooling Fan
4 Bolt (M6 X 12, 4 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) 5 Bolt (M10 X 45, 1 piece) ...................... 40.5 - 49.5 Nm (29.8 - 36.5 lb-ft)
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1. Remove the engine hanger bracket bolts. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
2. Remove the engine hanger bracket. 3. Remove the cooling fan bolts.
YAD1D320
Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
4. Hold the cooling fan pulley using the fan clutch holder 603 589 00 40 00.
5. Remove the viscous clutch mounting bolts and viscous clutch. Installation Notice Tightening Torque 40.5 - 49.5 N m (29.8 - 36.5 lb-ft)
Important: There are two chambers in the viscous clutch. Be sure to make the viscous clutch stand on the ground not to flow silicone oil into another chamber in the viscous clutch. Do not lay down the clutch.
YAD1D330
6. Installation should follow the removal procedure in the reverse order.
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COOLING FAN AND VISCOUS CLUTCH (M161 ENGINE)

YAD1D340
1 Bolt (M6 X 14, 3 piece) .................................... 9 - 11 N m (80 - 97 lb-in) 2 Cooling Fan
3 Viscous Clutch 4 Union Nut (Left Threaded Screw) ...................... 40.5 - 49.5 Nm (29.8 - 36.5 lb-ft)
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Tools Required 111 589 02 01 00 Open End Wrench 111 589 00 40 00 Holder

1. Install the holder 111 589 00 40 00 to the bolt at the pulley as shown in the right figure to hold the pulley. 2. Remove the viscous clutch using an open end wrench 111 589 02 01 00. Installation Notice
YAD1D370
Tightening Torque
40.5 - 49.5 N m (29.8 - 36.5 lb-ft)
The union nut is left threaded screw. 3. Remove the 3 bolts (1) from the viscous clutch and remove the cooling fan and the viscous clutch. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
You may change the procedure (2) and (3) if necessary. 4. Installation should follow the removal procedure in the reverse order.
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COOLING FAN AND VISCOUS CLUTCH (DIESEL ENGINE)
YAD1D380
1 Cooling Fan Pulley 2 Viscous Clutch 3 Cooling Fan
4 Bolt ................ 40.5 - 49.5 Nm (29.8 - 36.5 lb-ft) 5 Bolt .............................. 9 - 11 Nm (80 - 97 lb-in)
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1. Hold the cooling fan pulley with fan clutch holder 603 589 00 40 00 and remove the bolt (4). Installation Notice Tightening Torque 40.5 - 49.5 N m (29.8 - 36.5 lb-ft)
YAD1D390
2. Remove the socket bolt (5) and then remove the cooling fan (3) and viscous clutch (2). Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
Keep the viscous clutch vertically. 3. Installation should follow the removal procedure in the reverse order.
YAD1D400
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COOLING FAN SHROUD (GASOLINE ENGINE)
YAD1D410
1 Fan Shroud Assembly
2 Bolt ................................ 3 - 7 N m (27 - 62 lb-in)
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1D-32 ENGINE COOLING Removal & Installation Procedure

1. Pull out the 2 clips (1) from the fan shroud assembly. 2. Remove the lower fan shroud (2). Notice: For installation, exactly align the lower fan shroud pin into the hole of the fan shroud assembly (4) and insert the clips. 3. Remove the bolts (3) and then remove the cooling fan shroud assembly (4). Installation Notice
YAD1D420
Tightening Torque
3 - 7 Nm (27 - 62 lb-in)
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COOLING FAN SHROUD (DIESEL ENGINE)
YAD1D430
1 Radiator 2 Cooling Fan Shroud
3 Bolt ............................... 3 - 7 N m (27 - 62 lb-in)

Cooling Fan Shroud 1. Remove the radiator deaeration hose and tube. 2. Remove the bolt (3) and then remove the cooling fan shroud (2). Installation Notice Tightening Torque 3 - 7 Nm (27 - 62 lb-in)
YAD1D440
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RADIATOR (GASOLINE ENGINE)

YAD1D510
1 2 3 4
Deaeration Hose Radiator Inlet Hose Bolt
5 6 7 8
Lower Radiator Insulator Plate Clip Upper Radiator Insulator
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1. Drain coolant from the radiator. 2. Remove the each coolant hoses.
YAD1B040
3. Remove the upper and lower automatic transmission oil cooling pipes from radiator. Installation Notice Tightening Torque 25 - 35 N m (18 - 26 lb-ft)
4. Remove the mounting bolt (9) from the automatic transmission oil cooler pipe (5) and then disconnect the cooler pipe (5). Installation Notice
YAD1B150
Tightening Torque
3 - 7 Nm (27 - 62 lb-in)
5. Remove the cooling fan shroud bolts and cooling fan shroud. Installation Notice Tightening Torque 3 - 7 Nm (27 - 62 lb-in)
6. Remove the radiator grille mounting screw and radiator grille.
YAD1D420
7. Remove the front and upper member mounting bolts and front end upper member. Installation Notice Tightening Torque 8. Remove the radiator 9. Check the radiator pin for crack, damage, leakage and bending and replace it if necessary. 10. Installation should follow the removal procedure in the reverse order. 11. Check for leakage in the cooling system. 30 - 40 N m (22 -30 lb-ft)
YAD1B080
SSANGYONG Y200
RADIATOR (DIESEL ENGINE)

Preceding : Removal of cooling fan shroud
YAD1D450
1 2 3 4 5 6
Radiator Inlet Hose Radiator Outlet Hose Radiator Deaeration Tube & Hose Clamp Spring Clamp Clip
7 8 9 10 11 12
Radiator Upper Insulator Coolant Thermo Switch Lower Insulator Lower Radiator Mounting Plate Clip
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1. Drain coolant from the radiator. 2. Remove the coolant thermoswich connector from radiator. 3. Remove the each coolant hose.
YAD1D070
4. Remove the automatic transmission oil cooler hose and cooling line. Installation Notice Tightening Torque 25 - 35 N m (18 - 26 lb-ft)
YAD1D460
5. Remove the cooling fan shroud bolts and cooling fan shroud. Installation Notice Tightening Torque 3 - 7 Nm (27 - 62 lb-in)
6. Remove the radiator grille mounting screw and radiator grille.
YAD1D470
7. Remove the front and upper member mounting bolts and front end upper member. Installation Notice Tightening Torque 30 - 40 N m (22 - 30 lb-ft)
YAD1B080
8. Remove the radiator. 9. Check the radiator pin for crack, damage, leakage and bending and replace it if necessary. 10. Installation should follow the removal procedure in the reverse order. 11. Check for leakage in the cooling system.
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SPECIFICATION
GENERAL SPECIFICATIONS
Application Cooling System Coolant Thermostat Type Capacity Type Initial Opening Temp. Fully Opening Temp. Fully Closing Temp. Stroke Cooling Fan Type Blades Diameter Low Speed ON Temp. Low Speed OFF Temp. High Speed ON Temp. High Speed OFF Temp. High Speed ON Temp. (By A/C PresCoolant Reservoir Water Pump sure) Pressure Valve Opening Pressure Vacuum Valve Opening Pressure Type Impeller Diameter Radiator Impeller Blades Type Core Width Core Height Core Thickness Coolant Temperature Gauge Engine Coolant Temperature Sensor Anti-Freeze Agent Minimum Radiation Capability Resistance (at 50 C ( 122 F)) Resistance (at 80 C ( 176 F)) Resistance (at 105 C ( 221 F)) Resistance (at 20 C ( 68 F)) Resistance (at 80 C ( 176 F)) Type Mixture of Water and Good Quality Ethylene Glycol-Base Anti-Freeze K 0.32 - 0.35 ALUTEC-P78 50 : 50 Unit L C (F) C (F) C (F) mm mm C (F) C (F) C (F) C (F) kPa (psi) kPa (psi) kPa (psi) mm mm mm mm Kcal/h K Gasoline Engine Water Cooling Forced Circulation 11.3 Wax Pellet Type 82 (180) 95 (203) 80 (176) 7 Electric Cooling Fan 5 320 95 (203) 90 (194) 105 (221) 100 (212) 269.8 (1860) 118 - 147 (17.1 - 21.3) 9.8 (1.4) Turbo Centrifugal 65 8 Cross-flow 701 372 18 45,000 185.2 47.4 28.2 3.33 - 37.8 11.0 88 (190) 85 (185) 92 (198) 89 (192) Down-flow Diesel Engine
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Application Automatic Transmission Oil Cooler Pipe Automatic Transmission Oil Cooler Pipe Mounting Bolt Coolant Drain Plug Cooling Fan Bolt Cooling Fan Shroud Bolt Engine Hanger Bracket and Coolant Outlet Port Bolt (M162 Engine) Oil Cooler Pipe Line Bolt (M161 Engine) Radiator Mounting Bracket Bolt Tensioning Device Shock Absorber Bolt (M161 Engine) Thermostat Cover Bolt (Diesel Engine) Thermostat Cover Bolt (M161 Engine) Thermostat Cover Bracket Bolt (M162 Engine) Thermostat Housing Bolt (M161 Engine) Viscous Clutch Mounting Bolt Water Pump Housing Bolt (Diesel Engine) Water Pump Housing Bolt (M161 Engine) Water Pump Mounting Bolt (Diesel Engine) Water Pump Mounting Bolt (M162 Engine) Water Pump Pulley Bolt (Diesel Engine) Water Pump Pulley Bolt (M161 Engine) M6 M8 M6 M8 Nm 20 3-7 30 9 - 11 3-7 22.5 - 27.5 9 - 11 3-7 22.5 - 27.5 9 - 11 9 - 11 9 - 11 9 - 11 22.5 - 27.5 40.5 - 49.5 9 - 11 9 - 11 22.5 - 27.5 9 - 11 22.5 - 27.5 9 - 11 9 - 11 Lb-Ft 15 22 16.6 - 20.3 16.6 - 20.3 16.6 - 20.3 29.8 - 36.5 16.6 - 20.3 16.6 - 20.3 Lb-In 27 - 62 80 - 97 27 - 62 80 - 97 27 - 62 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97
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SPECIAL TOOLS TABLE
111 589 00 40 00 Holder
111 589 02 01 00 Open End Wrench
YAD1D350
YAD1D360
124 589 15 21 00 Leakage Tester
603 589 00 40 00 Fan Clutch Holder
YAD1D020
KAA1C2D0
SSANGYONG Y200
SECTION 1E
ENGINE ELECTRICAL
TABLE OF CONTENTS
Description and Operation ............................... 1E-2 Battery .............................................................. 1E-2 Ratings.............................................................. 1E-2 Charging Time Required .................................. Charging a Completely Discharged Battery (off the Vehicle) ............................................. Jump Starting Procedure ................................. Generator .......................................................... Charging System .............................................. Starter ............................................................... Starting System ................................................ 1E-2 1E-3 1E-3 1E-4 1E-4 1E-4 1E-4 Battery .............................................................1E-11 Spark Plug and Ignition Coil (Gasoline Engine) .........................................1E-12 Glow Plug (Diesel Engine) ............................... 1E-13 Unit Repair ........................................................ 1E-14 Starter .............................................................. 1E-14 Generator (Mando Type) .................................1E-22 Specifications ................................................... 1E-28 General Specifications .................................... 1E-28 Fastener Tightening Specifications................. 1E-29 Schematic and Routing Diagrams ................. 1E-30 Starting and Charging System (Gasoline Engine) .........................................1E-30 Starting and Charging System (Diesel Engine) .............................................1E-31 Preheating System (Diesel Engine) ................1E-32 Special Tools and Equipment ........................ 1E-33 Special Tools Table ......................................... 1E-33
Diagnostic Information and Procedure .......... 1E-5 Ignition System ................................................. 1E-5 Preheating System (Diesel Engine) ................. 1E-7 Repair Instructions ............................................ 1E-9 On-Vehicle Service ........................................... 1E-9 Generator (Gasoline Engine) ............................ 1E-9 Generator (Diesel Engine) ................................ 1E-9 Starter .............................................................. 1E-10
1E-2 ENGINE ELECTRICAL

BATTERY
The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is completely sealed, except for two small vent holes in the sides. These vent holes allow the small amount of gas produced in the battery to escape. The battery has the following advantages over conventional batteries: No water addition for the life of the battery. Overcharge protection. If too much voltage is applied to the battery, it will not accept as much current as a conventional battery. In a conventional battery, the excess voltage will still try to charge the battery, leading to gassing, which causes liquid loss. Not as liable to self-discharge as a conventional battery. This is particularly important when a battery is left standing for long periods of time. More power available in a lighter, smaller case. The battery has three major functions in the electrical system. First, the battery provides a source of energy for cranking the engine. Second, the battery acts as a voltage stabilizer for the electrical system. Finally, the battery can, for a limited time, provide energy when the electrical demand exceeds the output of the generator. The battery is not designed to last indefinitely. However, with proper care, the battery will provide many years of service. If the battery tests well, but fails to perform satisfactorily in service for no apparent reason, the following factors may point to the cause of the trouble: Vehicle accessories are left on overnight. Slow average driving speeds are used for short periods. The vehicles electrical load is more than the generator output, particularly with the addition of aftermarket equipment. Defects in the charging system, such as electrical shorts, a slipping generator belt, a faulty generator, or a faulty voltage regulator. Battery abuse, including failure to keep the battery cable terminals clean and tight or a loose battery hold-down clamp. Mechanical problems in the electrical system, such as shorted or pinched wires.
CHARGING TIME REQUIRED

The time required to charge a battery will vary depending upon the following factors: Size of Battery A Completely discharged large heavy-duty battery required more than twice the re-charging time as a completely discharged small passenger car battery. Temperature A longer time will be needed to charge any battery at 18 C (0 F) than at 27 C (80 F). When a fast charger is connected to a cold battery, the current accepted by the battery will be very low at first. The battery will accept a higher current rate as the battery warms. Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more. State-of-Charge A completely discharged battery requires more than twice as much charge as a one-half charged battery. Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery, the current accepted by the battery is very low at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current will likewise increase.
RATINGS
A battery has two ratings: (1) a reserve capacity rating designated at 27 C (80 F), which is the time a fully charged battery will provide 25 amperes of current flow at or above 10.5 volts; (2) a cold cranking amp rating determined under testing at -18 C (0 F), which indicates the cranking load capacity.
Reserve Capacity
The reserve capacity (RC) is the maximum length of time it is possible to travel at night with the minimum electrical load and no generator output. Expressed in minutes, the RC rating is the time required for a fully charged battery, at a temperature of 27 C (80 F) and being discharged at a current of 25 amperes, to reach a terminal voltage of 10.5 volts.
Cold Cranking Amperage

The cold cranking amperage test is expressed at a battery temperature of -18 C (0 F). The current rating is the minimum amperage, which must be maintained by the battery for 30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts. This rating is a measure of cold cranking capacity.
SSANGYONG Y200
ENGINE ELECTRICAL 1E-3
CHARGING A COMPLETELY DISCHARGED BATTERY (OFF THE VEHICLE)

Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced. The following procedure should be used to recharge a completely discharged battery: 1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts, the charge current will be very low, and it could take some time before the battery accepts the current in excess of a few milliamperes. Refer to Charging Time Required in this section, which focuses on the factors affecting both the charging time required. Such low current may not be detectable on ammeters available in the field. 2. Set the battery charger on the high setting. Important: Some chargers feature polarity protection circuitry, which prevents charger unless the charger leads are correctly connected to the battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly, making it appear that the battery will not accept charging current. Therefore, follow the specific charger manufacturers instruction for by passing or overriding the circuitry so that the charger will turn on and charge a low-voltage battery. 3. Continue to charge the battery until the charge current is measurable. Battery chargers vary in the amount of voltage and current provided. The time required for the battery to accept a measurable charger current at various voltages may be as follows: Voltage 16.0 or more 14.0 - 15.9 13.9 or less Hours Up to 4 hours Up to 8 hours Up to 16 hours
JUMP STARTING PROCEDURE

1. Position the vehicle with the charged battery so that the jumper cables will reach from the charged battery to the battery that requires charging. 2. Turn off the ignition, all the lights, and all the electrical loads in both vehicles. 3. Leave the hazard flasher on if jump starting where there may be other traffic and any other lights needed for the work area. 4. Apply the parking brake firmly in both vehicles. Notice: In order to avoid damaging the vehicle make sure the cables are not on or near pulleys, fans, or other parts that will move when the engine starts. 5. Shift an automatic transmission to PARK. Caution: In order to avoid injury, do not use cables that have loose or missing insulation. 6. Clamp one end of the first jumper cable to the positive terminal on the booster battery. Make sure it does not touch any other metal parts. 7. Clamp the other end of the same cable to the positive terminal on the discharged battery. Never connect the other end to the negative terminal of the discharged battery. Caution: Do not attach the cable directly to the negative terminal of the discharged battery. Doing so could cause sparks and possible battery explosion. 8. Clamp one end of the second cable to the negative terminal of the booster battery. 9. Make the final connection to a solid engine ground, such as the engine lift bracket at least 450 millimeters (18 inches) from the discharged battery. 10. Start the engine of the vehicle with the good battery. Run the engine at a moderate speed for several minutes. 11. Then start the engine of the vehicle with the discharged battery. 12. Remove the jumper cables by reversing the above sequence exactly, removing the negative cable from the vehicle with the discharged battery first. While removing each clamp, take care that it does not touch any other metal while the other end remains attached.
If the charge current is not measurable at the end of the above charging times, the battery should be replaced. If the charge current is measurable during the charging time, the battery is good, and charging should be completed in the normal manner.
Important: It is important to remember that a completely discharged battery must be recharged for a sufficient number of ampere hours (AH) to restore the battery to a usable state.
If the charge current is still not measurable after using the charging time calculated by the above method, the battery should be replaced.
SSANGYONG Y200
GENERATOR
Generators are equipped with internal regulators. Unlike three-wire generators, the generator may be used with only two connections: battery positive and an D+ terminal to the charge indicator lamp. As with other charging systems, the charge indicator lamp lights when the ignition switch is turned to RUN, and goes out when the engine is running. If the charge idicator is on with the engine running, a charging system defect is indicated. This indicator light will glow at full brilliance for several kinds of defects as well as when the system voltage is too high or too low. The regulator voltage setting varies with temperature and limits the system voltage by controlling rotor field current. Achieve correct average field current for proper system voltage control by varying the on-off time. At high speeds, the on-time may be 10 percent and the off-time 90 percent. At low speeds, with high electrical loads, the on-time may be 90 percent and the off-time 10 percent.
STARTER
Wound field starter motors have pole pieces, arranged around the armature, which are energized by wound field coils. Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger enclosed in the drive housing, protecting them from exposure to dirt, icy conditions, and splashes. In the basic circuit, solenoid windings are energized when the switch is closed. The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear. The solenoid main contacts close. Cranking then takes place. When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should be released immediately after the engine starts.
CHARGING SYSTEM
Generators use a new type of regulator that incorporates a diode trio. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.
STARTING SYSTEM
The engine electrical system includes the battery, the ignition, the starter, the generator, and all the related wiring. Diagnostic tables will aid in troubleshooting system faults. When a fault is traced to a particular component, refer to that component section of the service manual. The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected electrically.
SSANGYONG Y200

IGNITION SYSTEM
Condition No Crank Probable Cause Correction
Low battery voltage. Battery cable is loose, corroded, or damaged. Faulty starter motor or starter motor circuit is open. Faulty ignition switch. Ground short. Low battery voltage. Battery. Battery cables are loose, corroded, or damaged. Faulty starter motor. Faulty starter motor. Faulty ignition switch. Broken the clutch pinion gear or faulty starter motor. Broken the flywheel ring gear. Connected circuit is open. Loosen the generator drive belt. The circuit is open or a short. Battery run down. Open ground circuit. Charging indicator lamp is blown or fuse is blown. Faulty ignition switch. Generator ground circuit is open or a short. Battery cable is corroded or damaged. Loosen the generator drive belt. Faulty wiring harness. Generator Voltage Regulator Faulty Voltage detecfing wiring faulty
Charging the battery or Replace the battery. Repair or Replace the battery cable. Repair or Replace the starter motor/starter motor circuit. Replace the ignition switch. Repair the ground short. Charging the battery or Replace the battery. Repair or Replace the battery cable. Repair or Replace the starter motor. Repair or Replace the starter motor. Replace the ignition switch. Replace the starter motor. Replace the flywheel. Repair the open circuit. Adjust the belt tension or Replace the belt. Repair the open or a short circuit. Replace the battery. Repair the open ground circuit. Repair or Replace the charging indicator lamp/fuse. Replace the ignition switch. Repair the circuit. Repair or Replace the battery cable. Adjust the belt tension or Replace the belt. Repair the wiring harness. Replace Generator Repair Wiring
Crank OK, But Too Slow
Starter Motor Does Not Stop
Starter Motor Running, But Not Cranking
Battery Discharge
Charging Indicator Lamp Does Not Work When the Ignition Switch ON (Engine Does Not Work)
Charging Indicator Lamp Does Not Put Out Lights After Starting the Engine
Battery Over Charging
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IGNITION SYSTEM (Contd)

Condition Hard Engine Starting Probable Cause Correction
Ignition coil faulty Distributor (including optical sensor) faulty Spark plug malfuntion Ignition timing faulty (spark plug light is normal) Spark plug malfunction Ignition coil faulty Ignition timing faulty Ignition timing faulty
Replace ignition coil Replace distribator (or sensor) Replace spark plug or adjust clearance Resetting valve timing Replace spark plug or adjust clearance Replace ignition coil Resetting valve timing Resetting valve timing
Unstable Engine Idling
Enging Acceralation Malfunction
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PREHEATING SYSTEM (DIESEL ENGINE)

General information
The preheating system consists of control relay, coolant temperature sensor and glow plugs. 1. Preheating time - control relay. Control relay functions as followings : Switching of preheating current. Indication of preheating finish. Control of preheating sequence. Indication of fault. 2. Coolant temperature sensor. Coolant temperature sensor senses coolant s temperature and signals it to the preheating relay continuously. 3. Glow plug The glow plug parts are housing with M12 1.25 thread and heating pin in housing. It is connected in a parallel circuit with the specified voltage of 11.5 V. The heating element has a heating coil and a control coil and they are connected in series.
YAD1E020
YAD1E010
4. Current and temperature of glow plug Current of glow plug While the preheating system operates, current of about 30 A flows in each glow plug and temperature of heating coil rises very fast. Due to the rise of temperature, the resistance of control coil increases therefore the current is controlled to about 8 - 15A and that protects the glow plug from overheating.
YAD1E030
Temperature of glow plug The temperature of the glow plug reaches up to 900 C (1,652 F) after about 9 seconds and up to 1,050 C (1,922 F) after 30 seconds.
YAD1E040
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1E-8 ENGINE ELECTRICAL Preheating System Operation

1. Preheating before start. Preheating time is different by coolant temperature and it is on until the glow indicator light goes off.
YAD1E050
2. Preheating after start. Preheating continues for max. 60 seconds to rise in characteristic of warming-up on engine after starting too. 3. Monitoring on glow plug. Glow plugs are monitored by low current by the micro processor in control relay respectively while running the engine. If glow indicator comes on after starting for about one minute, it indicates one or several plugs are faulty.
YAD1E060
Problem 1 Glow indicator does not come on in preheating time and comes on after starting the engine. Glow indicator does not come on while preheating and after starting engine.
Possible Cause One or several glow are faulty Faulty glow indicator Faulty circuit of glow indicator Faulty control relay
Glow indicator does not come on and engines starting is difficult or does not start at all.
Circuits short in one or several glow plugs Faulty preheating circuits Faulty control relay
4 5
Glow indicator comes on after starting for about one minute. Glow indicator comes on constantly.
One or several glow plugs are faulty Faulty circuit of glow indicator Faulty control relay
Preheating time until glow indicator goes off is too short/long.
Faulty coolant temperature sensor Faulty control relay Short/Open circuit in wire.
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GENERATOR (GASOLINE ENGINE)
Preceding Work : Removal of the polly V-belt

1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation Notice Tightening Torque
YAD1E070
14 - 18 N m (10 - 13 lb-ft)
3. Unscrew the nut and disconnect the terminal (2). Installation Notice Tightening Torque 4 - 5 Nm (35 - 44 lb-in)
4. Unscrew the combination bolt (3). Installation Notice Tightening Torque 42 - 50 N m (31 - 37 lb-ft)
5. Remove the generator. 6. Installation should follow the removal procedure in the reverse order.
YAD1E080
GENERATOR (DIESEL ENGINE)

Preceding Work: Removal of the polly V-belt

1. Disconnect the negative battery terminal. 2. Disconnect the plug connection. 3. Unscrew the bolts and take out the generator. Installation Notice Tightening Torque
YAD1E090
42 - 50 N m (31 - 37 lb-ft)
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STARTER
1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the battery cable(1). Installation Notice Tightening Torque 12 - 15 N m (9 - 11 lb-ft)
YAD1E100
3. Unscrew the nut and disconnect the engine electric wire (2). Installation Notice Tightening Torque 6 - 7 Nm (53 - 62 lb-in)
4. Unscrew the mounting bolts (3) of starter. Installation Notice Tightening Torque 35 - 48 N m (26 - 35 lb-ft)
5. Remove the starter. 6. Installation should follow the removal procedure in the reverse order.
YAD1E110
SSANGYONG Y200

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BATTERY
Notice:
Disconnect the negative battery cable first. Insert the clamp bolt (8) into the battery tray hole (11) from inside when installing.
YAD1E120
1. Disconnect the negative battery cable and then disconnect the positive battery cable. Installation Notice Tightening Torque 12 - 18 N m (9 - 13 lb-ft)
2. Remove the nut from the battery clamp bolt that fasten the battery holddown bracket. Installation Notice Tightening Torque
YAD1E130
15 N m (11 lb-ft)
3. Remove the battery. 4. Installation should follow the removal procedure in the reverse order.
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SPARK PLUG AND IGNITION COIL (GASOLINE ENGINE)

Preceding Work : Removal of intake air duct Tools Required 120 589 02 09 00 Spark Plug Wrench
1. Disconnect the negative battery cable. 2. Remove the ignition cable cover bolts and remove the ignition cable cover.
YAD1E140
Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
3. Separate the ignition cable from the ignition coil and the spark plug. 4. Remove the two bolts (M6 X 25) from each ignition coil and remove the ignition coil. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
YAD1E150
Make sure that the ignition cables are correctly routed. Exactly install the ignition cable guide pin into the vehicle to be grounded. The ignition cables are located on the cylinder head cover. Each ignition coil provides the high voltage to two spark plugs simultaneously. - M162 ENGINE T 1/1 : Cylinder 2 and 5 T 1/2 : Cylinder 3 and 4 T 1/3 : Cylinder 1 and 6 - M161 ENGINE T 1/1 : Cylinder 1 and 4 T 1/2 : Cylinder 2 and 3
YAD1E160
SSANGYONG Y200

5. Remove the spark plug using the spark plug wrench 120 589 02 09 00. Installation Notice Tightening Torque Clearance 25 - 30 N m (15 - 22 lb-ft) 0.8 + 0.1 mm
YAD1E170
GLOW PLUG (DIESEL ENGINE)

1. Disconnect the negative battery cable. 2. Remove the nut (2). Installation Notice Tightening Torque 4 N m (35 lb-in)
YAD1E180
3. Remove the glow plug (4). Installation Notice Tightening Torque 20 N m (15 lb-ft)
YAD1E190
SSANGYONG Y200
UNIT REPAIR
STARTER
YAD1E200
1 2 3 4 5 6
Starter Motor Assembly Starter Solenoid Assembly Starter Housing Shift Lever Armature Set Armature
7 8 9 10 11 12
Pinion Gear Assembly Ring Set Field Frame Assembly Brush Holder Assembly Contact End Frame Assembly Starter Through Bolts
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Inspection/Measurement (Before the Overhaul)
1. Remove the starter. Refer to Starter in this section. 2. Pinion clearance inspection. Disconnect the starter motor terminal M (1).
Connect the 12-volt battery lead to the starter motor terminals M and S.
Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds)
YAD1E210
Switch on to move the pinion gear (2). Now check the clearance between the pinion and the stopper with the filler gauge (3). If the clearance does not fall within the limits, check for improper installation and replace all wom parts.
YAD1E220
3. Magnetic switch pull-in test. Disconnect the starter motor terminal M (1). Connect the 12-volt battery lead to the starter motor terminals M and S. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds)
YAD1E230
Inspect the pinion gears moving to the outside (2). If the pinion gear does not move outside, replace the magnetic switch.
YAD1E240
SSANGYONG Y200

4. Solenoid hold-in test. Disconnect the starter motor terminal M (1).
Connect the 12-volt battery lead to the starter motor terminal S and body.
Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.
YAD1E250
Check the pinion gear s moving to the outside (2). If the pinion gear move to the inside, the circuit is open. Replace the magnetic switch.
YAD1E260
5. Solenoid return test. Disconnect the starter motor terminal M (1). Connect the 12-volt battery lead to the starter motor terminal S and body. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.
YAD1E270
Check the returning speed of pinion gear (2). If the returning speed is fast, the operation is normal. Replace the solenoid if the operation is abnormal.
YAD1E280
SSANGYONG Y200

5. No-road test. Connect the 12-volt battery lead to the starter circuit.

YAD1E290
Connect the current and the voltage (1). Install the starter motor rpm gage (2). Start the starter motor with the switch on (3). Measure the speed of pinion gear and the current. If the measurement satisfy the limit, the starter motor is normal.
Desciption The speed of pinion gear Condition : Voltage/ Current
Limit Minimum : 2,000 rpm Maximum : 9V / 150A
Replace the starter motor if necessary.
YAD1E300
Disassembly Procedure
1. Remove the starter contact end frame. Remove the through-bolts (1). Remove the contact end frame bolts (2). Remove the frame with the spacer (3).
YAD1E310
2. Remove the brush holder assembly. Remove the starter motor terminal M nut (1).
Remove the brush holder assembly (2).
YAD1E320
SSANGYONG Y200

3. Remove the field frame assembly from the armature set (1).
YAD1E330
4. Remove the solenoid assembly.
Remove the solenoid screws (1). Remove the magnetic switch (2). Remove the spring (3).
YAD1E340
5. Remove the armature set and solenoid from the starter housing.
Remove the armature set (1). Remove the rubber sealer (2). Remove the shift lever plate (3). Remove the shift lever (4). Remove the solenoid (5). Remove the gasket (6).
YAD1E350
Inspection / Measurement (After the Overhaul)

1. Ground test for armature coil. Inspect the insulation between commutator and armature coil using the voltmeter. Replace the armature assembly if necessary.
YAD1E360
SSANGYONG Y200

2. Short circuit test for armature coil. If test equipment is available, check the armature for short circuit by placing it on a growler, and holding back a saw blade over the armature core while the armature is rotated. If the saw blade vibrates, replace the armature.
YAD1E370
3. Open circuit test for armature coil.
Check the continuity between the commutator bars using multimeter. Replace the armature assembly if necessary.
YAD1E380
4. Inspect the brushes wear. Inspect the brushes, the pop-out springs and the brush holder for wear and damage, Replace the brushes, if necessary. a. Brushes wear limit. Desciption Brushes wea Standard Limit
11.3 - 11.5 mm 7.0 - 7.25 mm (0.445 - 0.453 in) (0.275 - 0.285 in)
YAD1E390
Inspection the Commutator Bar

1. Inspect the wear length using the dial indicator after placing the armature coil on the two V block. Application Standard (mm) Wear 0.05 Limit (mm) 0.1
YAD1E400
SSANGYONG Y200

2. Measure the outside diameter of the commutator bar. Application Standard (mm) O.D. 29.4 Limit (mm) 28.4
YAD1E410
3. Check the under-cut depth between segments. Application Standard (mm) Under-cut depth 0.5 Limit (mm) 0.2
YAD1E420
Brush Holder
Inspect the continuity between the brush holder plate and (+) brush holder. If the current does not send, its normal.
YAD1E430
Overrunning Clutch
1. Rotate the pinion grabbing the clutch housing. The driving pinion must rotate softly at one direction and must not rotate at opposite direction. If the driving pinion rotates at opposite direction, replace the overrunning clutch assembly. 2. Check the wear and damage of the pinion and replace the pinion as needed. If the pinion gets damaged, inspect the wear and damage of the ring gear. 3. Front and rear bracket bushing Check the wear and damage of the bushing and replace the front and rear bracket as needed.
SSANGYONG Y200
YAD1E440

Assembly Procedure
1. Installation should follow the removal procedure in the reverse order. For installing the lever to the starter housing, install it according to its proper direction. (The lever should be installed to the hole of the starter housing at one direction.) 2. Tighten nuts/bolts as specified torque. a. Starter M terminal nut b. Starter pass-through bolt
YAD1E450
SSANGYONG Y200
GENERATOR (MANDO TYPE)
YAD1E460
1 2 3 4 5 6 7 8 9
Generator Assembly Generator Shackle Generator Drive End Nut Generator Pully Generator Collar (Large) Generator Front Bracket Front Bearing Bearing Spot Plate Generator Collar (Small)
10 11 12 13 14 15 16 17
Generator Rotor Assembly Rear Bearing Generator Stator Assembly Rectifier Assembly Voltage Regulator / Brush Holder Assembly Generator Rear Bracket Battery Positive Terminal Nut Through Bolt
SSANGYONG Y200

1. Remove the generator. Refer to Generator in this section. 2. Remove the front bracket and rear bracket. Remove the through-bolts (1).
YAD1E470
Pry front bracket downwards using a screwdriver (2). Separate the front bracket and rear bracket (3).
YAD1E480
3. Remove the pulley and rotor assembly from the front bracket. Cover the rotor with the cloth (1). Place the pulley upwards and vice the rotor (2). Remove the pulley nut (3). Remove the pulley (4).
YAD1E490
4. Remove the front bracket, rotor and collar. Remove the collar (large) (1).
Remove the rotor from the front bracket (2). Remove the collar (small) from the rotor shaft (3).
YAD1E500
SSANGYONG Y200

5. Remove the front bearing. Remove the support plate screws (1).
Remove the plate (2). Remove the front bearing using the press (3).
YAD1E510
6. Remove the battery positive terminal nut from the rear bracket. Remove the battery position terminal nut (1). Remove the washer (2).
YAD1E520
7. Remove the stator assembly from the rear bracket. Remove the rectifier screw (1). Remove the brush holder and regulator assembly screw (2). Remove the stator assembly with the rectifier / brush holder / regulator (3).
YAD1E530
8. Remove the rectifier / brush holder / regulator from the stator.
Remove the rectifier / brush holder / regulator connections (1). Remove the stator and rectifier connections (2).
Notice: If the stator connections are welded, melt the lead. Avoid overheating as it can damage the diodes.
YAD1E540
SSANGYONG Y200
Inspection / Measurement
1. Inspect the rotor assembly.
Test the rotor for an open circuit by using the ohmmeter (1). Replace the rotor if necessary.
YAD1E550
Test the rotor for open or short circuit (2). Desciption The measured resistance Limit 2.9
Replace the rotor if necessary. Test the rotor for open or ground circuit by using the ohmmeter (3). Replace the rotor if necessary.
YAD1E560
2. Inspect the stator. Test the stator for an open circuit by using the ohmmeter (1). Replace the stator if necessary.
YAD1E570
Test the stator for open or ground circuit by using the ohmmeter (2). Replace the starter if necessary.
YAD1E580
SSANGYONG Y200

3. Inspect the rectifier. Positive rectifier test : Inspect the open circuit for stator coil lead terminals using the ohmmeter (1). Replace the rectifier if necessary.
YAD1E590
Negative rectifier test: Inspect the open circuit for stator coil lead terminals using the ohmmeter (2). Replace the rectifier if necessary.
YAD1E600
4. Inspect trio diodes. Inspect the open circuit for trio diodes using the ohmmeter (1). Replace the heat sink if necessary (a).
YAD1E610
5. Inspect the brush wear. If the brush wear exceeds the specified valve (a), replace the brush. Application Brushes wear Standard 18.5 (0.73) Limit 13.5 (0.53)
YAD1E620
SSANGYONG Y200

Assembly Procedure
1. Install in the reverse order of removal. Assemble the stator assembly into the rear bracket and rotor assembly. a. Brushes. b. Hole.
YAD1E630
2. Install the bolts / nuts / screws. Tighten Tighten the brush holder / regulator / rectifier screws to 9 - 12 Nm (80 - 106 Ib-in) (a).
Tighten the battery positive terminal nut to 4 - 7 Nm (35 - 62 Ib-in) (b).
YAD1E640
Tighten the front bearing spot plate screws to 6 - 8Nm (53 - 71 Ib-in) (c).
YAD1E650
Tighten the generator pulley nut to 80 - 110 Nm (59 - 81 Ib-ft) (d). Tighten the through-bolts to 4 - 6 Nm (35 - 53 Ib-in)
YAD1E660
SSANGYONG Y200
SPECIFICATIONS
Starter Application Type Output Power No Load Test @ 12 volts Drive Pinion Speed at No Load Drive Pinion Speed at Load Brush Length Armature Diameter Armature Run-out Segment Groove Depth Generator Type Output Voltage / Current Regulator Type Regulating Voltage Brush Length Quantity Abrasion Limit Battery Type Capacity Reserve Capacity Ignition Coil Type Primary Coil Resistance Secondary Coil Resistance Spark Plug High Tension Cable Glow Plug Type Clearance Resistance Unit Kw A rpm rpm/A mm mm mm mm V/A V mm mm AH RC K K /m Gasoline Engine PG170S 1.8 98 2,600 1,087/380 16.1 54.1 0.08 19.6 SG135 14/115 HYBRID 14.7 18.5 2 13.5 MF 75 130 DIS 0.3 - 0.9 6 - 8.5 WR8DC 0.8 - 0.9 1.9 Diesel Engine WP220 2.2 160 4500 1700/430 18 55 0.1 21.7 CS128D 14/90 14.6 12.5 2 7 MF 90 160 -
Type Used Voltage Circuit Connection Preheating Time
sec
11.5 Parallel 60 - 90
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Application Batter Cable Nut Battery Cable Nut on Starter Batter Mounting Bracket Nut Engine Electric Wire Nut on Starter Generator Combination Bolt Generator Terminal B+ Nut Generator Terminal D+ Nut Glow Plug Glow Plug Nut Ignition Cable Cover Bolt Ignition Coil Bolt Spark Plug Starter Mounting Bolt Nm 12 - 18 12 - 15 12 - 18 6-7 42 - 50 14 - 18 4-5 20 4 9 - 11 9 - 11 25 - 30 35 - 48 Lb-Ft 9 - 13 9 - 11 9 - 13 31 - 37 10 - 13 15 15 - 22 26 - 35 Lb-In 53 - 62 35 - 44 35 80 - 97 80 - 97 -
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SCHEMATIC AND ROUTING DIAGRAMS
STARTING AND CHARGING SYSTEM (GASOLINE ENGINE)
YAD1E680
SSANGYONG Y200
STARTING AND CHARGING SYSTEM (DIESEL ENGINE)
YAD1E690
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PREHEATING SYSTEM (DESEL ENGINE)
YAD1E700
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SPECIAL TOOLS TABLE
120 589 02 09 00 Spark Plug Wrench
YAD1E670
SSANGYONG Y200
SECTION 1F1
M162 ENGINE CONTROLS

CAUTION: Disconnect the negative battery cabl e beforer emoving or i nstalling any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other-wise noted.
TABLE OF CONTENTS
Engine and ECM Problem Check Report ........... 1F1-3 Diagnostic Information and Procedure ............. 1F1-4 Failure Code Diagnosis ...................................... 1F1-4 Clearing Failure Codes ....................................... 1F1-4 Failure Codes Table ........................................... 1F1-4 Ignition System ................................................... 1F1-8 Ignition Coil ......................................................1F1-10 Crankshaft Position (CKP) Sensor .....................1F1-12 Camshaft Position (CMP) Sensor ....................... 1F1-16 Camshaft Actuator ............................................1F1-20 Knock Sensor (KS) ...........................................1F1-22 Spark Plug ....................................................... 1F1-24 System Voltage ................................................1F1-28 Ignition Switch .................................................. 1F1-29 Fuel System ...................................................... 1F1-30 Fuel Pump ........................................................ 1F1-32 Fuel Injector ......................................................1F1-36 Purge Control Valve .......................................... 1F1-40 Fuel Rail ...........................................................1F1-42 Fuel Pressure Regulator .................................... 1F1-44 Induction System .............................................. 1F1-46 Throttle Valve Actuator ...................................... 1F1-46 Hot Film Air Mass (HFM) Sensor ........................ 1F1-50 Engine Coolant Temperature (ECT) Sensor ........ 1F1-54 Accelerator Pedal Module .................................1F1-58 Clutch Switch ................................................... 1F1-61 Cooling Fan ......................................................1F1-62 A/C Compressor Relay .....................................1F1-63 Cruise Control Switch ........................................ 1F1-64 Traction Control System (TCS) ...........................1F1-65 Resonance Flap ................................................1F1-66 Stop Lamp Switch ............................................. 1F1-67 Engine RPM ..................................................... 1F1-68 Exhaust System ................................................ 1F1-69 Catalytic Converter ...........................................1F1-69 Oxygen Sensor ................................................. 1F1-70 Engine Control Module .................................... 1F1-76 Serial Data Communication ............................... 1F1-77 Internal Failure .................................................. 1F1-79 Electronic Throttle Controller Safety Malfunction . 1F1-80 Immobilizer ......................................................1F1-82 Maintenance and Repair ................................. 1F1-83 On-Vehicle Service ........................................... 1F1-83 Discharging the Pressure in Fuel System .......... 1F1-83 Fuel Pump ........................................................ 1F1-83 Fuel Filter .......................................................... 1F1-84 Fuel Tank .......................................................... 1F1-85 Fuel Pressure Regulator .................................... 1F1-86 Fuel Rail and Injector ........................................1F1-87 Engine Coolant Temperature Sensor .................. 1F1-88 Throttle Body (Integrated with the Actuator) .......1F1-89 Hot Film Air Mass (HFM) Sensor ........................ 1F1-90 Knock Sensor ................................................... 1F1-90 Pedal Position Sensor ....................................... 1F1-91 Oxygen Sensor ................................................. 1F1-91 Purge Control Valve .......................................... 1F1-92 Canister............................................................ 1F1-92 Camshaft Position Sensor .................................1F1-92 Crankshaft Position Sensor ............................... 1F1-93 Engine Control Module ...................................... 1F1-93
1F1-2 M162 ENGINE CONTROLS

Schematic and Routing Diagrams ................... 1F1-94 ECM Wiring Diagram (3.2L DOHC - MSE 3.63D) ............................... 1F1-94 Specifications ................................................. 1F1-101 Engine Data Display Table .............................. 1F1-101 Fastener Tightening Specifications .................. 1F1-102 Fuel System Specification ............................... 1F1-103 Temperature vs Resistance ............................. 1F1-103 Special Tools and Equipment ........................ 1F1-104 Special Tools Table ......................................... 1F1-104
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M162 ENGINE CONTROLS 1F1-3
ENGINE AND ECM PROBLEM CHECK REPORT

VEHICLE AND CUSTOMER INFORMATION
Date Problem Occurred Customer Name Driver Name Purchase date License No. Vehicle Model VIN Engine Model Mileage Km miles
MIL INFORMATION
Condition of MIL DTC inspection (if available) Remains on Normal Freeze Frame data ( Sometimes illuminates Malfunction code(s) (code ) Does not illuminate )
PROBLEM DESCRIPTION
Engine Does Not Start Hard to Start Poor Idling Poor Driveability Engine Stall No cranking Slow cranking Others Incorrect first Idle Idling Unstable Hesitation Surging Abnormal idle rpm Others Back fire Knocking Muffler explosion (after-burning) Poor performance Other High (rpm) Low (rpm) No initial combustion No complete combustion
Soon after starting
After accelerator pedal depressed During A/C operation
After accelerator pedal released Shifting from N to D or D to N At full steering Others Others
CONDITION WHEN PROBLEM OCCURS

Problem Frequency Weather Ambient Temperature Place Engine Temperature Engine Operation Constant Fine Hot Highway Rough Road Cold Any temp. Starting Others Just after starting (min.) Acceleration Other Idling Racing Driving Deceleration Intermittent (times per day/month) Cloudy Warm Suburbs Others Warming Up Before warming up After warm-up Rainy Cool Inner City Snowy Uphill Once only Others
Various/Others Downhill
Cold (approx.____F/____C)
Constant speed
A/C switch ON/OFF
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DIAGNOSTIC INFORMATION AND PROCEDURE FAILURE CODE DIAGNOSIS

CLEARING FAILURE CODES
Notice: To prevent Engine Control Module(ECM) damage, the key must be OFF when disconnecting or reconnecting the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.) Parameters listed in the table may not be exactly the same as your reading due to the type of instrument or other factors. If a failure code is displayed during the TROUBLE CODE in scan tool check mode, check the circuit for the code listed in the table below. For details of each code, turn to the page referred to under the See Page for the re-spective Failure Code in the below table. Failure codes should be cleared after repairs have been completed.
FAILURE CODES TABLE

Failure Code 00 01 02 03 04 05 06 08 09 10 11 17 18 19 20 21 23 24 25 26 27 29 30 31 32 33 34 35 40 41 See Page 1F1-56 1F1-56 1F1-56 1F1-52 1F1-52 1F1-52 1F1-56 1F1-28 1F1-52 1F1-52 1F1-52 1F1-13 1F1-13 1F1-17 1F1-13 1F1-79 1F1-77 1F1-77 1F1-82 1F1-77 1F1-78 1F1-78 1F1-78 1F1-78 1F1-68 1F1-68 1F1-33 1F1-33 1F1-41 1F1-41 Description Engine coolant temperature sensor low voltage Engine coolant temperature sensor high voltage Engine coolant temperature sensor plausibility Intake air temperature sensor low voltage Intake air temperature sensor high voltage Intake air temperature sensor plausibility Engine coolant temperature insufficient for closed loop fuel control System voltage too low Mass air flow sensor plausibility Mass air flow sensor low voltage Mass air flow sensor high voltage Crankshaft position sensor signal failure (no engine revolution signal) Crankshaft position sensor signal failure (rpm > max. value) Camshaft position senosr signal : No.1 cylinder recognition failure Crankshaft position sensor signal failure (gap recognition failure) Transmission coding failure CAN communication failure : ASR/MSR CAN communication failure : ABS Communication with transponder missing CAN communication failure : TCU (A/T only) CAN communication failure : TOD (E32 only) CAN communication failure : ID 200h not plausible CAN communication failure : ID 208h not plausible CAN communication failure : communication initialization failure Engine rpm output circuit short circuit to battery Engine rpm output circuit short circuit to ground or open Fuel pump relay short circuit to battery Fuel pump relay short circuit to ground or open Purge control valve short circuit to battery Purge control valve short circuit to ground or open
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FAILURE CODES TABLE (Contd)

Failure code 44 45 54 56 57 58 59 60 62 64 65 66 67 68 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 89 93 96 97 98 99 100 101 102 See Page 1F1-62 1F1-62 1F1-41 1F1-23 1F1-23 1F1-17 1F1-78 1F1-78 1F1-61 1F1-11 1F1-11 1F1-11 1F1-13 1F1-25 1F1-29 1F1-37 1F1-37 1F1-37 1F1-37 1F1-37 1F1-38 1F1-38 1F1-38 1F1-72 1F1-73 1F1-72 1F1-72 1F1-72 1F1-72 1F1-72 1F1-72 1F1-72 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 Description Cooling fan (HI) relay short circuit to power Cooling fan (HI) relay short circuit to ground or open Purge control circuit malfunction No.1 knock sensor signal failure No.2 knock sensor signal failure Camshaft position sensor signal : No.1 cylinder synchronization failure CAN communication failure : MSR data transmission not plausible CAN communication failure : ASR data transmission not plausible Clutch switch defective No ignition voltage output (No.1 ignition coil) No ignition voltage output (No.2 ignition coil) No ignition voltage output (No.3 ignition coil) Crankshaft position sensor adaptation failure Random/Multiple Misfire Starter signal recognition failure No.1 injector short circuit to battery No.1 injector short circuit to ground or open No.2 injector short circuit to battery No.2 injector short circuit to ground or open No.3 injector short circuit to battery No.3 injector short circuit to ground or open No.4 injector short circuit to battery No.4 injector short circuit to ground or open Oxygen sensor high voltage Bank 1 system short term fuel trim adaptation below lean threshold Oxygen sensor no activity detected Oxygen sensor not lean after overrun fuel shut -off Oxygen sensor slow response Oxygen sensor heater failure Oxygen sensor heater short circuit to battery Oxygen sensor heater short circuit to ground or open Oxygen sensor low voltage Bank 1 system short term fuel trim adaptation above rich threshold Bank 1 system short term fuel trim at rich stop Bank 1 system short term fuel trim at lean stop Bank 1 system idle adaptation failure (above rich threshold) Bank 1 system idle adaptation failure (below lean threshold) Bank 1 system learning control failure (rich, low load) Bank 1 system learning control failure (lean, low load) Bank 1 system learning control failure (rich, high load)
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Failure code 103 104 105 108 109 110 116 117 119 120 121 122 123 125 126 127 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 150 151 160 161 162 163 164 See Page 1F1-73 1F1-47 1F1-47 1F1-47 1F1-47 1F1-80 1F1-47 1F1-80 1F1-47 1F1-80 1F1-47 1F1-59 1F1-47 1F1-47 1F1-48 1F1-48 1F1-64 1F1-64 1F1-64 1F1-64 1F1-64 1F1-64 1F1-67 1F1-79 1F1-79 1F1-80 1F1-80 1F1-80 1F1-82 1F1-79 1F1-79 1F1-79 1F1-79 1F1-79 1F1-65 1F1-65 1F1-59 1F1-59 1F1-59 1F1-59 1F1-59 Description Bank 1 system learning control failure (lean, high load) Throttle position sensor 1 low voltage Throttle position sensor 1 high voltage Throttle position sensor 2 low voltage Throttle position sensor 2 high voltage Throttle actuator learning data fault Throttle actuator learning control failure Exceed fuel -cut safety time Throttle valve return spring failure Cruise control interruption memory failure Throttle actuator failure Accelerator pedal position sensor signal failure Different Mass air flow sensor signal with throttle position sensor Both throttle position sensors failure Throttle position sensor 1 not plausible with throttle position sensor 2 High permanent throttle signal Cruise control OFF due to message counter failure Vehicle speed signal failure Vehicle speed signal failure Cruise control lever failure Cruise control acceleration failure Cruise control deceleration failure Stop lamp switch failure ECU failure (RAM) ECU failure (EPROM) Call monitoring Servo motor control output interruption memory failure Servo motor open/short Unprogramed ECU with immobilizer Uncoded/unprogramed ECU ECU failure (EEPROM/Flash-EPROM checksum failure) ECU failure (coding ID checksum failure) ECU failure (coding checksum failure) ECU failure (programing checksum failure) TCS input signal short circuit to battery TCS input signal short circuit to ground or open Accelerator pedal position sensor 1 low voltage Accelerator pedal position sensor 1 high voltage Accelerator pedal position sensor 2 low voltage Accelerator pedal position sensor 2 high voltage Accelerator pedal position sensor 1 not plausible with pedal position sensor 2
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Failure code 167 185 186 187 188 189 190 192 193 194 195 198 199 226 227 228 229 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 See Page 1F1-59 1F1-48 1F1-80 1F1-80 1F1-80 1F1-80 1F1-80 1F1-38 1F1-38 1F1-38 1F1-38 1F1-66 1F1-66 1F1-21 1F1-21 1F1-63 1F1-63 1F1-80 1F1-80 1F1-80 1F1-80 1F1-80 1F1-80 1F1-80 1F1-80 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-81 1F1-85 Description Both setpoint accelerator pedal position sensor defective Mass air flow sensor and throttle position sensor failure ECU failure (incompatible CPU) ECU failure (CPUs communication failure) ECU failure (CPU 2 configuration failure) ECU failure (CPU 2 fault) ECU failure (CPU run time failure between CPUs) No.5 injector short circuit to battery No.5 injector short circuit to ground or open No.6 injector short circuit to battery No.6 injector short circuit to ground or open Resonance flap short circuit to battery Resonance flap short circuit to ground or open Camshaft actuator short circuit to battery Camshaft actuator short circuit to ground or open A/C compressor relay short circuit to battery A/C compressor relay short circuit to ground or open ECU failure (CPU 2 cruise control message counter failure) Over decceleration limit (CPU 2) Over acceleration limit (CPU 2) Cruise control lever dual operation (CPU 2) Cruise control lever safety terminal failure (CPU 2) Unusual pedal position variation (CPU 2) Unusual throttle position variation (CPU 2) Unusual throttle controller monitor data comparison fault (CPU 2) Unusual accelerator pedal position sensor comparison fault (CPU 2) Throttle potentiometer comparision fault (CPU 2) Unusual CPU communication (CPU 2) Unusual CPU configuration (CPU 2) A/D converter failure (CPU 2) Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2 Position controller setpoint fault between CPU 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint fault between CPU 1 and CPU 2 A/D converteroverflow (CPU 2) ROM f aul t (CPU 2) RAM f aul t (CPU 2) Cycle monitor fault (CPU 2)
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IGNITION SYSTEM
This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then determines Electronic Spark Timing (EST) and triggers the electronic ignition system ignition coil. This type of distributorless ignition system uses a waste spark method of spark distribution. Each cylinder is paired with the cylinder that is opposite it (1-6 or 2-5 or 3-4). The spark occurs simultaneously in the cylinder coming upon the compression stroke and in the cylinder coming up on the exhaust stroke. The cylinder on the exhaust stroke requires very little of the available energy tofire the spark plug. The remaining energy is available to the spark plug in the cylinder on the compression stroke. These systems use the EST signal from the ECM to control the EST. The ECM uses the following information: Engine load (mass air flow sensor). Engine temperature. Intake air temperature. Crankshaft position. Engine speed (rpm).
YAD1F080
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BLANK
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IGNITION COIL
YAD1F090
1 2 3 4
Control Cable Connection Ignition Cable Spark Plug Connector Coupling Plug
5a, 5b E L1 L2
Secondary Voltage Connection Iron Core Secondary Ignition Coil Primary Ignition Coil
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover. The double ended coils receive the signal for the Engine Control Module (ECM) which controls the spark advance. Each EI system ignition coil provides the high voltage to two spark plugs simultaneously; T1/1: cylinder 2 and 5 T1/2: cylinder 3 and 4 T1/3: cylinder 1 and 6 The EI system ignition coil is not serviceable and must be replaced as an assembly.
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YAD1F100
Failure Code
Description No ignition voltage output (No. 1 ignition coil)
Trouble Area Malfunction of ignition circuit Primary current values or secondary short circuit
Maintenance Hint
64
Inspection the ECM pin 70 (71 and72) about short circuit or open with bad contact Inspection the power source to ignition Inspection the power source to ignition coil Inspection the ignition coil, high tension cords etc. Inspection the spark plug (wet, cracks, wear, improper gap, burned electrodes, heavy deposit) Inspection the ECM
65
No ignition voltage output (No. 2 ignition coil) No ignition voltage output (No. 3 ignition coil)
66
Circuit Description The Electronic Ignition (EI) system uses a waste spark method of spark distribution. The Crankshaft Position (CKP) sensor sends reference pulses to the ECM. The ECM then triggers the EI system ignition coils. Once the ECM triggers the EI system ignition coils both of the connected spark plugs fire at the same time. One cylinder is on its compression stroke at the same time that the other is on the exhaust stroke, resulting in lower energy needed to fire the spark plugin the cylinder on its exhaust stroke. This leaves there remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke. Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed.
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CRANKSHAFT POSITION (CKP) SENSOR
YAD1F110
1 Crankshaft Position Sensor 2 Bolt
3 Segment 4 Flywheel
This Electronic Ignition (EI) system uses inductive or pick up type magnetic Crankshaft Position (CKP) sensor. The CKP sensor is located in the opposite side of the crankshaft pulley and triggers the pick-up wheel teeth which is equipped 60 - 2 teeth with a gap of 2 teeth at 360 degree spacing. This sensor protrudes throughits mount to within 1.1 0.14 mm. The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60 - 2 wheel generates a positive half wave. The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends to the ignition coils and to the fuel injectors.
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YAD1F120
Failure Code 17
Description Crankshaft position sensor signal failure (no engine revolution signal) Crankshaft position sensor signal failure (rpm > max. value)
Trouble Area Even through cam position recognition is normal, no crankshaft position signal recognition When more than applicable revolution values or implausible to 60-2 teeth scan tool
Maintenance Hint
Monitoring the actual rpm through or scan tool Inspection the ECM pin 100, 99 about short circuit with bad contact Inspection the CKP sensor Inspection the air gap between sensor and drive plate Inspection the drive plate (teeth condition) Inspection the ECM
18
20
Crankshaft position When implausible recognition sensor signal failure of cam and crank angle signal (gap recognition failure) or intermittent sensing the signal or error count of undetected gap. Crankshaft position sensor adaptation failure When faulty crank angle sensor adaption
67
Circuit Description
The 58X reference signal is produced by the CKP sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The ECM uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the number of pulses on the 58X reference circuit and compares them to the number of Camshaft Position (CMP) signal pulses being received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, this failure code will set.
Crankshaft Position Sensor Resistance Inspection

1. Disconnect the coupling E of ECM while the ignition switch is in OFF position. 2. Measure the resistance between the coupling terminal pin No. 99 and No. 100 using a multimeter. Specified Value 1,050 ~ 1,400
Notice: Measure the insulator resistance of the CKP sensor if out of the specified value.
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1F1-14 M162 ENGINE CONTROLS Crankshaft Position Sensor Output Wave Inspection
1. Measure the output wave between the ECM terminals No. 99 and No. 100 using the scan tool or the oscilloscope while engine cranking (start motor activated). Notice: Check the segment or crankshaft position sensor and air gap if cannot get the output wave as shown in the figure.
YAD1F130
Crankshaft Position Sensor Insulator Resistance Inspection

1. Disconnect the coupling from ECM while the ignition switch is in OFF position. 2. Measure the resistance between the coupling terminal pin No. 100 and No. 69 using a multimeter. Specified Value >20 k
Notice: Measure the check and ground terminal of the CKP sensor if out of the specified value.
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BLANK
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CAMSHAFT POSITION (CMP) SENSOR
YAD1F140
1 Camshaft Position Sensor Connector 2 Bolt
3 Camshaft Position Sensor 4 O-ring
The Camshaft Position (CMP) sensor sends a CMP signal to the Engine Control Module (ECM). The ECM uses this signal as a synchronized pulse to trigger the injectors in the proper sequence. The ECM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel injection mode of operation.
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YAD1F150
Failure Code
Description Camshaft position sensor signal : No. 1 cylinder recognition failure
Trouble Area When no cam recognition signal during TN 24 counts more. (maintain the constant low or high level)
Maintenance Hint
Inspection the source voltage of CMP sensor Inspection the ECM pin 106, 104 about short circuit or open with bad contact Inspection the CMP sensor Inspection the damage of sensor or sprocket Inspection the ECM
19
58
Camshaft position When synchronization fault of sensor signal : No. 1 cylinder 1 cylinder synchronization (TDC recognition) failure
Circuit Description
The CMP sensor sends a cam position signal to the ECM. If the cam position signal is lost while the engine is running, the fuel injection system shifts to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine continuous to run.
Camshaft Position Sensor Signal Voltage Inspection

1. Measure the voltage between the ECM terminal No. 11 and No. 106 while the engine speed is at idle. Specified Value 1.2 ~ 1.7 v
Notice: The signal voltage will be changed in the range of 1.2 ~ 1.7 v.
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1F1-18 M162 ENGINE CONTROLS Camshaft Position Sensor Output Wave Inspection
1. Measure the output wave between the ECM terminals No. 104 and No. 106 using the scan tool or the oscilloscope while engine speed is at idle. Notice: Replace the CAM sensor if cannot get the out-put wave as shown in the figure.
YAD1F160
Camshaft Position Sensor Power Supply Inspection

1. Disconnect the CMP sensor Connector. 2. Measure the voltage between the No. 1and No. 3 pin of the CMP sensor connector while the ignition switch is in ON position. Specified Value 11 ~ 14 v
Notice: If the measured value is not within the specified value, check the cable.
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BLANK
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CAMSHAFT ACTUATOR
YAD1F170
1 Bolt 2 Camshaft Actuator 3 Bolt
4 Armature 5 Roll Pin 6 Nut
When the engine is running, the camshaft actuator rotates the intake camshaft hydraulically and mechanically relative to the camshaft sprocket by 32 crank angle to the advanced position and back to the retard position. The camshaft actuator is actuated electro-mechanically by the Engine Control Module (ECM). The positioning time of apporx. 1 second is dependent on the engine oil pressure at the camshaft actuator and on the oil viscosity and oil temperature, respectively. The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an input parameter for the engine ignition control unit.
Operation Condition of Camshaft Actuator

Engine RPM Engine stop 0 ~ 1,500 rpm Camshaft Position Retard Retard Effect Idle speed is improved Blow-by gas is decreased Valve overlap is decreased Torque is increased 1,500 ~ 4,300 rpm Above 4,300 rpm Advanced Retard Fuel loss is decreased NOx is decreased Engine overrun is prohibited
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YAD1F150
Failure Code
Description Camshaft actuator short circuit to battery
Trouble Area When malfunction of cam phasing control
Maintenance Hint
226
Monitoring the actual operational status through scan tool Inspection the ECM pin 73 about short circuit or open Inspection the power source short circuit or open to cam actuator Inspection the magnet and hardware Inspection the ECM
227
Camshaft actuator short circuit to ground or open
Camshaft Actuator Current Consumption Inspection

1. Run the engine to reach the coolant temperature above 70 C. 2. Increase the engine rpm up to 2000 rpm 3. Measure the current between the No. 1 and No. 2 pin of the camshaft actuator connector. Specified Value 1 ~1.5 A
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KNOCK SENSOR (KS)
YAD1F180
The Knock Sensor (KS) detects abnormal knocking in the engine. The two KS are mounted in the engine block near the cylinders. The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark knock.
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YAD1F190
Failure Code
Description No. 1 knock sensor signal failure
Trouble Area When recognition in more than control gain threshold at normal operational condition of other system during over 75 and 3,000 rpm running area (cylinder 1, 2, 3) When recognition in more than control gain threshold at normal operational condition of other system during over 75 and 3,000 rpm running area (cylinder 4, 5, 6)
Maintenance Hint
Inspection the ECM pin 118, 117about short circuit or open with bad contact Inspection the KS 1 malfunction Inspection the ECM Inspection the ECM pin 115, 114 about short circuit or open with bad contact Inspection the KS 2 malfunction Inspection the ECM
56
No. 2 knock sensor signal failure 57
Circuit Description
The KS system is used to detect engine detonation, allowing the ECM to retard the ignition control spark timing based on the KS signal being received. The KS signals amplitude and frequency depend upon the amount of knock being experienced. The ECM monitors the KS signal and can diagnose the KS sensor and circuitry.
Knock Sensor Resistance Inspection

1. Disconnect the coupling from ECM while the ignition switch is in OFF position. 2. Measure the resistance between the coupling terminal pin No. 118 and No. 117 and terminal pin No. 115 and No. 114 using a multimeter. Specified Value >10 M
Notice: Replace the KS if the measured values is out of the specified values. Check the connector and wire connection between ECM and the KS if the measured values are normal.
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SPARK PLUG
YAD1F200
1 Ignition Coil Cable Cover 2 Bolt 3 Spark Plug
T 1/1 Ignition Coil T 1/2 Ignition Coil T 1/3 Ignition Coil
Cylinder 2 and 5 Cylinder 3 and 4 Cylinder 1 and 6
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YAD1F210
Failure Code
Description Random / Multiple Misfire
Trouble Area When detection misfire of multiple cylinder for source of over the emission threshold or catalyst damage
Maintenance Hint
68
Inspection the ignition system Inspection the injection system Inspection the fuel pressure Inspection the compression pressure Inspection the valve timing or clearance Inspection the air flow sensor Inspection the crankshaft position sensor and air gap Inspection the engine wiring system Inspection the Engine Control Module (ECM)
Circuit Description
The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness value is compared with the actual (emission and catalyst damage) threshold.
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1F1-26 M162 ENGINE CONTROLS Spark Plug Cable Resistance Inspection

1. Turn the ignition switch OFF position. 2. Disconnect the spark plug cables Refer to Section 1E1, Engine electrical. 3. Measure the spark plug resistance using a multimeter. Specified Value 1.8 ~ 2.2 k
Notice: Replace the spark plug cable if the measured values is out of the specified values.
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BLANK
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SYSTEM VOLTAGE
YAD1F220
Failure Code
Description System voltage too low
Trouble Area Malfunction in recognition of system source voltage. Less than minimum 8 volts in 2,000 rpm below, or less than 10 volts in 2,000 rpm above.
Maintenance Hint
Monitoring the actual battery voltages through the scan tool Inspection the Engine Control Module (ECM) pin 12, 11, 10, 5 about short circuit or open with bad contact Inspection the over voltage protection relay Inspection the battery Inspection ECM
08
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IGNITION SWITCH
YAD1F230
Failure Code
Description Starter signal recognition failure
Trouble Area When not detection of starter signal
Maintenance Hint
71
Inspection the Engine Control Module (ECM) pin 2 circuit short or open with bad contact Inspection ECM
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FUEL SYSTEM
The function of the fuel metering system is to deliver the correct amount of fuel to the engine under all operating conditions. The fuel is delivered to the engine by the individual fuel injectors mounted into the intake manifold near each cylinder. The main fuel control sensors are the Mass Air Flow (MAF) sensor and the oxygen (O2) sensors. The MAF sensor monitors the mass flow of the air being drawn into the engine. An electrically heated element is mounted in the intake air stream, where it is cooled by the flow of incoming air. Engine Control Module (ECM) modulates the flow of heating current to maintain the temperature differential between the heated film and the intake air at a constant level. The amount of heating current required to maintain the temperature thus provides an index for the mass air flow. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve. Under high fuel demands, the MAF sensor reads a high mass flow condition, such as wide open throttle. The ECM uses this information to enrich the mixture, thus increasing the fuel injector ontime, to provide the correct amount of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by the ECM, which then decreases the fuel injector ontime due to the low fuel demand conditions. The O2 sensors are located in the exhaust pipe before catalytic converter. The O2 sensors indicate to the ECM the amount of oxygen in the exhaust gas, and the ECM changes the air/fuel ratio to the engine by controlling the fuel injectors. The best air/fuel ratio to minimize exhaust emissions is 14.7 to 1, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a closed loop system. The ECM uses voltage inputs from several sensors to determine how much fuel to provide to the engine. The fuel is delivered under one of several conditions, called modes. the amount of fuel delivered in the starting mode by changing how long the fuel injector is turned on and off. This is done by pulsing the fuel injectors for very short times.
Run Mode
The run mode has two conditions called open loop and closed loop .
Open Loop
When the engine is first started and it is above 690 rpm, the system goes into open loop operation. In open loop, the ECM ignores the signal from the O2S and calculates the air/fuel ratio based on inputs from the ECT sensor and the MAF sensor. The ECM stays in open loop until the following conditions are met: The O2 has a varying voltage output, showing that it is hot enough to operate properly. The ECT sensor is above a specified temperature (22.5 C). A specific amount of time has elapsed after starting the engine.
Closed Loop
The specific values for the above conditions vary with different engines and are stored in the Electronically Erasable programmable Read-Only Memory (EEPROM). When these conditions are met, the system goes into closed loop operation. In closed loop , the ECM calculates the air/fuel ratio (fuel injector on-time) based on the signals from the O2 sensors. This allows the air/fuel ratio to stay very close to 14.7 to 1.
Acceleration Mode
The ECM responds to rapid changes in throttle position and airflow and provides extra fuel.
Deceleration Mode
The ECM responds to changes in throttle position and airflow and reduces the amount of fuel. When deceleration is very fast, the ECM can cut off fuel completely for short periods of time.
Battery Voltage Correction Mode

When battery voltage is low, the ECM can compensate for a weak spark delivered by the ignition module by using the following methods: Increasing the fuel injector pulse width. Increasing the idle speed rpm. Increasing the ignition dwell time.
Starting Mode
When the ignition is turned ON, the ECM turns the fuel pump relay on for 1 second. The fuel pump then builds fuel pressure. The ECM also checks the Engine Coolant Temperature (ECT) sensor and the Throttle Position (TP) sensor and determines the proper air/fuel ratio for starting the engine. This ranges from1.5 to 1 at -36 C (-33 F) coolant temperature to 14.7 to 1 at 94 C (201 F) coolant temperature. The ECM controls
Fuel Cut-Off Mode

No fuel is delivered by the fuel injectors when the ignition is off. This prevents dieseling or engine runon. Also, the fuel is not delivered if there are no reference pulses received from the CKP sensor. This prevents flooding.
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BLANK
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FUEL PUMP
YAD1F240
1 2 3 4
Flange and Harness Assembly Spring Fuel Pump Float
5 6 7 8
Thermistor Float Arm Thermistor Housing Resistor Card and Wiper
Requirements for Fuel Pump

Item System Pressure Maximum Pressure Minimum Pressure Nominal Voltage Minimum Amount of Fuel Supply Specified Value 3.8 bar 8.5 bar (12 V) 5.0 bar (12 V) 12 V 114 Liter/Hr (12 V, 3.8 bar, -30 ~ +70 C) Item Minimum Delivery at 8V Operating Voltage Maximum Allowable Current Ambient Temperature Maximum Amount of Fuel Supply 7.5 A -30 ~ +70 C 165 Liter/Hr (12V, 3.8 bar, -30 ~ +70 C) Specified Value 30 Litre/Hr 8V
SSANGYONG Y200
YAD1F250
Failure Code 34
Description Fuel pump relay short circuit to battery Fuel pump relay short circuit to ground or open
Trouble Area When short circuit to power source When short circuit to ground or open open with bad contact
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 33 about short circuit or open with bad contact Inspection the fuel pump relay Inspection the ECM
35
Circuit Description
When the ignition switch is turned ON, the ECMwill activate the pump relay and run the in-tank fuel pump. The fuel pump will operate as long as the engine is cranking or running and the ECMis receiving ignition reference pulses. If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignition switch is turned ON, engine stopped or engine stalled.
Fuel Pump Relay Inspection

Measure the voltage between the ECM terminal No. 33 and ground. Ignition Switch : ON Cranking 0 V (for1 ~ 2 sec.) 0V
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1F1-34 M162 ENGINE CONTROLS Measure the Fuel Delivery from the Fuel Pump
1. 2. 3. 4. 5. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it. Place the hose end into the beaker with the minimum capacity of 1 Liter Turn the ignition switch to ON position. Connect the terminal No. 33 and No. 5 of ECM with a service wire. Measure the fuel delivery from the fuel pump Specified Value 1 Liter/max. 35 sec.
Notice: Check the fuel filter and fuel line when the fuel delivery is not within specified value.
Measure the Current Consumption of Fuel Pump

1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to ON position. 2. Using a multimeter, measure the current consumption by connecting the terminal No. 30 and No. 87 of the fuel pump relay connector. Specified Value 5 ~9 A
Notice: Replace the fuel pump relay if the measured value is over 9 A.
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BLANK
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FUEL INJECTOR
YAD1F260
1 Fuel Rail 2 O-Ring 3 Injector Bracket
4 Injector 5 O-Ring
The Multipoint Fuel Injection (MFI) assembly is a solenoid-operated device controlled by the Engine Control Module (ECM) that meters pressurized fuel to an each individual cylinder. The injector sprays the fuel, in precise quantities at a point in time determined by the ECM, directly to ward the cylinder intake valve. ECM energizes the fuel injector solenoid to lift the needle valve and to flow the fuel through the orifice. This injectors discharge orifice is calibrated to meet the effective fuel atomization necessary for both ensuring the maximum homogeneity in the air-fuel mixture and holding the condensation along the walls of the intake tract to a minimum. Fuel enters the top feed injector from above and flows through its vertical axis. The lower end extends into the intake valve. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engineis shut down. Also, an extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be delivered to the engine after the ignition is turned off.
SSANGYONG Y200
YAD1F270
Failure Code
Description No. 1 injector short circuit to battery
Trouble Area When malfunction of injector circuit Injector #1 short circuit to power
Maintenance Hint
72
Inspection the power to injector #1 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 63 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #2 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 61 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #3 or bad contact Inspection the injector Inspection the ECM
73
No. 1 injector short circuit to ground or open
When malfunction of injector circuit Injector #1 short circuit to ground or open When malfunction of injector circuit Injector #2 short circuit to power
74
No. 2 injector short circuit to battery
75
No. 2 injector short circuit to ground or open No. 3 injector short circuit to battery
76
SSANGYONG Y200

Failure Code Description No. 3 injector short circuit to ground or open Trouble Area When malfunction of injector circuit Injector #3 short circuit to ground or open When malfunction of injector circuit Injector #4 short circuit to power No. 4 injector short circuit to ground or open When malfunction of injector circuit Injector #4 short circuit to ground or open When malfunction of injector circuit Injector #5 short circuit to power No. 5 injector short circuit to ground or open No. 6 injector short circuit to battery When malfunction of injector circuit Injector #5 short circuit to ground or open When malfunction of injector circuit Injector #6 short circuit to power No. 6 injector short circuit to ground or open When malfunction of injector circuit Injector #6 short circuit to ground or open Maintenance Hint
Inspection the ECM pin 66 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #4 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 62 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #5 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 65 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #6 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 64 about short circuit or open with bad contact Inspection the injector Inspection the ECM
77
78
79
192
193
194
195
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Injector Spray Pattern Check

1. Turn the ignition switch OFF. 2. Remove the fuel injector connectors. 3. Remove the fuel distributor and injector with a unit. At this time, do not remove the supply and return line. Notice: Prepare the beaker for taking the fuel. 4. Connect the shop made cable to the injector with a firing order. 5. Connect the other end of shop made cable to the positive battery cable and negative battery cable. 6. Turn the ignition switch ON. 7. Check the injector for normal spray pattern as shown in the figure. Check injector for leaks or later drop
YAD1F280
Injector Resistance Inspection

1. Turn the ignition switch OFF. 2. Remove the fuel injector connectors. 3. Measure the fuel injector coil resistance using a multimeter. Specified Value 14 ~ 17
YAD1F290
Notice: Replace the fuel injector if the measured value is out of the specified values. Check the connector and wire connection between the ECM and the injector if the measured values are normal.
Injector Pulse Width Inspection

1. 2. 3. 4. Turn the ignition switch OFF. Install the scan tool. Turn the ignition switch ON. Monitor the INJECTION TIME with a scan tool. Cranking Engine Idle Wide Open Throttle (WOT) 8.0 ms 3 ~5 ms 14 ms
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PURGE CONTROL VALVE
YAD1F300
1 Purge Control Valve 2 Line to Engine
3 Line to Conister
The fuel vaporization control system is in stalled to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in the canister abstracts through the purge control valve purification during the engine combustion (except the decreasing mode) and coolant temperature of over 80 C. For this reason, the Engine Control Module (ECM) transacts the engine speed, air inflow quantity, coolant temperature, and intake temperature. The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the purification rate. The purification rate is determined by the continuous valve opening interval. The purge control valve is activated by the ECM for the following conditions: Coolant temperature of over 80 C Engine speed of over 1,000 rpm 2 minutes after starting When the fuel cut-off mode is not activated
SSANGYONG Y200
YAD1F310
Failure Code 40 41
Description Purge control valve short circuit to battery Purge control valve short circuit to ground or open Purge control circuit malfunction
Trouble Area When short circuit to power source When short circuit to ground or open circuit or open with bad contact When malfunction of purge control : not work vale
Maintenance Hint
Inspection the ECM pin 34 about short circuit or open with bad contact. Inspection the source power of valve Inspection the purge control solenoid vale Inspection the ECM
54
Test
1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ECM terminal No. 11 and No. 34 and check for normal operation through the output waves using oscilloscope. Notice: Test during purge control valve operation after the minimum of 1 minute after the engine turned on. 3. Connect the ECM terminal No. 34 and No.10 and check for current consumption during the ignition switch ON. Specified Value 0.3 ~ 0.5 A
YAD1F0J0
4. Remove the line to canister and measure the pressure with the vacuum pressure gauge. > 500 mbar (after approx. 1 min.) purge control valve operates at this time
Specified Value
Notice: Test while at normal temperature and at idling state by operating the engine.
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FUEL RAIL
YAD1F320
1 2 3 4
Injector Connector Injector Fuel Rail Fuel Supply Line
5 6 7 8
Fuel Return Line Bolt Vacuum Hose O-Ring
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Fuel Pressure Test
Tools Required 103 589 00 21 00 Fuel Pressure Gauge 1. Turn the ignition switch to OFF position. 2. Remove the fuel pressure test connector. 3. Connect the fuel pressure gauge to the fuel pressure test connector. 4. Test the fuel pressure at idling by operating the engine using the fuel pressure gauge 103 589 00 21 00. Vacuum Hose Connected (bar) 3.2 ~ 3.6 Vacuum Hose Disconnected (bar) 3.7 ~ 4.2
YAD1F330
5. Replace the pressure regulator diaphragm if out of the specification.
Internal Leakage Test

1. Connect thefuel pressure gauge 103 589 00 21 00 to the fuel pressure test connector. 2. Stop the engine for approximately 30 minutes and then check the fuel pressure changes. Pressure change Fuel pressure drops slowly
YAD1F340
Fuel pressure drops rapidly
Fuel leakage at the injector Faulty fuel pressure regulators diaphragm and O-ring Faulty check valve in the fuel pump
3. If there is no change in fuel pressure and maintain the following pressure over 30 minutes, it is normal. Fuel pressure (bar) 2.5
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FUEL PRESSURE REGULATOR
YAD1F350
1 Vacuum Hose 2 Circlip 3 Fuel Pressure Regulator
4 O-Ring 5 O-Ring
Function of the Fuel Pressure Regulator

The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3.2 bars to 3.8 bars according to the intake manifold pressure. This operating pressure cannot be changed, and the fuel injection volume will be only determined by the injection time. Over supplied fuel returns to the fuel tank through the return line. <Operating at full load> There is no negative pressure applied to the spring chamber (9) during the full load, and it is separated from the fuel chamber (8) by the diaphragm (5). When the fuel pressure goes up, the diaphragm forces the compression spring (6) in the direction of compression. At this moment, the valve (3) sticks to the diaphragm by the fuel pressure, and the fuel return line (2) opens. The fuel over supplied returns to the fuel tank through the return line.
YAD1F360
2 3 5 6 8 9
Fuel return line Valve Diaphragm Compression Spring Fuel Chamber Spring Chamber
A Valves Closed B Valves Opened
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The pressure difference between the fuel pressure and the intake manifold is about 3.8 bars during the full load.
YAD1F390
YAD1F370
1 2 3 4 5 6
Fuel Pressure Regulator Intake Manifold Fuel Return (to fuel tank) Fuel Supply (from fuel pump) Fuel Pressure (approx. 3.8 bars) Intake Manifold Negative Pressure (0 bar)
1 2 3 4 7 8
Fuel Pressure Regulator Intake Manifold Fuel Return (to fuel tank) Fuel Supply (from fuel pump) Fuel Pressure (approx. 3.2 bars) Intake Manifold Negative Pressure (0.6 bars)
<Fuel Pressure Diagram>
<Operating at Idle and partial load> The spring chamber (9) is connected to the intake manifold with the vacuum hose at the intake pipe connection (7). The negative pressure generated in the intake manifold activates the diaphragm, and thus the fuel pressure gets reduced to the rate of the operating extent of the diaphragm by the intake manifold s negative pressure.
YAD1F400
A B LL TL VL
Fuel pressure Intake Manifold Negative Pressure Idling Partial load Full load
YAD1F380
Consequently, the fuel pressure in the fuel distributor changes by the intake manifolds negative pressure, and the injector s fuel pressure gets reduced independently to the throttle valve s position. Thus, the fuel injection volume can only be determined according to the injectors injecting duration. The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling.
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INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR
YAD1F410
The throttle actuator is actuated by the Engine Control Module(ECM) according to the position of the accelerator pedal position. It has two potentiometers which signal the position of the throttle valve to the ECM to enable it to recognize the various engine load states.
Consequently, the throttle valve opening is a constant 10-12 approximately. At no load, this produces an engine speed of about 1,800 rpm
Driving
When driving (part/full throttle), the servo motor controls the throttle valve in line with the various load states and according to the input signals from the pedal value sensor according to the input signals from the pedal value sensor according to the position of the accelerator pedal. The function of the EA (electronic accelerator) in the ECM determines the opening angle of the throttle valve through the throttle actuator. Further functions are; Idle speed control Cruise control Reducing engine torque for ASR/ABS operation Electronic accelerator emergency running Storing faults Data transfer through CAN
Ignition Off
In the de-energized states the throttle valve position is determined to be spring capsule.
Ignition On
When the ignition S/W on the servo motor in the throttle actuator is operated by the ECM. The throttle valve adopts a position in line with the coolant temperature.
Closed position
In the closed throttle position, the servo motor controls engine speed by operating the throttle valve further (greater mixture) or closing it further (reduced mixture), depending on coolant temperature and engine load. When this is done, the throttle valve can be closed further by the servo motor overcoming the force of the spring capsule (mechanical end stop). If the actuator is deenergized, the throttle valve is resting against the spring capsule.
SSANGYONG Y200
YAD1F420
Failure Code 104 105 108 109 116
Description Throttle position sensor 1 low voltage Throttle position sensor 1 high voltage Throttle position sensor 2 low voltage Throttle position sensor 2 high voltage Throttle actuator learning control failure Throttle valve return spring failure Throttle actuator failure
Trouble Area TPS 1 short circuit to ground or open TPS 1 short circuit to power TPS 2 short circuit to ground or open TPS 2 short circuit to power When actuator adaption fluctuation or not meet the condition scan tool When return spring defective of actuator with bad contact When supply voltage of the actuator short circuit to power Inspection the ECM When shut down of output driver When defective of both potentiometers
Maintenance Hint
Monitoring the actual values through Inspection the ECM pin 84, 85, 87, 112, 67, 68 about short circuit or open with bad contact Inspection the throttle valve actuator Inspection the ECM
119
121 Different mass air flow sensor signal with throttle position sensor Both throttle position sensor failure
123
125
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Failure Code Description Trouble Area Maintenance Hint
Throttle position sensor When difference between TPS 1 not plausible with 1 and TPS 2 126 Throttle position sensor 2 High permanent throttle When failure of wiring harness signal or actuator Mass air flow sensor and throttle position sensor failure When difference between MAF and TPS signal
Monitoring the actual values through scan tool Inspection the ECM pin 84, 85, 87, 112, 67, 68 about short circuit or open with bad contact Inspection the throttle valve actuator Inspection the ECM
127
185
Circuit Description
The ECM supplies a 5 volt reference signal and a ground to the TP sensor. The TP sensor sends a voltage signal back to the ECM relative to the throttle plate opening. The voltage signal will vary from approximately 0.3 ~ 0.9 volts at closed throttle, to over 4.0 ~ 4.6 volts at Wide Open Throttle (WOT). The TP sensors serve for engine load control according to the drive pedal command. Load adjustments independent of the drive pedal command can be implemented; such functions are, for instance, idle control, speed control, drive slip control, load shock damping, and similar functions. When the actuator current fails, the throttle valve is returned to emergency operating position by a spring. The throttle valve position, thereby the actuator drive position check back is provided by two potentiometers. The motor positions the throttle valve against the return spring force. Motor and return spring are two separate energy sources. Each of Them is able to position the throttle valve in emergency position alone. Throttle valve position check back and monitoring is provided by two actual value potentiometers connected to the engine control electronics.
Throttle Actuator Inspection

1. Turn the ignition switch to ON position. 2. Measure the TPS 1 signal voltage at the ECM pin No. 87 and TPS 2 signal voltage at the ECM pin No. 85. Pedal Position Closed TPS 1 TPS 2 Opened Closed Opened Specified Value 0.3 ~ 0.9 v 1 4.0 ~ 4.6 v 4.0 ~ 4.6 v 0.3 ~ 0.9 v
Throttle Actuator DC Motor Inspection

1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin No. 67 and No. 68. Application Ignition ON Engine Status Idling Specified Value 0.8 ~ 2.3 v 1.0 ~ 2.5 v (Coolant temperature is over 70 C)
Throttle Actuator DC Motor Resistance

1. Turn the ignition switch to OFF position. 2. Measure the resistance between the ECM pin No. 67 and No. 68. Specified Value <10
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BLANK
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HOT FILM AIR MASS (HFM) SENSOR
YAD1F430
1 Housing 2 Protector Net 3 Electronic Housing
4 Connector 5 Hot Film Air Mass Sensor 6 Measuring Port
The Hot Film Air Mass (HFM) sensor with recognition of flow direction related to pulsating flow is designed for recording load on Engine Control Module (ECM) by measuring the output voltage proportional to the reference voltage of the ECM.
Mass Air Flow Sensor

Mass Air Flow (MAF) is a thermal flow meter whose sensor element with its temperature sensors and heating area is exposed to the MAF to be measured. A heating area located in the center of a thin membrane is controlled to an over-temperature by a heating resistor and a temperature sensor of this membrane. And the value of overtemperature depends on the temperature of the in-flowing air. Two temperature sensors on upstream and downstream of the heating area show the same temperature without incoming flow. With incoming flow, upstream part is cooled down but downstream temperature retains its temperature more or less due to the air heated up in the heating area. This temperature difference in quantity and direction depends on the direction of the incoming flow. ECM modulates the flow of heating current to maintain the temperature differential between the heated film and the intake air at a constant level. The amount of heating current required to maintain the temperature thus provides an index for the MAF. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve.
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Under high fuel demands, the MAF sensor reads a high mass flow condition, such as Wide Open Throttle (WOT). The ECM uses this information to enrich the mixture, thus increasing the fuel injector on-time, to provide the correct amount of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by the ECM, which then decreases the fuel injector on-time due to the low fuel demand conditions. To facilitate the installation of the HFM in the intake passage, lubricating agents may be used. However, when lubricants are used care must be taken to ensure that they do not enter the flow passage and cannot be sucked in with the air flow. The following tables show the relationship between MAF and output voltage. Mass Air Flow (kg/h) 0 10 15 30 60 120 Voltage (V) 0.95 ~ 1.05 1.28 1.41 1.71 2.16 2.76 Mass Air Flow (kg/h) 250 370 480 640 800 Voltage (V) 3.51 3.93 4.23 4.56 4.82
Intake Air Temperature

The Intake Air Temperature (IAT) sensor is a part of Hot Film Air Mass (HFM) sensor and is a thermistor, a resistor which changes value based on the temperature of the air entering the engine. Low temperature produces a high resistance, while high temperature causes a low resistance as the following table. The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage to determine the IAT. The voltage will be high when the manifold air is cold and low when the air is hot. The ECM knows the intake IAT by measuring the voltage. The IAT sensor is also used to control spark timing when the manifold air is cold. Temp. ( C) -40 -20 0 20 40 60 80 100 120 130 R min.() 35140 12660 5119 2290 1096 565 312 184 114 91 R nom. () 39260 13850 5499 2420 1166 609 340 202 127 102 R max. () 43760 15120 5829 2551 1238 654 370 222 141 114
SSANGYONG Y200
YAD1F440
Failure Code 03 04
Description Intake air temperature sensor low voltage Intake air temperature sensor high voltage Intake air temperature sensor plausibility Mass air flow sensor plausibility
Trouble Area IAT sensor short circuit to ground or open IAT sensor short circuit to power Malfunction in recognition of IAT When functional problem Malfunction in recognition of MAF When air mass not plausible
Maintenance Hint
Monitoring the actual air temperature through scan tool Inspection the ECM pin 80, 79 about short circuit or open with bad contact Inspection the IAT sensor (integrated in HFM sensor) Inspection the ECM Monitoring the actual air mass flow through scan tool Inspection the ECM pin 81, 105 about short circuit or open with bad contact Inspection the MAF sensor (integrated 11 in HFM sensor) Inspection the ECM
05
09 10 11
Mass air flow sensor low voltage Mass air flow sensor high voltage
MAF sensor short circuit to ground or open MAF sensor short circuit to power
Circuit Description
The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the other elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The separation of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal decoupling between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is located on a single layer. The voltage at the heater provides the index for the mass air flow. The MAFs electronic circuitry then converts the voltage to a level suitable for processing in the ECM. This device does not need a burn off process to maintain its measuring precision over an extended period. In recognition of the fact that most deposits collect on the sensor elements leading edge, the essential thermal transfer elements are located downstream on the ceramic layer. The sensor element is also design to ensure that deposits will not influence the flow pattern around the sensor. The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the intake air is warm, resistance is low; therefore the IAT signal voltage will be low.
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M162 ENGINE CONTROLS 1F1-53 Mass Air Flow Sensor Input Voltage Inspection
1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin Application Ignition ON Engine Status Idling Specified Value 0.9 ~ 1.1 V 1.3 ~ 1.7 V (Coolant temperature is over 70 C)
Notice: If the measured value is not within the specified value, the possible cause may be in cable or MAF sensor in itself. Perform the 5 volt power supply inspection procedures.
Mass Air Flow Sensor 5 volt Power Supply Inspection

1. Turn the ignition switch to OFF position. 2. Disconnect the HFM sensor connector. 3. Turn the ignition switch to ON position. 4. Measure the voltage between the ECM pin No. 108 and MAF sensor connecter terminal No. 3. Specified Value 4.7 ~ 5.2 V
Notice: If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling. 5. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 4. Specified Value 4.7 ~ 5.2 V
Notice: If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
Mass Air Flow Sensor 12 volt Power Supply Inspection

1. 2. 3. 4. Turn the ignition switch to OFF position. Disconnect the HFM sensor connector. Turn the ignition switch to ON position. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 2. Specified Value 11 ~ 14 V
Notice: If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage Protection Relay (OVPR).
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ENGINE COOLANT TEMPERATURE (ECT) SENSOR
YAD1F450
1 Artificial Resin Housing 2 Metal Housing 3 NTC (Negative Temperature Coefficient) Resistor
4 Connector 5 Engine Coolant Temperature Sensor
Engine Coolant Temperature (ECT) sensor detects coolant temperature and supplies information to the ECM. It is composed of metal housing with two NTC resistor, 4 pin connector. The ECM provides a 5 volt signal to the ECT sensor through a dropping resistor. When the engine is cold, the ECT sensor provides high resistance, which the ECM detects as a high signal voltage. As the engine warms up, the sensor resistance becomes lower, and the signal voltage drops. At normal engine operating temperature, the ECT signal will measure about 1.5 to 2.0 volts. The ECM uses information about coolant temperature to make the necessary calculations for: Fuel delivery Ignition control Knock sensor system Idle speed Torque converter clutch application
Canister purge Cooling fan operation Others
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Temperature (C) Resistance () -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 48,550 27,000 15,570 9,450 5,890 3,790 2,500 1,692 1,170 826 594 434 322 243 185 143 111.6 88 71.2 Voltage (V) 4.90 4.82 4.70 4.52 4.43 3.96 3.57 3.14 2.70 2.26 1.86 1.51 1.22 0.98 0.78 0.63 0.50 0.40 0.33
YAD1F460
SSANGYONG Y200
YAD1F470
Failure Code 00
Description Engine coolant temperature sensor low voltage Engine coolant temperature sensor high voltage Engine coolant temperature sensor plausibility Engine coolant temperature insufficient for closed loop fuel control
Trouble Area ECT sensor short circuit to ground or open ECT sensor short circuit to power Malfunction in recognition of ECT When drop to about 50 C below after warm up Malfunction in recognition of ECT When minimum temperature for lambda control after warm up
Maintenance Hint
Monitoring the actual coolant temperature through scan tool Inspection the ECM pin 78, 79 about short circuit or open with bad contact Inspection the ECT sensor Inspection the ECM
01
02
06
Circuit Description
The ECT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies a voltage on the signal circuit to the sensor. When the engine coolant is cold, the resistance is high; therefore the ECT signal voltage will be high
Engine Coolant Temperature Sensor Inspection

1. Turn the ignition switch to ON position. 2. Measure the voltage between the ECM pin No. 78 and No. 79. Temperature (C) 20 80 100 Specified Value (V) 3.57 1.22 0.78
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3. 4. 5. 6. Turn the ignition switch to OFF position. Disconnect the ECT sensor connector. Turn the ignition switch to ON position. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4. Temperature (C) 20 80 100 Specified Value () 2,500 322 185
Notice: Replace wiring and coolant temperature sensor if out of specified value.
SSANGYONG Y200
ACCELERATOR PEDAL MODULE
YAD1F480
1 Accelerator Pedal 2 Accelerator Pedal Sensor 3 Bolts
4 6-Pin Connector 5 Kick-down Switch 6 Nut
The Acceleration Pedal Position (APP) sensor is mounted on the accelerator pedal assembly. The sensor is actually two individual APP sensors and one housing. This sensor works with the Throttle Position (TP) sensor to provide input to the Engine Control Module (ECM) regarding driver requested accelerator pedal and throttle angle at the throttle body.
When the APP sensor is defected:

When the APP1 or APP 2 sensor is defected condition, the engine is still running at idle condition but, the accelerator pedal reaction is not response correctly and also, the engine rpm will be reacted to 4,000 rpm slowly. If the APP 1 sensor is out of order, the APP 2 sensor will be conducted with signal as a default signal but, the throttle valve opening is limited 60% and delayed opening speed.
When the TP sensor or servo motor is defected:

When the TP 1, 2 sensor or servo motor is defected condition, the throttle valve will be closed to the spring capsule by spring force, at this condition, the throttle valve will open 10 ~ 20 and engine rpm will be controlled by ECM with opening (On/Off) time of injector. The engine rpm will be maintaining 900 rpm (at idle) to 1,800 according to the engine load.
SSANGYONG Y200
YAD1F490
Failure Code 122
Description Acceleration pedal position sensor signal failure Acceleration pedal position 1 sensor low voltage Acceleration pedal position sensor 1 high voltage Acceleration pedal position sensor 2 low voltage Acceleration pedal position sensor 2 high voltage Accelerator pedal position sensor 1 not plausible with accelerator pedal position sensor 2 Both setpoint accelerator pedal position sensor defective
Trouble Area When malfunction of APP sensor APP 1 sensor short circuit to ground or open APP 1 sensor short circuit to power APP 2 sensor short circuit to ground or open APP 2 sensor short circuit to power bad contact When difference between APP 1 sensor and APP 2 sensor
Maintenance Hint
Monitoring the actual values through scan tool Inspection the ECM pin 31, 47, 32, 48, 59, 51 about short circuit or open with Inspection the APP sensor Inspection the ECM
160
161
162
163
164
When defective of both APP sensor
167
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1F1-60 M162 ENGINE CONTROLS Circuit Description

The ECM supplies a 5 or 2.5 volt reference signal and a ground to the APP sensor 1or 2. The ECM calculates on these signal lines. The APP sensor output changes as the accelerator pedal is moved. The output of the APP 1and APP2 sensor are low, about 0.4 ~ 0.7 volts and 0.2 ~ 0.35 volts respectively at the closed throttle position. As pushing the accelerator pedal, the output increases so that the output voltages will be about 4.3 ~ 4.8 volts and 2.1 ~ 2.4 volts individually when accelerating fully with the kick down, at Wide Open Throttle (WOT).
Acceleration Pedal Position Sensor 1 Inspection

1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin No. 47andNo. 31while operating the accelerator pedal as following conditions. Not depress the pedal (closed throttle position) Fully depress the pedal (full throttle with kick down) Condition of Throttle Valve Closed Throttle Valve Fully Depressed Throttle Valve Specified Value (V) 0.3 ~ 0.7 4.3 ~ 4.8
Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to APP 1 sensor.
Acceleration Pedal Position Sensor 2 Inspection

1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin No. 48 and No. 50 while operating the accelerator pedal as following conditions. Not depress the pedal (closed throttle position) Fully depress the pedal (full throttle with kick down) Condition of Throttle Valve Closed Throttle Valve Fully Depressed Throttle Valve Specified Value (V) 0.1 ~ 0.4 2.1 ~ 2.5
Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to APP sensor 2.
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CLUTCH SWITCH
YAD1F500
Failure Code
Description Clutch switch defective
Trouble Area When malfunction of clutch switch
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 43 about shout circuit or open Inspection the clutch switch Inspection the ECM
62
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COOLING FAN
YAD1F510
Failure Code 44
Description Cooling fan (HI) relay short circuit to power Cooling fan (HI) relay short circuit to ground or open
Trouble Area Cooling fan short circuit to power Cooling fan short circuit to ground or open with bad contact
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 35 about short circuit or open with bad contact Inspection the power source Inspection the cooling fan Inspection the ECM
45
Circuit Description
Ignition voltage is supplied directly to the cooling fan relay coil. The ECM controls the relay by grounding the control circuit. When the ECM is commanding a command ON, the voltage of the control circuit should be low (near 0 volt). When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit senses a voltage other than what is expected, the fault line status will change causing the fault code to set.
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A/C COMPRESSOR RELAY
YAD1F520
Failure Code 228
Description A/C compressor relay short circuit to battery A/c compressor relay short circuit to ground or open
Trouble Area When malfunction of A/C compressor control
Maintenance Hint
Monitoring the actual operation through scan tool Inspection the Engine Control Module (ECM) pin 44 about short circuit or open with bad contact Inspection the relay short circuit or open Inspection the ECM
229
Circuit Description
When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM.
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CRUISE CONTROL SWITCH
YAD1F530
Failure Code 129
Description Cruise control OFF due to message counter failure Vehicle speed signal failure Vehicle speed signal failure Cruise control lever failure Cruise control acceleration failure
Trouble Area Cruise control system message counter fault When malfunction of auto-cruise system Implausible condition of vehicle speed signal. Cruise control lever defective Cruise control system Implausible condition of acceleration signal Cruise control system Implausible condition of deceleration signal
Maintenance Hint
Monitoring the actual recognition status and vehicle speed signal through scan tool Inspection the Engine Control Module (ECM) pin 52 53 54 55 57 about short circuit or open with bad contact Inspection the CAN and ABS Inspection the cruise control lever switch Inspection the ECM
130 131 132
133
134
Cruise control deceleration failure
Circuit Description
Cruise control is an automatic speed control system that maintain a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 40 km/h to engage cruise control.
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TRACTION CONTROL SYSTEM (TCS)
YAD1F540
Failure Code 150
Description TCS input signal short circuit to battery TCS input signal short circuit to ground or open
Trouble Area TCS short circuit to power TCS short circuit to ground or open
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 45 about short circuit or open with bad contact Inspection the TCS lamp of I/P cluster. Inspection the ECM
151
Circuit Description
Battery voltage is supplied to the TCS warning lamp with the ignition in ON and START. The warning lamp can be activated only by the Electrical Brake Control Module (EBCM) internally supplying ground to terminal 21. If the TCS input circuit is open or short, this failure code will be set.
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RESONANCE FLAP
YAD1F150
Failure Code
Description Resonance flap short circuit to battery
Trouble Area Resonance flap short circuit to power
Maintenance Hint
198
Monitoring the actual operational status and vehicle speed signal through scan tool Inspection the Engine Control Module (ECM) pin 97 about short circuit or open with bad contact Inspection the power source short circuit or open to resonance flap Inspection the resonance flap solenoid and hardware Inspection the ECM
199
Resonance flap short circuit to ground or open
Resonance flap short circuit to ground or open
Circuit Description
A pneumatically actuated resonance flap is located on the intake manifold, and will be opened and closed by load, which operates resonance flap according to engine and controlled by ECM and rpm. Resonance flap is closed at idle/partial load (less than 3,800/rpm). The switch valve will be adjusted by ECM and resonance flap will be closed. By increasing air flow passage through dividing intake air flow toward both air collection housing. This leads to a significant increase in the torque in the lower speed range. Resonance flap is open at full load (over 3,800/rpm). The switch valve will not be adjusted by ECM and resonance flap will be open. The collected air in the air collection housing will not be divided and intake air passage will be shorten.
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STOP LAMP SWITCH
YAD1F550
Failure Code
Description Stop lamp switch failure
Trouble Area When malfunction of stop lamp switch - implausible condition of stop lamp signal input
Maintenance Hint
Monitoring the actual operational status and vehicle speed signal through scan tool Inspection the Engine Control Module (ECM) pin 49 about short circuit or open with bad contact Inspection the contact condition of stop lamp switch Inspection the ECM
135
Circuit Description
The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released.
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ENGINE RPM
YAD1F560
Failure Code 32
Description Engine rpm output circuit short circuit to battery Engine rpm output circuit short circuit to ground or open
Trouble Area When short circuit to battery
Maintenance Hint
33
When short circuit to ground or open
Inspection the cluster panel board circuit Inspection the ECM Monitoring the actual rpm in cluster Inspection the Engine Control Module (ECM) pin 60 about short circuit or open
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EXHAUST SYSTEM
CATALYTIC CONVERTER
The purpose of the catalytic converter is to convert the three pollutants of carbon monoxide(CO), hydrocarbons (HC) and oxides of nitrogen (NOx) contained in the exhaust of gasoline engines, into the harmless compounds of water (H2O), carbon dioxide (CO2) and nitrogen (N2). The catalytic converter contains a catalyst, a word coming from the Greek and which designates the element essential for catalyst which triggers chemical reactions without itself being consumed. These catalysts in the 3-way catalytic converter are the rare metals platinum (Pt) and rhodium (Rh). The catalytic converter consists essentially of three main elements. The exhaust gases flow through the catalytic converter and, in so doing, coming into contact with rare metals (Pt and Rh). The following chemical reaction are produced. CO + O 2 CO 2 HC + O 2 CO 2 + H 2O NO x N 2 + O 2
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OXYGEN SENSOR
YAD1F570
The oxygen sensor is unique among the engine control sensors because is acts like a battery and is able to generate its own low voltage signal. It is located the exhaust system and monitors the amount of oxygen in the exhaust stream and provides feedback to the Engine Control Module (ECM). The electrically heated oxygen sensor warms up quickly and remains hot, even at idle when the exhaust manifold may cool down. The ECM applies a reference voltage of 450 mv to the oxygen sensor, the ECM compares this reference voltage with the voltage generated by oxygen sensor. The amount of voltage the oxygen sensor generates is proportionate to the difference between the amount of oxygen in the outside air and the exhaust gases. The atmosphere contains about 21% oxygen. The exhaust from a rich air/fuel ratio contains almost no oxygen. With a large difference between the amounts of oxygen containing the two surface, the sensor generates less voltage.
When the exhaust gas is rich (below 14.7:1), the voltage output is high, above450mv. When the exhaust gas is lean (above 14.7:1 air/fuel ratio), the sensors voltage output is low, below 450 mv. The ECM uses oxygen sensor information for: Open loop / closed loop criteria Ideal air / fuel ratio
YAD1F580
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YAD1F590
SSANGYONG Y200
YAD1F600
Failure Code 80
Description Oxygen sensor high voltage
Trouble Area When recognition the output that more than nominal threshold, malfunction of sensing voltage. When recognition the output that more than nominal threshold, malfunction of sensing voltage. When recognition the output that not active the sensor etc. When recognition the output that no lean signal after overrun fuel shut-off When slow response of sensor signal When recognition the heating circuit When recognition the heating currents that more or less than set values (less than 0.2 A or more than 2 A) When recognition the heating voltages than less than set values (less than 2v)
Maintenance Hint
Monitoring the actual output signal through scan tool Inspection the ECM pin 16, 17 about short circuit or open with bad contact Inspection the oxygen sensor Inspection the ECM
89
Oxygen sensor low voltage
82
Oxygen sensor no activity detected Oxygen sensor not lean after overrun fuel shut-off Oxygen sensor slow response Oxygen sensor heater failure Oxygen sensor heater short circuit to battery
83
84 85
Monitoring the heating status through scan tool Inspection the ECM pin 9 about short circuit or open with bad contact Inspection the heating power source Inspection the heating circuit of oxygen sensor Inspection the ECM
86
87
Oxygen sensor heater short circuit to ground or open
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Failure Code Description Bank 1 system short term fuel trim adaptation below lean threshold Trouble Area When recognition the value less than nominal control threshold, it means that when big deviation in control range of adaptation values through fuel and air mixture formation When recognition the value more than nominal control threshold, it means that when big deviation in control range of adaptation values through fuel and air mixture formation When recognition the short term fuel trim that more than nominal threshold When recognition the short term fuel trim that less than nominal threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold Maintenance Hint
Inspection the intake air leakage Inspection the injection quantities with injector block or leakage Inspection the exhaust leakage Inspection the ECM
81
93
Bank 1 system short term fuel trim adaptation above rich threshold
96
Bank 1 system short term fuel trim at rich stop Bank 1 system short term fuel trim at lean stop Bank 1 system idle adaptation failure (above rich threshold) Bank 1 system idle adaptation failure (below rich threshold) Bank 1 system learning control failure (rich, low load) Bank 1 system learning control failure (lean, low load) Bank 1 system learning control failure (rich, high load) Bank 1 system learning control failure (rich, low load)
97
98
99
100
101
102
103
Circuit Description
In order to control emissions, a catalytic converter is used to covert harmful emissions into harmless water vapor and carbon dioxide. The ECM has the ability to monitor this process by using a oxygen sensor. The oxygen sensor produces and output signal which indicates the storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust emission effectively. If the oxygen sensor pig tail wiring, connector, or terminal is damaged. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly, it must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair the wires, connector, or terminal and degrade the oxygen sensor performance.
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1F1-74 M162 ENGINE CONTROLS Oxygen Sensor Signal Voltage Inspection

1. Maintain the engine speed is at idle while the coolant temperature is over 80 C. 2. Measure the oxygen sensor signal voltage between the ECM terminal No. 16 and No. 17. Specified Value 2 ~ 1.0 V
Notice: If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECM
Oxygen Sensor Heating Voltage Inspection

1. Maintain the engine speed is at idle while the coolant temperature is over 80 C. 2. Measure the oxygen sensor signal voltage between the ECM terminal No. 11 and No. 9. Specified Value 11 ~ 14 V
Oxygen Sensor Heating Current Consumption Inspection

1. Turn the ignition switch to ON position. 2. Measure the oxygen sensor heating current consumption between the ECM terminal No. 9 and No. 5. Specified Value 0.2 ~ 2.0 A
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BLANK
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ENGINE CONTROL MODULE
YAD1F610
1 2 3 4
Cover Plate Connector Flat Pin Vehicle Side : No. 1-12 Engine Side : No. 61-72
5 Pin Vehicle Side : No. 13-60 Engine Side : No. 73-120 A Vehicle Side Connector : Black B Engine Side Connector : Gray
The Engine Control Module (ECM), located inside the right side kick panel, is the control center of the fuel injection system. It constantly looks at the information from various sensors and controls the systems that affect the vehicles performance. Engine rpm and air mass are used to measure the air intake quantity resulting in fuel injection metering. The ECM also performs the diagnostic functions of the system. It can recognize operational problems, store failure code(s) which identify the problem areas to aid the technician in making repairs. There are no serviceable parts in the ECM. The calibrations are stored in the ECM in the Programmable Read Only Memory (PROM). The ECM supplies either 5 or 12 volts to power the sensors or switches. This is done through resistance in the ECM which are so high in value that a test light will not come ON when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give and accurate reading because its resistance is too low. You must use a digital voltmeter with a 10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as the ignition coils, the fuel injectors, the fuel pump relay, the intake manifold resonance flap, the camshaft actuator, the canister purge valve, etc., by controlling the ground circuit.
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SERIAL DATA COMMUNICATION
YAD1F620
Failure Code
Description CAN communication failure: ASR/MSR
Trouble Area When CAN signal message missing or implausibility for ASR/MSR unit or not initialized condition
Maintenance Hint
Inspection the ASR unit with CAN connection Inspection the Engine Control Module (ECM) pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the TCM unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM
23
CAN communication failure: ABS 24
When CAN signal message missing or implausibility for ABS unit or not initialized condition
CAN communication failure: TCU (A/T only) 26
When CAN signal message missing or implausibility for TCU unit or not initialized condition
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Failure Code Description CAN communication failure: TOD (E32 only) 27 Trouble Area When CAN signal message missing or implausibility for TOD unit or not initialized condition Maintenance Hint
Inspection the TOD unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS/ABD unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS/ABD unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the each control unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the MSR unit with CAN connection Inspection the Engine Control Module (ECM) pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ASR unit with CAN connection Inspection the Engine Control Module (ECM) pin 38, 37 about short circuit or open with bad contact Inspection the ECM
29
CAN communication failure: ID 200h not plausible
When CAN signal message missing or implausibility for ABS/ABD unit or not initialized condition
30
31
CAN communication failure: communication initialization failure
When CAN signal message missing or implausibility for each unit (ABS, ASR, TCM, TOD etc.) or not initialized condition When CAN signal message missing or implausibility for MSR unit or not initialized condition
59
CAN communication failure: MSR data transmission not plausible
60
CAN communication failure: ASR data transmission not plausible
When CAN signal message missing or implausibility for ASR unit or not initialized condition
Circuit Description
The provision for communicating with the ECM is the Data Link Connector (DLC). It is located in the instrument panel fuse block. The DLC is used to connect the scan tool. Battery power and ground is supplied for the scan tool through the DLC. CAN line is used to communicate with the other module such as the Transmission Control Module (TCM) and Transfer Case Control Unit (TCCU).
Keyword 2000 Serial Data Communications

Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmitting and receiving multiple signals over a singles wire. The message carried on KWP 2000 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will must wait.
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INTERNAL FAILURE
Failure Code Description Transmission coding failure 21 Trouble Area When faulty of variant coding of transmission Maintenance Hint
Inspection the coding condition through scan tool Inspection the Engine Control Module (ECM) Inspection the CAN line Inspection the TCM Inspection the ECM
ECM failure (RAM) 136 Uncoded/ unprogramed ECM ECM failure (EPROM) ECM failure (EEPROM/ Flash - EPPOM checksum failure) ECM failure (coding ID checksum failure) ECM failure (coding checksum failure) ECM failure (programming checksum failure)
When malfunction of random access memory - ECM internal error When malfunction of ECM coding-required ECM encoding When malfunction of ECM internal
Fulfill the ECM variant coding
142 137 143
Inspection the ECM
144 145 146
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ELECTRONIC THROTTLE CONTROLLER SAFETY MALFUNCTION

Failure Code 110 117 120 138 139 140 186 187 188 189 190 Description Throttle actuator learning data fault Exceed fuel-cut safety time Cruise control interruption memory failure Call Monitoring Servo motor control output interruption memory failure Servo motor open/short ECM failure (incompatible CPU) ECM failure (CPUs communication failure) ECM failure (CPU 2 configuration failure) ECM failure (CPU 2 fault) ECM failure (CPU run time failure between CPUs) ECM failure (CPU 2 cruise control message counter failure) Over deceleration limit (CPU 2) Over acceleration limit (CPU 2) Cruise control lever dual operation (CPU 2) Cruise control lever safety terminal failure (CPU 2) Unusual pedal position variation (CPU 2) Unusual throttle position variation (CPU 2) Unusual throttle controller monitoring data comparison fault (CPU 2) Trouble Area System internal failure Maintenance Hint
Inspection the Engine Control Module (ECM)
231 232 233 234 235
236 237
238
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Failure Code Description Unusual accelerator pedal position sensor comparison fault (CPU 2) Throttle potentiometer comparison fault (CPU 2) Unusual CPU communication (CPU 2) Unusual CPU configuration (CPU 2) A/D converter failure (CPU 2) Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2 (ECM) Position controller setpoint fault between CPU 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint fault between CPU 1 and CPU 2 A/D converter overflow (CPU 2) ROM fault (CPU 2) RAM fault (CPU 2) Cycle monitor fault (CPU 2) Trouble Area System internal failure Maintenance Hint
Inspection the Engine Control Module
239
240 241 242 243
244
245
246
247
248 249 250 251
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IMMOBILIZER
YAD1F630
Failure Code
Description Communication with transponder missing
Trouble Area When missing the transponder signal
Maintenance Hint
D Inspection the Engine Control Module (ECM) pin 13, 14 about short circuit or open with bad contact Inspection the power source or ground short circuit or open of immobilizer unit Inspection the transponder condition (broken etc.) Inspection the ECM Fulfill the immobilizer pairing
25
Unprogramed ECM with immobilizer 141
When malfunction of immobilizer Required immobilizer encoding, no paired condition of immobilizer even through start trial
Circuit Description
Immobilizer is a device disabling vehicle ignition unless a specific key is used and designed to help prevent vehicle theft. Immobilizer is comprised of two devices, a key with encoded transponder and ECM with the same encoding of the transponder. When a key is inserted into the hole to start vehicle and turned to ON, the ECM reads and decodes the transponder code and, if the same, starts the engine, it is called immobilizer. It means immobilizer system disables starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other.
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MAINTENANCE AND REPAIR ON-VEHICLE SERVICE

DISCHARGING THE PRESSURE IN FUEL SYSTEM
Removal and Installation Procedure
1. Remove the fuel pressure test connector. Installation Notice Tightening Torque 25 N m (18 lb-ft)
KAA1F430
2. Remove the fuel pressure in fuel system by pressing the service valve with a clean, pointy tool. Notice: Place a cloth so that the fuel doesnt stain around. 3. Installation should follow the removal procedure in the reverse order.
KAA1F440
FUEL PUMP
Tools Required 661 589 00 46 00 Fuel Tank Cap Wrench

Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Relieve the fuel system pressure. Refer to Discharging the Pressure in Fuel System in this section. 2. Disconnect the negative battery cable. 3. Put aside the floor carpet to remove the fuel pump access cover. 4. Remove the fuel pump access cover. 5. Remove the fuel pump wiring connectors. 6. Disconnect the fuel supply and return pipes. 7. Remove the fuel pump locking cap band.
YAA1F170
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8. Using the fuel tank cap wrench 661 589 00 46 00, remove the locking cap. 9. Remove the pump from the fuel tank. Notice: Check the condition of the seal and replace if necessary. Drain the fuel before removing the pump. 10. Perform an operational check of the fuel pump. 11. Installation should follow the removal procedure in the reverse order.
YAA1F550
FUEL FILTER
1. Disconnect the negative battery cable. Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 2. Relieve the fuel system pressure. Refer to Discharging the Pressure in Fuel System in this section. 3. Disconnect the fuel lines from the fuel filter. Installation Notice Tightening Torque 28 N m (21 lb-ft)
YAA1F190
4. Remove the fuel filter mounting bracket bolt. Installation Notice Tightening Torque 28 N m (21 lb-ft)
Notice: Place the fuel pump pad. There may be a corrosion due to the contact between the fuel filter and the bracket. 5. 6. 7. 8. Remove the fuel filter. Install the fuel filter. Perform a leak test of the fuel filter. Installation should follow the removal procedure in the reverse order.
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FUEL TANK
Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Relieve the fuel pressure. Refer to Discharging the Pressure in Fuel System in this section. 2. Disconnect the negative battery cable. 3. Drain the fuel tank.
KAA1F370
4. Put aside the floor carpet to remove the fuel pump access cover. 5. Remove the fuel pump access cover.
6. Disconnect the return line. 7. Disconnect the supply line. 8. Disconnect the fuel tank-to-canister hose from the fuel tank. 9. Disconnect the fuel pump wiring connector.
YAA1F170
10. Disconnect the fuel filler hose and air vent hose from the fuel tank. 11. Support the fuel tank. 12. Remove the fuel tank retaining nuts. Installation Notice Tightening Torque 38 N m (28 lb-ft)
13. Carefully lower the fuel tank.
YAA1F160
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14. Turn the roll over valves counterclockwise at an angle of 90 degrees. 15. Turn the lock ring counterclockwise. 16. Remove and discard the gasket. 17. Installation should follow the removal procedure in the reverse order.
YAA1F180

1. Disconnect the negative battery cable. 2. Remove the fuel pressure test connector. Installation Notice Tightening Torque 25 N m (18 lb-ft)
KAA1F430
Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 3. Relieve the fuel pressure in fuel supply system by pressing the service valve.
KAA1F440
4. Disconnect the vacuum hose. 5. Disconnect the circlip and remove the fuel pressure regulator. 6. Apply the oil to O-ring lightly and then replace it. 7. Perform a leak test of the fuel pressure regulator with the engine off and the ignition on. 8. Installation should follow the removal procedure in the reverse order.
KAA1F130
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FUEL RAIL AND INJECTORS

Caution: The fuel system is under pressure. To avoidfuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Discharge the fuel pressure from the fuel pressure test connector. 2. Disconnect the negative battery cable. 3. Disconnect the vacuum hose from the fuel pressure regulator. 4. Remove the cable guide. 5. Disconnect the Hot Film Air Mass (HFM) sensor connector. 6. Remove the intake air duct mounting bolts. Installation Notice Tightening Torque 9 N m (80 lb-ft)
KAA1F440
7. Remove the intake air duct clamps. 8. Remove the intake air duct.
KAA1F060
9. Remove the fuel return and supply line. Notice: For removal, cover around parts with cloths not to be stained by fuel. In case of checking the injector only, do not remove the fuel return and supply line. Installation Notice Tightening Torque 23 N m (17 lb-ft)
10. Remove the six injector connectors.

KAA1F070
11. Remove the two left and two right bolts and one center bolt of the fuel rail assembly from the intake manifold. Installation Notice Tightening Torque 25 N m (18 lb-ft)
KAA1F080
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Notice: Before removal, the fuel rail assembly may be cleaned with as pray type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service. Important: If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.
KAA1F090
12. Remove the injectors and the fuel rail carefully. 13. Remove the fuel injector retainer clips. 14. Remove the fuel injectors by pulling them down and out. 15. Discard the fuel injector O-rings. 16. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors. 17. Perform a leak check of the fuel rail and fuel injectors. 18. Installation should follow the removal procedure in the reverse order.

1. Relieve the coolant system pressure. 2. Disconnect the negative battery cable. 3. Disconnect the engine coolant temperature sensor connector. Notice: Take care when handling the engine coolant temperature sensor. Damage to the sensor will affect the proper operation of the fuel injection system. 4. Remove the engine coolant temperature sensor from the pump hosing. Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAA1F150
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THROTTLE BODY (INTEGRATED WITH THE ACTUATOR)

1. Disconnect the negative battery cable. 2. Disconnect the mass air flow sensor connector. 3. Disconnect the mass air flow sensor from the air filter housing. 4. Remove the intake air duct mounting bolts. Installation Notice Tightening Torque
KAA1F010
9 N m (80 lb-ft)
5. Remove the air inlet housing clamps. 6. Remove the inlet air housing.
7. Disconnect the throttle body electrical connector. 8. Remove the throttle body bolts. Installation Notice Tightening Torque 9. Remove the vacuum hose. 12 N m (106 lb-ft)
KAA1F230
10. Remove the throttle body and discard the gasket. Important: Use care in cleaning old gasket material. Sharp tools may damage sealing surfaces. 11. Installation should follow the removal procedure in the reverse order.
KAA1F240
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1. Disconnect the negative battery cable. 2. Disconnect the Hot Film Air Mass (HFM) sensor electrical connector. 3. Remove the HFM sensor retaining screws. 4. Turn the HFM sensor coupling in the direction shown in the figure in the left so that it gets separated from the contact surface.
KAA1F190
Notice: Make sure the HFM sensor coupling connects completely with the contact surface installation. 5. Remove the HFM sensor. 6. Installation should follow the removal procedure in the reverse order.
KNOCK SENSOR
Removal and installation Procedure
1. Disconnect the negative battery cable. 2. Disconnect the knock sensor electrical connector from the intake manifold bracket. 3. Remove the knock sensor mounting bolt from the knock sensor installed on the cylinder block. Installation Notice Tightening Torque
KAA1F180
25 N m (18 lb-ft)
4. Remove the knock sensor. 5. Installation should follow the removal procedure in the reverse order.
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PEDAL POSITION SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the pedal position sensor connector. 3. Unscrew the bolts and nut. Installation Notice Tightening Torque 6 N m (53 lb-ft)
KAA1F410
4. Remove the pedal and sensor assembly. 5. Installation should follow the removal procedure in the reverse order.
OXYGEN SENSOR
1. Disconnect the negative battery cable. Notice: The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or the connector could affect proper operation of the oxygen sensor. Do not drop the oxygen sensor. 2. Disconnect the electrical connector. 3. Carefully remove the oxygen sensor from the exhaust pipe. Installation Notice Tightening Torque 55 N m (41 lb-ft)
YAD1F640
Important: A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or serviced sensors will al-ready have the compound applied to the threads. If a sensor is removed from any engine and is to be rein-stalled, the threads must have an anti-seize compound applied before reinstallation. 4. Coat the threads of the oxygen sensor with an antiseize compound, if needed. 5. Installation should follow the removal procedure in the reverse order.
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PURGE CONTROL VALVE

1. Disconnect the negative battery cable. 2. Disconnect the purge control valve connector. 3. Disconnect the throttle body-to-purge control valve hose from the purge control valve. 4. Disconnect the canister-to-purge control valve hose from the purge control valve. 5. Remove the purge control valve. 6. Installation should follow the removal procedure in the reverse order.
YAD1F650
CANISTER
Caution: Canister and vacuum hoses contain fuel vapors. Do not smoke in the area or permit an open flame. 1. Disconnect the fuel tank-to-canister hose form the canister. 2. Disconnect the canister-to-purge control valve hose form the canister.
YAD1F660
3. Remove the canister mounting bolts. Installation Notice Tightening Torque 6 N m (53 lb-ft)
4. Remove the canister. 5. Installation should follow the removal procedure in the reverse order.
YAD1F670
CAMSHAFT POSITION SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the camshaft position sensor. 3. Remove the camshaft position sensor retaining bolt. Installation Notice Tightening Torque
KAA1F170
10 N m (89 lb-ft)
SSANGYONG Y200

4. Check the O-ring for damage and replace it if neces sary. 5. Installation should follow the removal procedure in the reverse order.
CRANKSHAFT POSITION SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the electrical connector at the crankshaft position sensor. 3. Remove the crankshaft position sensor retaining bolt. Installation Notice Tightening Torque
KAA1F160
25 N m (18 lb-ft)

1. Disconnect the negative battery cable. 2. Remove the cowl side trim form passenger side. Refer to Section 9G, Interior trim. 3. Remove the four securing nuts for the Engine Control Module (ECM) from the mounting bracket. Installation Notice Tightening Torque
KAA1F200
25 N m (18 lb-ft)
4. Pull out the ECM from the bracket. 5. Disconnect the vehicle side coupling. 6. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
ECM WIRING DIAGRAM (3.2L DOHC - 1 OF 7) (MSE 3.63D)
YAD1F010
SSANGYONG Y200
SSANGYONG Y200
YAD1F020
SSANGYONG Y200
YAD1F030
SSANGYONG Y200
YAD1F040
SSANGYONG Y200
YAD1F050
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YAD1F060
SSANGYONG Y200
YAD1F070
SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter Engine Coolant Temp. Intake Air Temp. Engine RPM Regular RPM Engine Load Mass Air Flow Meter Throttle Position Angle Spark Advance Indicated Engine Torque Injection Time Battery Voltage Front Axle Speed Rear Axle Speed Accel. Pedal Position 1 Accel. Pedal Position 2 Throttle Position 1 Throttle Position 2 Fuel Integrator Oxygen Sensor A/C S/W Condition Full Load State Shift Gear State (A/T) A/C Control State Clutch Switch (M/T) Cam Actuator State Knocking Control Protect Mission Purge Control Valve Lambda Function Catalyst Heating Overrun Fuel Cut Ful l Fuel Cut Brake Switch Cruise Control Status *Condition : Warmed up, idle, P/N or neutral mv 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF Unit C C rpm rpm % Kg/h TA CA Nm ms V Km/h Km/h V V V V Value greater than 95 C after warm up -40 ~ 130 C (varies with ambient temp. or engine mode) 700 50 (P/N), 600 50 (D) 700 50 (P/N), 600 50 (D) 18 ~ 25 % 16 ~ 25 Kg/h 0 TA (up to 100 TA at t he wi de open throttle) CA (6 ~ 9 CA) Varies with engine condition 3 ~5 ms 13.5 ~ 14.1 v (engine running) 0 ~ 265 Km/h 0 ~ 265 Km/h 0.4 ~ 4.8 V 0.2 ~ 2.4 V 0.3 ~ 4.6 V 0.3 ~ 4.6 V 0.8 ~ 1.2 100 ~ 900 mv -
SSANGYONG Y200

Application Camshaft Position Sensor Retaining Bolts Canister Mounting Bolts Coolant Temperature Sensor Crankshaft Position Sensor Retaining Bolt Engine Control Module (ECM) Mounting Bracket Nuts Fuel Filter Mounting Bracket Bolt Fuel Filter Lines Fuel Pressure Test Connector Fuel Rail Assembly Bolts Fuel Return And Supply Lines Fuel Tank Retaining Nuts Intake Air Duct Mounting Bolts Knock Sensor Mounting Bolt Oxygen Sensor Pedal Position Censor Mounting Bolts And Nut Throttle Body Bolts Nm 10 6 30 10 10 6 28 25 25 23 38 9 25 55 6 12 Lb-Ft 22 21 18 18 17 28 18 41 Lb-In 89 53 89 89 53 80 53 106
SSANGYONG Y200
FUEL SYSTEM SPECIFICATION

Use Only Unleaded Fuel Rated at 89 Octane or Higher
Fuel quality and additives contained in fuel have a significant effect on power output, drivability, and life of theengine. Fuel with too low an octane number can cause engine knock. Caution: Use of fuel with an octane number lower than 89 may damage engine and exhaust system. Notice: To prevent accidental use of leaded fuel, the nozzles for leaded fuel are larger, and will not fit the fuel filler neck of your vehicle.
This type of fuel can reduce vehicle performance and damage components of the fuel system. Caution: Use of methanol may damage the fuel system.
Vehicle Fueling from Drums or Storage Containers

For safety reasons (particularly when using noncommercial fueling systems) fuel containers, pumps and hoses must be properly earthed. Static electricity build up can occur under certain atmospheric and fuel flow conditions if unearthed hoses, par-ticularly plastic, are fitted to the fuel-dispensing pump. It is therefore recommended that earthed pumps with integrally earthed hoses be used, and that storage containers be properly earthed during all noncommercial fueling operations.
Do Not Use Methanol

Fuels containing methanol (wood alcohol) should not be used in vehicle.
TEMPERATURE VS RESISTANCE
C F ECT sensor ohms ( ) 88 111.6 143 202 261 340 452 609 835 1166 1662 2420 3604 5499 8609 13850 22960 39260 102 127 159 202 261 340 452 609 835 1166 1662 2420 3604 5499 8609 13850 22960 39260 IAT sensor
Temperature vs Resistance Values (Approximate) 130 120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 266 248 230 212 194 176 158 140 122 113 86 68 50 32 14 -4 -22 -40
SSANGYONG Y200

SPECIAL TOOLS TABLE
661 589 00 46 00 Fuel Tank Cap Wrench
103 589 00 21 00 Fuel Pressure Gauge
YAA1F890
KAA1F490
SSANGYONG Y200
SECTION 1F2
M161 ENGINE CONTROLS

CAUTION: Disconnect the negative battery cable before removi ng or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
Engine and ECM Problem Check Report ........... 1F2-3 Diagnostic Information and Procedure ............. 1F2-4 Failure Code Diagnosis ...................................... 1F2-4 Clearing Failure Codes ....................................... 1F2-4 Failure Codes Table ........................................... 1F2-4 Ignition System ................................................... 1F2-8 Ignition Coil ...................................................... 1F2-10 Crankshaft Position (CKP) Sensor .................... 1F2-12 Camshaft Position (CMP) Sensor ....................... 1F2-16 Camshaft Actuator ............................................ 1F2-20 Knock Sensor (KS) ...........................................1F2-22 Spark Plug ....................................................... 1F2-24 System Voltage ................................................1F2-28 Ignition Switch .................................................. 1F2-29 Fuel System ...................................................... 1F2-30 Fuel Pump ........................................................ 1F2-32 Fuel Injector...................................................... 1F2-36 Purge Control Valve .......................................... 1F2-40 Fuel Rail ........................................................... 1F2-42 Fuel Pressure Regulator .................................... 1F2-44 Induction System .............................................. 1F2-46 Throttle Valve Actuator ...................................... 1F2-46 Hot Film Air Mass (HFM) Sensor ........................ 1F2-50 Engine Coolant Temperature (ECT) Sensor ........ 1F2-54 Accelerator Pedal Module .................................1F2-58 Cooling Fan ...................................................... 1F2-62 A/C Compressor Relay .....................................1F2-63 Cruise Control Switch ........................................ 1F2-64 Traction Control System (TCS) ...........................1F2-65 Stop Lamp Switch............................................. 1F2-66 Engine RPM ..................................................... 1F2-67 Exhaust System ................................................ 1F2-69 Catalytic Converter ...........................................1F2-69 Oxygen Sensor ................................................. 1F2-70 Engine Control Module .................................... 1F2-76 Serial Data Communication ............................... 1F2-78 Internal Failure .................................................. 1F2-80 Electronic Throttle Controller Safety Malfunction .................................................... 1F2-82 Immobilizer ......................................................1F2-84 Maintenance and Repair ................................. 1F2-85 On-Vehicle Service ........................................... 1F2-85 Discharging the Pressure in Fuel System .......... 1F2-85 Fuel Pump ........................................................ 1F2-85 Fuel Filter .......................................................... 1F2-86 Fuel Tank .......................................................... 1F2-87 Fuel Pressure Regulator .................................... 1F2-88 Fuel Rail and Injector ........................................1F2-89 Engine Coolant Temperature Sensor .................. 1F2-90 Throttle Body (Integrated with the 91 Actuator) ....................................................... 1F2-91 Hot Film Air Mass (HFM) Sensor ........................ 1F2-92 Knock Sensor ................................................... 1F2-92 Pedal Position Sensor ....................................... 1F2-93 Oxygen Sensor ................................................. 1F2-93 Purge Control Valve .......................................... 1F2-94 Canister............................................................ 1F2-94 Camshaft Position Sensor .................................1F2-94 Crankshaft Position Sensor ............................... 1F2-95 Engine Control Module ...................................... 1F2-95 Schematic and Routing Diagrams ................... 1F2-96 ECM Wiring Diagram (2.3L DOHC - MSE 3.53D) ..............................1F2-96

Specifications ................................................. 1F2-103 Engine Data Display Table .............................. 1F2-103 Fastener Tightening Specifications .................. 1F2-104 Fuel System Specification ............................... 1F2-105 Temperature vs Resistance ............................. 1F2-105 Special Tools and Equipment ........................ 1F2-106 Special Tools Table ......................................... 1F2-106
SSANGYONG Y200
ENGINE AND ECM PROBLEM CHECK REPORT

VEHICLE AND CUSTOMER INFORMATION
Date Problem Occurred Customer Name Driver Name Purchase date License No. Vehicle Model VIN Engine Model Mileage Km miles
MIL INFORMATION
Condition of MIL DTC inspection (if available) Remains on Normal Freeze frame data ( Sometimes illuminates Malfunction code(s) (code ) Does not illuminate )
PROBLEM DESCRIPTION
Engine Does Not Start Hard to Start Poor Idling Poor Driveability Engine Stall No cranking Slow cranking Others Incorrect first Idle Idling Unstable Hesitation Surging Abnormal idle rpm Others Back fire Knocking Muffler explosion (after-burning) Poor performance Other High (rpm) Low (rpm) No initial combustion No complete combustion
Soon after starting
After accelerator pedal depressed During A/C operation
After accelerator pedal released Shifting from N to D or D to N At full steering Others Others
CONDITION WHEN PROBLEM OCCURS

Problem Frequency Weather Ambient Temperature Place Engine Temperature Engine Operation Constant Fine Hot Highway Rough Road Cold Any temp. Starting Others Just after starting (min.) Acceleration Other Idling Racing Driving Deceleration Intermittent (times per day/month) Cloudy Warm Suburbs Others Warming Up Before warming up After warm-up Rainy Cool Inner City Snowy Uphill Once only Others
Various/Others Downhill
Cold (approx.____F/____C)
Constant speed
A/C switch ON/OFF
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DIAGNOSTIC INFORMATION AND PROCEDURE FAILURE CODE DIAGNOSIS

CLEARING FAILURE CODES
Notice: To prevent Engine Control Module (ECM) damage, the key must be OFF when disconnecting or reconnecting the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.) Parameters listed in the table may not be exactly the same as your reading due to the type of instrument or other factors. If a failure code is displayed during the TROUBLE CODE in scan tool check mode, check the circuit for the code listed in the table below. For details of each code, turn to the page referred to under the See Page for the respective Failure Code in the below table. Failure codes should be cleared after repairs have been completed.
FAILURE CODES TABLE

Failure code 00 01 02 03 04 05 06 08 09 10 11 17 18 19 20 21 23 24 25 26 29 30 31 32 33 34 35 40 41 See Page 1F2-56 1F2-56 1F2-56 1F2-52 1F2-52 1F2-52 1F2-56 1F2-28 1F2-52 1F2-52 1F2-52 1F2-13 1F2-13 1F2-17 1F2-13 1F2-80 1F2-78 1F2-78 1F2-84 1F2-78 1F2-79 1F2-79 1F2-79 1F2-67 1F2-67 1F2-33 1F2-33 1F2-41 1F2-41 Description Engine coolant temperature sensor low voltage Engine coolant temperature sensor high voltage Engine coolant temperature sensor plausibility Intake air temperature sensor low voltage Intake air temperature sensor high voltage Intake air temperature sensor plausibility Engine coolant temperature insufficient for closed loop fuel control System voltage too low Mass air flow sensor plausibility Mass air flow sensor low voltage Mass air flow sensor high voltage Crankshaft position sensor signal failure (no engine revolution signal) Crankshaft position sensor signal failure (rpm > max. value) Camshaft position sensor signal : No.1 cylinder recognition failure Crankshaft position sensor signal failure (gap recognition failure) Transmission coding failure CAN communication failure : ASR/MSR CAN communication failure : ABS Communication with transponder missing CAN communication failure : TCU (A/T only) CAN communication failure : ID 200h not plausible CAN communication failure : ID 208h not plausible CAN communication failure : communication initialization failure Engine rpm output circuit short circuit to battery Engine rpm output circuit short circuit to ground or open Fuel pump relay short circuit to battery Fuel pump relay short circuit to ground or open Purge control valve short circuit to battery Purge control valve short circuit to ground or open
SSANGYONG Y200

Failure code 44 45 54 56 58 59 60 64 65 67 68 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 89 93 96 97 98 99 100 101 102 103 104 105 See Page 1F1-62 1F1-62 1F1-41 1F1-23 1F1-17 1F1-79 1F1-79 1F1-11 1F1-11 1F1-13 1F1-25 1F1-29 1F1-37 1F1-37 1F1-37 1F1-37 1F1-37 1F1-38 1F1-38 1F1-38 1F1-72 1F1-73 1F1-72 1F1-72 1F1-72 1F1-72 1F1-72 1F1-72 1F1-72 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-73 1F1-47 1F1-47 Description Cooling fan (HI) relay short circuit to power Cooling fan (HI) relay short circuit to ground or open Purge control circuit malfunction No.1 knock sensor signal failure Camshaft position sensor signal : No.1 cylinder synchronization failure CAN communication failure : MSR data transmission not plausible CAN communication failure : ASR data transmission not plausible No ignition voltage output (No.1 ignition coil) No ignition voltage output (No.2 ignition coil) Crankshaft position sensor adaptation failure Random/Multiple Misfire Starter signal recognition failure No.1 injector short circuit to battery No.1 injector short circuit to ground or open No.2 injector short circuit to battery No.2 injector short circuit to ground or open No.3 injector short circuit to battery No.3 injector short circuit to ground or open No.4 injector short circuit to battery No.4 injector short circuit to ground or open Oxygen sensor high voltage Bank 1 system short term fuel trim adaptation below lean threshold Oxygen sensor no activity detected Oxygen sensor not lean after overrun fuel shut -off Oxygen sensor slow response Oxygen sensor heater failure Oxygen sensor heater short circuit to battery Oxygen sensor heater short circuit to ground or open Oxygen sensor low voltage Bank 1 system short term fuel trim adaptation above rich threshold Bank 1 system short term fuel trim at rich stop Bank 1 system short term fuel trim at lean stop Bank 1 system idle adaptation failure (above rich threshold) Bank 1 system idle adaptation failure (below lean threshold) Bank 1 system learning control failure (rich, low load) Bank 1 system learning control failure (lean, low load) Bank 1 system learning control failure (rich, high load) Bank 1 system learning control failure (lean, high load) Throttle position sensor 1 low voltage Throttle position sensor 1 high voltage
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Failure code 108 109 110 116 117 119 120 121 122 123 125 126 127 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 150 151 160 161 162 163 164 167 185 186 See Page 1F1-47 1F1-47 1F1-82 1F1-47 1F1-82 1F1-47 1F1-82 1F1-47 1F1-59 1F1-47 1F1-47 1F1-48 1F1-48 1F1-64 1F1-64 1F1-64 1F1-64 1F1-64 1F1-64 1F1-66 1F1-80 1F1-80 1F1-82 1F1-82 1F1-82 1F1-84 1F1-80 1F1-80 1F1-80 1F1-80 1F1-80 1F1-65 1F1-65 1F1-59 1F1-59 1F1-59 1F1-59 1F1-59 1F1-59 1F1-48 1F1-82 Throttle position sensor 2 low voltage Throttle position sensor 2 high voltage Throttle actuator learning data fault Throttle actuator learning control failure Exceed fuel-cut safety time Throttle valve return spring failure Cruise control interruption memory failure Throttle actuator failure Accelerator pedal position sensor signal failure Different Mass air flow sensor signal with throttle position sensor Both throttle position sensors failure Throttle position sensor 1 not plausible with throttle position sensor 2 High permanent throttle signal Cruise control OFF due to message counter failure Vehicle speed signal failure Vehicle speed signal failure Cruise control lever failure Cruise control acceleration failure Cruise control deceleration failure Stop lamp switch failure ECU failure (RAM) ECU failure (EPROM) Call monitoring Servo motor control output interruption memory failure Servo motor open/short Unprogramed ECU with immobilizer Uncoded/unprogramed ECU ECU failure (EEPROM/Flash-EPROM checksum failure) ECU failure (coding ID checksum failure) ECU failure (coding checksum failure) ECU failure (programing checksum failure) TCS input signal short circuit to battery TCS input signal short circuit to ground or open Accelerator pedal position sensor 1 low voltage Accelerator pedal position sensor 1 high voltage Accelerator pedal position sensor 2 low voltage Accelerator pedal position sensor 2 high voltage Accelerator pedal position sensor 1 not plausible with pedal position sensor 2 Both setpoint accelerator pedal position sensor defective Mass air flow sensor and throttle position sensor failure ECU failure (incompatible CPU) Description
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Failure code 187 188 189 190 226 227 228 229 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 See Page 1F1-82 1F1-82 1F1-82 1F1-82 1F1-21 1F1-21 1F1-63 1F1-63 1F1-82 1F1-82 1F1-82 1F1-82 1F1-82 1F1-82 1F1-82 1F1-82 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 1F1-83 Description ECU failure (CPUs communication failure) ECU failure (CPU 2 configuration failure) ECU failure (CPU 2 fault) ECU failure (CPU run time failure between CPUs) Camshaft actuator short circuit to battery Camshaft actuator short circuit to ground or open A/C compressor relay short circuit to battery A/C compressor relay short circuit to ground or open ECU failure (CPU 2 cruise control message counter failure) Over decceleration limit (CPU 2) Over acceleration limit (CPU 2) Cruise control lever dual operation (CPU 2) Cruise control lever safety terminal failure (CPU 2) Unusual pedal position variation (CPU 2) Unusual throttle position variation (CPU 2) Unusual throttle controller monitor data comparison fault (CPU 2) Unusual accelerator pedal position sensor comparison fault (CPU 2) Throttle potentiometer comparision fault (CPU 2) Unusual CPU communication (CPU 2) Unusual CPU configuration (CPU 2) A/D converter failure (CPU 2) Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2 Position controller setpoint fault between CPU 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint fault between CPU 1 and CPU 2 A/D converteroverflow (CPU 2) ROM f aul t (CPU 2) RAM f aul t (CPU 2) Cycle monitor fault (CPU 2)
SSANGYONG Y200
IGNITION SYSTEM
This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then determines Electronic Spark Timing (EST) and triggers the electronic ignition system ignition coil. This type of distributorless ignition system uses a waste spark method of spark distribution. Each cylinder is paired with the cylinder that is opposite it (2-3 or 1-4). The spark occurs simultaneously in the cylinder coming up on the compression stroke and in the cylinder coming up on the exhaust stroke. The cylinder on the exhaust stroke requires very little of the available energy to fire the spark plug. The remaining energy is available to the spark plug in the cylinder on the compression stroke. These systems use the EST signal from the ECM to control the EST. The ECM uses the following information: Engine load (mass air flow sensor). Engine temperature. Intake air temperature. Crankshaft position. Engine speed (rpm).
YAA1F910
SSANGYONG Y200
BLANK
SSANGYONG Y200
IGNITION COIL
YAA1F920
1 2 3 4
Control Cable Connection Ignition Cable Spark Plug Connector Coupling Plug
5a, 5b E L1 L2
Secondary Voltage Connection Iron Core Secondary Ignition Coil Primary Ignition Coil
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover. The double ended coils receive the signal for the Engine Control Module (ECM) which controls the spark advance. Each EI system ignition coil provides the high voltage to two spark plugs simultaneously; T1/1: cylinder 1 and 4 T1/2: cylinder 2 and 3 The EI system ignition coil is not serviceable and must be replaced as an assembly.
SSANGYONG Y200
YAD1F0E0
Failure Code
Description
Trouble Area
Maintenance Hint
64 No ignition voltage output (No. 1 ignition coil) Malfunction of ignition circuit Primary current values or secondary short circuit 65 No ignition voltage output (No. 2 ignition coil)
Inspection the ECM pin 71 and 72 about short circuit or open with bad contact Inspection the power source to ignition coil Inspection the ignition coil, high tension cords etc. Inspection the spark plug (wet, cracks, wear, improper gap, burned electrodes, heavy deposit) Inspection the ECM
Circuit Description The Electronic Ignition (EI) system uses a waste spark method of spark distribution. The Crankshaft Position (CKP) sensor sends reference pulses to the ECM. The ECM then triggers the EI system ignition coils. Once the ECM triggers the EI system ignition coils both of the connected spark plugs fire at the same time. One cylinder is on its compression stroke at the same time that the other is on the exhaust stroke, resulting in lower energy needed to fire the spark plug in the cylinder on its exhaust stroke. This leaves the remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke. Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed.
SSANGYONG Y200
CRANKSHAFT POSITION (CKP) SENSOR
YAA1F940
1 Crankshaft Position Sensor Connector 2 Bolt
3 Crankshaft Position Sensor
This Electronic Ignition (EI) system uses inductive or pick up type magnetic Crankshaft Position (CKP) sensor. The CKP sensor is located in the opposite side of the crankshaft pulley and triggers the pick-up wheel teeth which is equipped 60-2 teeth with agap of 2 teeth at 360 degree spacing. This sensor protrudes through its mount to within 1.1 0.14 mm. The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60-2 wheel generates a positive half wave. The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends to the ignition coils and to the fuel injectors.
SSANGYONG Y200
YAD1F120
Failure Code 17
Description Crankshaft position sensor signal failure (no engine revolution signal) Crankshaft position sensor signal failure (rpm > max. value) Crankshaft position sensor signal failure (gap recognition failure) Crankshaft position sensor adaptation failure
Trouble Area Even through cam position recognition is normal, no crankshaft position signal recognition When more than applicable revolution values or implausible to 60-2 teeth. When implausible recognition of cam and crank angle signal or intermittent sensing the signal or error count of undetected gap. When faulty crank angle sensor adaption
Maintenance Hint
Monitoring the actual rpm through or scan tool Inspection the ECM pin 100, 99 about short circuit with bad contact Inspection the CKP sensor Inspection the air gap between sensor and drive plate Inspection the drive plate (teeth condition) Inspection the ECM
18
20
67
Circuit Description The 58X reference signal is produced by the CKP sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The ECM uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the number of pulses on the 58X reference circuit and compares them to the number of Camshaft Position (CMP) signal pulses being received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, this failure code will set. Crankshaft Position Sensor Resistance Inspection 1. Disconnect the coupling E of ECM while the ignition switch is in OFF position. 2. Measure the resistance between the coupling terminal pin No. 99 and No. 100 using a multimeter. Specified Value 1,050 ~ 1,400
Notice: Measure the insulator resistance of the CKP sensor if out of the specified value.
SSANGYONG Y200

Crankshaft Position Sensor Output Wave Inspection 1. Measure the output wave between the ECM terminals No. 99 and No. 100 using the scan tool or the oscilloscope while engine cranking (start motor activated). Notice: Check the segment or crankshaft position sensor and air gap if cannot get the output wave as shown in the figure.
YAD1F130
a Voltage b Identifying the No. 1-2 Missing Teeth Crankshaft Position Sensor Insulator Resistance Inspection 1. Disconnect the coupling from ECM while the ignition switch is in OFF position. 2. Measure the resistance between the coupling terminal pin No. 100 and No. 69 using a multimeter. Specified Value >20 k
Notice: Measure the check and ground terminal of the CKP sensor if out of the specified value.
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BLANK
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1F2-16 M161 ENGINE CONTROLS CAMSHAFT POSITION (CMP) SENSOR
YAA1F950
1 Camshaft Position Sensor Connector 2 Bolt
3 Camshaft Position Sensor 4 O-Ring
The Camshaft Position (CMP) sensor sends a CMP signal to the Engine Control Module (ECM). The ECM uses this signal as a synchronized pulse to trigger the injectors in the proper sequence. The ECM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel injection mode of operation.
SSANGYONG Y200
YAD1F150
Failure Code
Description Camshaft position sensor signal : No. 1 cylinder recognition failure Camshaft position sensor signal : No. 1 cylinder synchronization failure
Trouble Area When no cam recognition signal during TN 24 counts more. (maintain the constant low or high level) When synchronization fault of cylinder 1 (TDC recognition)
Maintenance Hint
Inspection the source voltage of CMP sensor Inspection the ECM pin 106, 104 about short circuit or open with bad contact Inspection the CMP sensor Inspection the damage of sensor or sprocket Inspection the ECM
19
58
Circuit Description The CMP sensor sends a cam position signal to the ECM. If the cam position signal is lost while the engine is running, the fuel injection system shifts to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine continuous to run. Camshaft Position Sensor Signal Voltage Inspection 1. Measure the voltage between the ECM terminal No. 11 and No. 106 while the engine speed is at idle. Specified Value 1.2 ~ 1.7 v
Notice: The signal voltage will be changed in the range of 1.2 ~ 1.7 v.
SSANGYONG Y200

Camshaft Position Sensor Output Wave Inspection 1. Measure the output wave between the ECM terminals No. 104 and No. 106 using the scan tool or the oscilloscope while engine speed is at idle. Notice: Replace the CAM sensor if cannot get the output wave as shown in the figure.
YAD1F160
Camshaft Position Sensor Power Supply Inspection 1. Disconnect the CMP sensor Connector. 2. Measure the resistance between the No. 1 and No. 3 pin of the CMP sensor connector while the ignition switch is in ON position. Specified Value 11 ~ 14 v
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BLANK
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CAMSHAFT ACTUATOR
YAA1F970
1 Bolt 2 Camshaft Actuator 3 Bolt
4 Armature 5 Roll Pin 6 Nut
When the engine is running, the camshaft actuator rotates the intake camshaft hydraulically and mechanically relative to the camshaft sprocket by 20 crank angle to the advanced position and back to the retard position. The camshaft actuator is actuated electro-mechanically by the Engine Control Module (ECM). The positioning time of apporx. 1 second is dependent on the engine oil pressure at the camshaft actuator and on the oil viscosity and oil temperature, respectively. The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an input parameter for the engine ignition control unit. Operation Condition of Camshaft Actuator Engine RPM Engine stop 0 ~ 1,740 rpm Camshaft Position Retard Retard Effect Idle speed is improved Blow-by gas is decreased Valve overlap is decreased Torque is increased Fuel loss is decreased NOx is decreased Engine overrun is prohibited
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1,740 ~ 3,540 rpm
Advanced
Above 3,540 rpm
Retard
YAD1F150
Failure Code
Description Camshaft actuator short circuit to battery
Trouble Area When malfunction of cam phasing control
Maintenance Hint
226
Monitoring the actual operational status through scan tool Inspection the ECM pin 73 about short circuit or open Inspection the power source short circuit or open to cam actuator Inspection the magnet and hardware Inspection the ECM
227
Camshaft actuator short circuit to ground or open
Camshaft Actuator Current Consumption Inspection 1. Run the engine to reach the coolant temperature above 70 C. 2. Increase the engine rpm up to 2000 rpm 3. Measure the current between the No. 1 and No. 2 pin of the camshaft actuator connector. Specified Value 1 ~1.5 A
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KNOCK SENSOR (KS)
YAD1F180
The Knock Sensor (KS) detects abnormal knocking in the engine. The two KS are mounted in the engine block near the cylinders. The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark knock.
SSANGYONG Y200
YAD1F0F0
Failure Code
Description No. 1 knock sensor signal failure
Trouble Area When recognition in more than control gain threshold at normal operational condition of other system during over 75 and 3,000 rpm running area (cylinder 1, 2, 3, 4)
Maintenance Hint
Inspection the ECM pin 118, 117 about short circuit or open with bad contact Inspection the KS 1 malfunction Inspection the ECM
56
Circuit Description The KS system is used to detect engine detonation, allowing the ECM to retard the ignition control spark timing based on the KS signal being received. The KS signals amplitude and frequency depend upon the amount of knock being experienced. The ECM monitors the KS signal and can diagnose the KS sensor and circuitry. Knock Sensor Resistance Inspection 1. Disconnect the coupling from ECM while the ignition switch is in OFF position. 2. Measure the resistance between the coupling terminal pin No. 118 and No. 117 using a multimeter. Specified Value >10 M
Notice: Replace the KS if the measured values is out of the specified values. Check the connector and wire connection between ECM and the KS if the measured values are normal.
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SPARK PLUG
YAA1F990
1 2 3 4 5
Screw Adaptor Ignition Coil Cable Cover Spark Plug Connector Ignition Coil Connector
6 7 8 9 10
Bolts Ignition Coil (T 1/1) Coupling Plug Spark Plug Ignition Coil (T 1/2)
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YAD1F0G0
Failure Code
Description Random / Multiple Misfire
Trouble Area When detection misfire of multiple cylinder for source of over the emission threshold or catalyst damage
Maintenance Hint
68
Inspection the ignition system Inspection the injection system Inspection the fuel pressure Inspection the compression pressure Inspection the valve timing or clearance Inspection the air flow sensor Inspection the crankshaft position sensor and air gap Inspection the engine wiring system Inspection the Engine Control Module (ECM)
Circuit Description The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness value is compared with the actual (emission and catalyst damage) threshold.
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Spark Plug Cable Resistance Inspection 1. Turn the ignition switch OFF position. 2. Disconnect the spark plug cables Refer to Section 1E1, Engine electrical. 3. Measure the spark plug resistance using a multimeter. Specified Value 1.8 ~ 2.2 k
Notice: Replace the spark plug cable if the measured values is out of the specified values.
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BLANK
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SYSTEM VOLTAGE
YAD1F220
Failure Code
Description System voltage too low
Trouble Area Malfunction in recognition of system source voltage. Less than minimum 8 volts in 2,000 rpm below, or less than 10 volts in 2,000 rpm above.
Maintenance Hint
Monitoring the actual battery voltages through the scan tool Inspection the Engine Control Module (ECM) pin 12, 11, 10, 5 about short circuit or open with bad contact Inspection the over voltage protection relay Inspection the battery Inspection ECM
08
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IGNITION SWITCH
YAD1F230
Failure Code
Description Starter signal recognition failure
Trouble Area When not detection of starter signal
Maintenance Hint
71
Inspection the Engine Control Module (ECM) pin 2 circuit short or open with bad contact Inspection ECM
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FUEL SYSTEM
The function of the fuel metering system is to deliver the correct amount of fuel to the engine under all operating conditions. The fuel is delivered to the engine by the individual fuel injectors mounted into the intake manifold near each cylinder. The main fuel control sensors are the Mass Air Flow (MAF) sensor and the oxygen (O2) sensors. The MAF sensor monitors the mass flow of the air being drawn into the engine. An electrically heated element is mounted in the intake air stream, where it is cooled by the flow of incoming air. Engine Control Module (ECM) modulates the flow of heating current to maintain the temperature differential between the heated film and the intake air at a constant level. The amount of heating current required to maintain the temperature thus provides an index for the mass air flow. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve. Under high fuel demands, the MAF sensor reads a high mass flow condition, such as wide open throttle. The ECM uses this information to enrich the mixture, thus increasing the fuel injector on-time, to provide the correct amount of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by the ECM, which then decreases the fuel injector on-time due to the low fuel demand conditions. The O2 sensors are located in the exhaust pipe before catalytic converter. The O2 sensors indicate to the ECM the amount of oxygen in the exhaust gas, and the ECM changes the air/fuel ratio to the engine by controlling the fuel injectors. The best air/fuel ratio to minimize exhaust emissions is 14.7 to 1, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a closed loop system. The ECM uses voltage inputs from several sensors to determine how much fuel to provide to the engine. The fuel is delivered under one of several conditions, called modes . of fuel delivered in the starting mode by changing how long the fuel injector is turned on and off. This is done by pulsing the fuel injectors for very short times.
Run Mode
The run mode has two conditions called open loop and closed loop .
Open Loop
When the engine is first started and it is above 690 rpm, the system goes into open loop operation. In open loop, the ECM ignores the signal from the HO2S and calculates the air/fuel ratio based on inputs from the ECT sensor and the MAF sensor. The ECM stays in open loop until the following conditions are met: The O2 has a varying voltage output, showing that it is hot enough to operate properly.
The ECT sensor is above a specified temperature (22.5 C). A specific amount of time has elapsed after starting the engine.
Closed Loop
The specific values for the above conditions vary with different engines and are stored in the Electronically Erasable Programmable Read-Only Memory (EEPROM). When these conditions are met, the system goes into closed loop operation. In closed loop , the ECM calculates the air/fuel ratio (fuel injector ontime) based on the signals from the O2 sensors. This allows the air/fuel ratio to stay very close to 14.7 to 1.
Acceleration Mode
The ECM responds to rapid changes in throttle position and airflow and provides extra fuel.
Deceleration Mode
The ECM responds to changes in throttle position and airflow and reduces the amount of fuel. When deceleration is very fast, the ECM can cut off fuel completely for short periods of time.
Battery Voltage Correction Mode

When battery voltage is low, the ECM can compensate for a weak spark delivered by the ignition module by using the following methods: Increasing the fuel injector pulse width. Increasing the idle speed rpm.
Starting Mode
When the ignition is turned ON, the ECM turns the fuel pump relay on for 1 second. The fuel pump then builds fuel pressure. The ECM also checks the Engine Coolant Temperature (ECT) sensor and the Throttle Position (TP) sensor and determines the proper air/fuel ratio for starting the engine. This ranges from1.5 to 1 at -36 C (-33 F) coolant temperature to 14.7 to 1 at 94 C (201 F) coolant temperature. The ECM controls the amount
Increasing the ignition dwell time.
Fuel Cut-Off Mode

No fuel is delivered by the fuel injectors when the ignition is off. This prevents dieseling or engine runon. Also, the fuel is not delivered if there are no reference pulses received from the CKP sensor. This prevents flooding.
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FUEL PUMP
YAD1F240
1 2 3 4
Flange and Harness Assembly Spring Fuel Pump Float
5 6 7 8
Thermistor Float Arm Thermistor Housing Resistor Card and Wiper
Requirements for Fuel Pump

Item System Pressure Maximum Pressure Minimum Pressure Nominal Voltage Minimum Amount of Fuel Supply Specified Value 3.8 bar 8.5 bar (12 V) 5.0 bar (12 V) 12 V 114 Liter/ Hr (12 V, 3.8 bar, -30 ~ +70 C) Item Minimum Delivery at 8V Operating Voltage Maximum Allowable Current Ambient Temperature Maximum Amount of Fuel Supply Specified Value 30 Litre/ Hr 8V 7.5 A -30 ~ +70 C 165 Liter/ Hr (12 V, 3.8 bar, -30 ~ +70 C)
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YAD1F250
Failure Code 34
Description Fuel pump relay short circuit to battery Fuel pump relay short circuit to ground or open
Trouble Area When short circuit to power source When short circuit to ground or open
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 33 about short circuit or open with bad contact Inspection the fuel pump relay Inspection the ECM
35
Circuit Description When the ignition switch is turned ON, the ECM will activate the pump relay and run the in-tank fuel pump. The fuel pump will operate as long as the engine is cranking or running and the ECM is receiving ignition reference pulses. If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignitions witch is turned ON, engine stopped or engine stalled. Fuel Pump Relay Inspection Measure the voltage between the ECM terminal No. 33 and ground. Ignition Switch : ON Cranking 0 V (for 1 ~ 2 sec.) 0V
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Measure the Fuel Delivery from the Fuel Pump 1. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it. 2. Place the hose end into the beaker with the minimum capacity of 1 Liter 3. Turn the ignition switch to ON position. 4. Connect the terminal No. 33 and No. 5 of ECM with a service wire. 5. Measure the fuel delivery from the fuel pump. Specified Value 1 Liter/max. 35 sec.
Notice: Check the fuel filter and fuel line when the fuel delivery is not within specified value. Measure the Current Consumption of Fuel Pump 1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to ON position. 2. Using a multimeter, measure the current consumption by connecting the terminal No. 30 and No. 87 of the fuel pump relay connector. Specified Value 5~9A
Notice: Replace the fuel pump relay if the measured value is over 9 A.
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BLANK
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FUEL INJECTOR
YAA1F0C0
1 O-Ring 2 Injector 3 Injector Bracket
4 O-Ring 5 Fuel Rail
The Multipoint Fuel Injection (MFI) assembly is a solenoid-operated device controlled by the Engine Control Module (ECM) that meters pressurized fuel to an each individual cylinder. The injector sprays the fuel, in precise quantities at a point in time determined by the ECM, directly towad the cylinder intake valve. ECM energizes the fuel injector solenoid to lift the needle valve and to flow the fuel through the orifice. This injectors discharge orificeis calibrated to meet the effective fuel atomization necessary for both ensuring the maximum homogeneity in the air-fuel mixture and holding the condensation along the walls of the intake tract to a minimum. Fuel enters the top feed injector from above and flows through its vertical axis. The lower end extends into the intake valve. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engine is shut down. Also, an extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be delivered to the engine after the ignition is turned off.
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YAD1F0H0
Failure Code
Description No. 1 injector short circuit to battery
Trouble Area When malfunction of injector circuit Injector #1 short circuit to power
Maintenance Hint
Inspection the power to injector #1 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 63 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #2 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 64 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #3 or bad contact Inspection the injector Inspection the ECM
72
73
No. 2 injector short circuit to battery 74
75
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Failure Code Description No. 3 injector short circuit to ground or open Trouble Area When malfunction of injector circuit Injector #3 short circuit to ground or open When malfunction of injector circuit Injector #4 short circuit to power No. 4 injector short circuit to ground or open When malfunction of injector circuit Injector #4 short circuit to ground or open Maintenance Hint
Inspection the ECM pin 65 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector #4 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 66 about short circuit or open with bad contact Inspection the injector Inspection the ECM
77
79
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Injector Spray Pattern Check 1. Turn the ignition switch OFF. 2. Remove the fuel injector connectors. 3. Remove the fuel distributor and injector with a unit. At this time, do not remove the supply and return line. Notice: Prepare the beaker for taking the fuel. 4. Connect the shop made cable to the inject or with a firing order. 5. Connect the other end of shop made cable to the positive battery cable and negative battery cable. 6. Turn the ignition switch ON. 7. Check the inject or for normal spray pattern as shown in the figure. Check inject or for leaks or later drop Injector Resistance Inspection 1. Turn the ignition switch OFF. 2. Remove the fuel injector connectors . 3. Meas ure the fuel injector coil resistance using a multimeter. Specified Value 14 ~ 17
YAD1F280
YAD1F290
Notice: Replace the fuel injector if the measured value is out of the specified values . Check the connector and wire connection between the ECM and the injector if the measured values are normal.
Injector Pulse Width Inspection 1. Turn the ignition switch OFF. 2. Install the scan tool. 3. Turn the ignition switch ON. 4. Monitor the INJECTION TIME with a scan tool. Cranking Engine Idle Wide Open Throttle (WOT) 8.0 ms 3 ~ 5 ms 14 ms
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PURGE CONTROL VALVE
YAA1F440
1 Purge Control Valve 2 Line to Engine
3 Line to Canister 4 Canister
The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in the canister abstracts through the purge control valve purification during the engine combustion (except the decreasing mode) and coolant temperature of over 80 C. For this reason, the Engine Control Module (ECM) transacts the engine speed, air inflow quantity, coolant temperature, and intake temperature. The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the purification rate. The purification rate is determined by the continuous valve opening interval. The purge control valve is activated by the ECM for the following conditions: Coolant temperature of over 80 C Engine speed of over 1,000 rpm 2 minutes after starting When the fuel cut-off mode is not activated
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YAD1F310
Failure Code 40
Description Purge control valve short circuit to battery Purge control valve short circuit to ground or open Purge control circuit malfunction
Trouble Area When short circuit to power source When short circuit to ground or open When malfunction of purge control : not work
Maintenance Hint
Inspection the ECM pin 34 about short circuit or open with bad contact Inspection the source power of valve Inspection the purge control solenoid vale Inspection the ECM
41 54
Test
1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ECM terminal No. 11 and No. 34 and check for normal operation through the output waves using oscilloscope. Notice: Test during purge control valve operation after the minimum of 1 minute after the engine turned on. 3. Connect the ECM terminal No. 34 and No.10 and check for current consumption during the ignition switch ON. Specified Value 0.3 ~ 0.5 A
4. Remove the line to canister and measure the pressure with the vacuum pressure gauge. > 500 mbar (after approx. 1 min.) purge control valve operates at this time
Specified Value
Notice: Test while at normal temperature and at idling state by operating the engine.
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FUEL RAIL
YAA1F0E0
1 2 3 4 5 6 7 8
O-Ring Fuel Pressure Regulator Circlip Vacuum Hose O-Ring Injector Injector Bracket Fuel Rail
9 10 11 12 13 14 15 16
Combination Bolt Bolt Clamp Fuel Return Line Hollow Bolt Seal Ring Seal Ring Fuel Pressure Test Connector
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M161 ENGINE CONTROLS 1F2-43 Fuel Pressure Test

Tools Required 103 589 00 21 00 Fuel Pressure Gauge 1. Turn the ignition switch to OFF position. 2. Remove the fuel pressure test connector. 3. Connect the fuel pressure gauge to the fuel pressure test connector. 4. Test the fuel pressure at idling by operating the engine using the fuel pressure gauge 103 589 00 21 00.
YAA1F700
Vacuum Hose Connected (bar) Vacuum Hose Disconnected (bar)
3.2 ~ 3.6 3.7 ~ 4.2
5. Replace the pressure regulator diaphragm if out of the specification.
Internal Leakage Test

1. Connect the fuel pressure gauge103 589 002100 to the fuel pressure test connector. 2. Stop the engine for approximately 30 minutes and then check the fuel pressure changes. Pressure change Fuel pressure drops slowly
Fuel leakage at the injector Faulty fuel pressure regulators diaphragm and O-ring Faulty check valve in the fuel pump
YAA1F0K0
Fuel pressure drops rapidly
3. If there is no change in fuel pressure and maintain the following pressure over 30minutes, it is normal. Fuel pressure (bar) 2.5
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YAA1F0F0
1 Vacuum Hose 2 Circlip 3 Fuel Pressure Regulator
4 O-Ring 5 O-Ring
Function of the Fuel Pressure Regulator

The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3.2 bars to 3.8 bars according to the intake manifold pressure. This operating pressure cannot be changed, and the fuel injection volume will be only determined by the injection time. Over supplied fuel returns to the fuel tank through the return line. <Operating at full load> There is no negative pressure applied to the spring chamber (9) during the full load, and it is separated from the fuel chamber (8) by the diaphragm (5). When the fuel pressure goes up, the diaphragm forces the compression spring (6) in the direction of compression. At this moment, the valve (3) sticks to the diaphragm by the fuel pressure, and the fuel return line (2) opens. The fuel over supplied returns to the fuel tank through the return line.
YAD1F360
2. 3. 5. 6. 8. 9.
Fuel return line Valve Diaphragm Compression Spring Fuel Chamber Spring Chamber
A. Valves Closed B. Valves Opened
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The pressure difference between the fuel pressure and the intake manifold is about 3.8 bars during the full load.
YAD1F390
YAD1F370
1. 2. 3. 4. 5. 6.
Fuel Pressure Regulator Intake Manifold Fuel Return (to fuel tank) Fuel Supply (from fuel pump) Fuel Pressure (approx. 3.8 bars) Intake Manifold Negative Pressure (0 bar)
1. 2. 3. 4. 7. 8.
Fuel Pressure Regulator Intake Manifold Fuel Return (to fuel tank) Fuel Supply (from fuel pump) Fuel Pressure (approx. 3.2 bars) Intake Manifold Negative Pressure (0.6 bars)
<Fuel Pressure Diagram>
<Operating at Idle and partial load> The spring chamber (9) is connected to the intake manifold with the vacuum hose at the intake pipe connection (7). The negative pressure generated in the intake manifold activates the diaphragm, and thus the fuel pressure gets reduced to the rate of the operating extent of the diaphragm by the intake manifold s negative pressure.
YAD1F400
A. B. LL. TL. VL.
Fuel pressure Intake Manifold Negative Pressure Idling Partial load Full load
YAD1F380
Consequently, the fuel pressure in the fuel distributor changes by the intake manifolds negative pressure, and the injector s fuel pressure gets reduced independently to the throttle valve s position. Thus, the fuel injection volume can only be determined according to the injector s injecting duration. The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling.
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INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR
YAA1F540
The throttle actuator is actuated by the Engine Control Module (ECM) according to the position of the accelerator pedal position. It has two potentiometers which signal the position of the throttle valve to the ECM to enable it to recognize the various engine load states.
the spring capsule. Consequently, the throttle valve opening is a constant 10-12 approximately. At no load, this produces an engine speed of about 1,800 rpm
Ignition Off
In the de-energized states the throttle valve position is determined to be spring capsule.
Driving
When driving (part/full throttle), the servo motor controls the throttle valve in line with the various load states and according to the input signals from the pedal value sensor according to the input signals from the pedal value sensor according to the position of the accelerator pedal. The function of the EA (electronic accelerator) in the ECM determines the opening angle of the throttle valve through the throttle actuator. Further functions are; Idle speed control Cruise control Reducing engine torque for ASR/ABS operation Electronic accelerator emergency running Storing faults Data transfer through CAN
Ignition On
When the ignition S/W on the servo motor in the throttle actuator is operated by the ECM. The throttle valve adopts a position in line with the coolant temperature.
Closed position
In the closed throttle position, the servo motor controls engine speed by operating the throttle valve further (greater mixture) or closing it further (reduced mixture), depending on coolant temperature and engine load. When this is done, the throttle valve can be closed further by the servo motor overcoming the force of the spring capsule (mechanical end stop). If the actuator is de-energized, the throttle valve is resting against
SSANGYONG Y200
YAD1F420
Failure Code 104 105 108 109
Description Throttle position sensor 1 low voltage Throttle position sensor 1 high voltage Throttle position sensor 2 low voltage Throttle position sensor 2 high voltage Throttle actuator learning control failure Throttle valve return spring failure Throttle act uator failure
Trouble Area TPS 1 short circuit to ground or open TPS 1 short circuit to power TPS 2 short circuit to ground or open TPS 2 short circuit to power When actuat or adaption fluctuation or not meet the condition When return spring defective of actuator When supply voltage of the actuat or short circuit to power When shut down of out put driver When defective of both potentiometers
Maintenance Hint
116
119 121
123
Different mass air flow sensor signal with throttle position sensor Both throttle position sensor failure
125
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Failure Code 126 127 185 Description Throttle position sensor 1 not plausible with Throttle position sensor 2 High permanent throttle signal Mass air flow sensor and throttle position sensor failure Trouble Area When difference between TPS 1 and TPS 2 When failure of wiring harness or actuator When difference between MAF and TPS signal Maintenance Hint
Circuit Description The ECM supplies a 5 volt reference signal and a ground to the TP sensor. The TP sensor sends a voltage signal back to the ECM relative to the throttle plate opening. The volt age signal will vary from approximately 0.3 ~ 0.9 volts at closed throttle, to over 4.0 ~ 4.6 volts at Wide Open Throttle (WOT). The TP sensors serve for engine load control according to the drive pedal command. Load adjustments independent of the drive pedal command can be implemented; such functions are, for instance, idle control, speed control, drive slip control, load shock damping, and similar functions . When the actuator current fails , the throttle valve is returned to emergency operating position by a spring. The throttle valve position, there by the actuator drive position check back is provided by two potentiometers. The motor positions the throttle valve against the return spring force. Motor and return spring are two separate energy sources . Each of them is able to position the throttle valve in emergency position alone. Throttle valve position check back and monitoring is provided by two actual value potentiometers connected to the engine control electronics. Throttle Actuator Inspection 1. Turn the ignition switch to ON position. 2. Measure the TPS 1 signal volt age at the ECM pin No. 87 and TPS 2 signal volt age at the ECM pin No. 85. Pedal Position TPS 1 Closed Opened Closed Opened Specified Value 0.3 ~ 0.9 v 4.0 ~ 4.6 v 4.0 ~ 4.6 v 0.3 ~ 0.9 v
TPS 2
Throttle Actuator DC Motor Inspection 1. Turn the ignition switch to ON position. 2. Measure the signal volt age between the ECM pin No. 67 and No. 68. Application Ignition ON Engine Status Idling Specified Value 0.8 ~ 2.3 v 1.0 ~ 2.5 v (Coolant temperature is over 70 C)
Throttle Actuator DC Motor Resistance 1. Turn the ignition switch to OFF position. 2. Measure the resistance between the ECM pin No. 67 and No. 68. Specified Value < 10
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BLANK
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YAD1F430
1 Housing 2 Protector Net 3 Electronic Housing
4 Connector 5 Hot Film Air Mass Sensor 6 Measuring Port
The Hot Film Air Mass (HFM) sensor with recognition of flow direction related to pulsating flow is designed for recording load on Engine Control Module (ECM) by measuring the output voltage proportional to the reference voltage of the ECM.
Mass Air Flow Sensor

Mass Air Flow (MAF) is a thermal flow meter whose sensor element with its temperature sensors and heating area is exposed to the MAF to be measured. A heating area located in the center of a thin membraneis controlled to an over temperature by a heating resistor and a temperature sensor of this membrane. And the value of overtemperature depends on the temperature of the in-flowing air. Two temperature sensors on upstream and downstream of the heating area show the same temperature without incoming flow. With incoming flow, upstream part is cooled down but downstream temperature retains its temperature more or less due to the air heated up in the heating area. This temperature difference in quantity and direction depends on the direction of the incoming flow. ECM modulates the flow of heating current to maintain the temperature differential between the heated film and the intake air at a constant level. The amount of heating current required to maintain the temperature thus provides an index for the MAF. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve.
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Under high fuel demands, the MAF sensor reads a high mass flow condition, such as Wide Open Throttle (WOT). The ECM uses this information to enrich the mixture, thus increasing the fuel injector on-time, to provide the correct amount of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by the ECM, which then decreases the fuel injector on-time due to the low fuel demand conditions. To facilitate the installation of the HFM in the intake passage, lubricating agents may be used. However, when lubricants are used care must be taken to ensure that they do not enter the flow passage and cannot be sucked in with the air flow. The following tables show the relationship between MAF and output voltage. Mass Air Flow (kg/h) 0 10 15 30 60 120 Voltage (V) 0.95 ~ 1.05 1.28 1.41 1.71 2.16 2.76 Mass Air Flow (kg/h) 250 370 480 640 800 Voltage (V) 3.51 3.93 4.23 4.56 4.82
Intake Air Temperature

The Intake Air Temperature (IAT) sensor is a part of Hot Film Air Mass (HFM) sensor and is a thermistor, a resistor which changes value based on the temperature of theair entering the engine. Low temperature produces a high resistance, while high temperature causes a low resistance as the following table. The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage to determine the IAT. The voltage will be high when the manifold air is cold and low when the air is hot. The ECM knows the intake IAT by measuring the voltage. The IAT sensor is also used to control spark timing when the manifold air is cold. Temp. (C) -40 -20 0 20 40 60 80 100 120 130 R min.() 35140 12660 5119 2290 1096 565 312 184 114 91 R nom. () 39260 13850 5499 2420 1166 609 340 202 127 102 R max. () 43760 15120 5829 2551 1238 654 370 222 141 114
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YAD1F440
Failure Code 03 04
Description Intake air temperature sensor low voltage Intake air temperature sensor high voltage Intake air temperature sensor plausibility Mass air flow sensor plausibility
Trouble Area IAT sensor short circuit to ground or open IAT sensor short circuit to power Malfunction in recognition of IAT When functional problem Malfunction in recognition of MAF When air mass not plausible
Maintenance Hint
Monitoring the actual air temperature through scan tool Inspection the ECM pin 80, 79 about short circuit or open with bad contact Inspection the IAT sensor (integrated in HFM sensor) Inspection the ECM Monitoring the actual air mass flow through scan tool Inspection the ECM pin 81, 105 about short circuit or open with bad contact Inspection the MAF sensor (integrated in HFM sensor) Inspection the ECM
05
09
10 11
Mass air flow sensor low voltage Mass air flow sensor high voltage
MAF sensor short circuit to ground or open MAF sensor short circuit to power
Circuit Description The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the other elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The separation of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal decoupling between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is located on a single layer. The voltage at the heater provides the index for the mass air flow. The MAF s electronic circuitry then converts the voltage to a level suitable for processing in the ECM. This device does not need a burn off process to maintain its measuring precision over an extended period. In recognition of the fact that most deposits collect on the sensor elements leading edge, the essential thermal transfer elements are located downstream on the ceramic layer. The sensor element is also design to ensure that deposits will not influence the flow pattern around the sensor. The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the intake air is warm, resistance is low; therefore the IAT signal voltage will be low.
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Mass Air Flow Sensor Input Voltage Inspection 1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin No. 103 and No. 104. Application Ignition ON Engine Status Idling Specified Value 0.9 ~ 1.1 V 1.3 ~ 1.7 V (Coolant temperature is over 70C)
Notice: If the measured value is not within the specified value, the possible cause may be in cable or MAF sensor in itself. Perform the 5 volt power supply inspection procedures. Mass Air Flow Sensor 5 volt Power Supply Inspection 1. Turn the ignition switch to OFF position. 2. Disconnect the HFM sensor connector. 3. Turn the ignition switch to ON position. 4. Measure the voltage between the ECM pin No. 108 and MAF sensor connecter terminal No. 3. Specified Value 4.7 ~ 5.2 V
Notice: If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling. 5. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 4. Specified Value 4.7 ~ 5.2 V
Notice: If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling. Mass Air Flow Sensor 12 volt Power Supply Inspection 1. Turn the ignition switch to OFF position. 2. Disconnect the HFM sensor connector. 3. Turn the ignition switch to ON position. 4. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 2. Specified Value 11 ~ 14 V
Notice: If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage Protection Relay (OVPR).
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ENGINE COOLANT TEMPERATURE (ECT) SENSOR
YAA1F590
1 Artificial Resin Housing 2 Metal Housing 3 NTC (Negative Temperature Coefficient) Resistor
4 Connector 5 Engine Coolant Temperature Sensor
Engine Coolant Temperature (ECT) sensor detects coolant temperature and supplies information to the ECM. It is composed of metal housing with two NTC resistor, 4 pin connector. The ECM provides a 5 volt signal to the ECT sensor through a dropping resistor. When the engine is cold, the ECT sensor provides high resistance, which the ECM detects as a high signal voltage. As the engine warms up, the sensor resistance becomes lower, and the signal voltage drops. At normal engine operating temperature, the ECT signal will measure about 1.5 to 2.0 volts. The ECM uses information about coolant temperature to make the necessary calculations for: Fuel delivery Ignition control Knock sensor system Idle speed Torque converter clutch application Canister purge Cooling fan operation Others
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Temperature (C) Resistance () -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 48,550 27,000 15,570 9,450 5,890 3,790 2,500 1,692 1,170 826 594 434 322 243 185 143 111.6 88 71.2 Voltage (V) 4.90 4.82 4.70 4.52 4.43 3.96 3.57 3.14 2.70 2.26 1.86 1.51 1.22 0.98 0.78 0.63 0.50 0.40 0.33
YAD1F460
SSANGYONG Y200
YAD1F470
Failure Code 00
Description Engine coolant temperature sensor low voltage Engine coolant temperature sensor high voltage Engine coolant temperature sensor plausibility Engine coolant temperature insufficient for closed loop fuel control
Trouble Area ECT sensor short circuit to ground or open ECT sensor short circuit to power Malfunction in recognition of ECT When drop to about 50 C below after warm up Malfunction in recognition of ECT When minimum temperature for lambda control after warm up
Maintenance Hint
Monitoring the actual coolant temperature through scan t ool Inspection the ECM pin 78, 79 about short circuit or open with bad contact Inspection the ECT sensor Inspection the ECM
01
02
06
Circuit Description The ECT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies a voltage on the signal circuit to the sensor. When the engine coolant is cold, the resistance is high; therefore the ECT signal voltage will be high Engine Coolant Temperature Sensor Inspection 1. Turn the ignition switch to ON position. 2. Measure the voltage between the ECM pin No. 78 and No. 79. Temperature (C) 20 80 100 Specified Value (V) 3.57 1.22 0.78
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3. 4. 5. 6. Turn the ignition switch to OFF position. Disconnect the ECT sensor connector. Turn the ignition switch to ON position. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4. Temperature (C) 20 80 100 Specified Value () 2,500 322 185
Notice: Replace wiring and coolant temperature sensor if out of specified value.
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ACCELERATOR PEDAL MODULE
YAD1F480
1 Accelerator Pedal 2 Accelerator Pedal Sensor 3 Bolts
4 6-Pin Connector 5 Kick-down Switch 6 Nut
The Acceleration Pedal Position (APP) sensor is mounted on the accelerator pedal assembly. The sensor is actually two individual APP sensors and one housing. This sensor works with theThrottle Position (TP) sensor to provide input to the Engine Control Module (ECM) regarding driver requested accelerator pedal and throttle angle at the throttle body.
When the APP sensor is defected:

When the APP 1 or APP 2 sensor is defected condition, the engineis still running at idle condition but, the accelerator pedal reaction is not response correctly and also, the engine rpm will be reacted to 4,000 rpm slowly. If the APP 1 sensor is out of order, the APP 2 sensor will be conducted with signal as adefault signal but, the throttle valve opening is limited 60% and delayed opening speed.
When the TP sensor or servo motor is defected:

When the TP 1, 2 sensor or servomotor is defected condition, the throttle valve will be closed to the spring capsule by spring force, at this condition, the throttle valve will open 10 ~ 20 and engine rpm will be controlled by ECM will opening (On/Off) time of injector. The engine rpm will be maintaining 900 rpm (at idle) to 1,800 according to the engine load.
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YAD1F490
Failure Code 122
Description Acceleration pedal position sensor signal failure Acceleration pedal position 1 sensor low voltage Acceleration pedal position sensor 1 high voltage Acceleration pedal position sensor 2 low voltage Acceleration pedal position sensor 2 high voltage Accelerator pedal position sensor 1 not plausible with accelerator pedal position sensor 2 Both setpoint accelerator pedal position sensor defective
Trouble Area When malfunction of APP sensor APP 1 sensor short circuit to ground or open APP 1 sensor short circuit to power APP 2 sensor short circuit to ground or open APP 2 sensor short circuit to power When difference between APP 1 sensor and APP 2 sensor
Maintenance Hint
Monitoring the actual values through scan tool Inspection the ECM pin 31, 47, 32, 48, 59, 51 about short circuit or open with bad contact Inspection the APP sensor Inspection the ECM
160
161
162
163
164
167
When defective of both APP sensor
Circuit Description The ECM supplies a 5 or 2.5 volt reference signal and a ground to the APP sensor 1 or 2. The ECM calculates on these signal lines. The APP sensor output changes as the accelerator pedal is moved. The output of the APP 1 and APP 2 sensor are low, about 0.4 ~ 0.7 volts and 0.2 ~ 0.35 volts respectively at the closed throttle position. As pushing the accelerator pedal, the output increases so that the output voltages will be about 4.3 ~ 4.8 volts and 2.1 ~ 2.4 volts individually when accelerating fully with the kick down, at Wide Open Throttle (WOT).
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Acceleration Pedal Position Sensor 1 Inspection 1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin No. 47 and No. 31 while operating the accelerator pedal as following conditions. Not depress the pedal (closed throttle position) Fully depress the pedal (full throttle with kick down) Condition of Throttle Valve Closed Throttle Valve Fully Depressed Throttle Valve 0.3 ~ 0.7 4.3 ~ 4.8 Specified Value (V)
Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to APP 1 sensor. Acceleration Pedal Position Sensor 2 Inspection 1. Turn the ignition switch to ON position. 2. Measure the signal voltage between the ECM pin No. 48 and No. 50 while operating the accelerator pedal as following conditions. Not depress the pedal (closed throttle position) Fully depress the pedal (full throttle with kick down) Condition of Throttle Valve Closed Throttle Valve Fully Depressed Throttle Valve 0.1 ~ 0.4 2.1 ~ 2.5 Specified Value (V)
Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to APP sensor 2.
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COOLING FAN
YAD1F510
Failure Code 44
Description Cooling fan (HI ) relay short circuit to power Cooling fan (HI ) relay short circuit to ground or open
Trouble Area Cooling fan short circuit to power Cooling fan short circuit to ground or open
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 35 about short circuit or open with bad contact Inspection the power source Inspection the cooling fan Inspection the ECM
45
Circuit Description Ignition voltage is supplied directly to the cooling fan relay coil. The ECM controls the relay by grounding the control circuit. When the ECM is commanding a command ON, the voltage of the control circuit should be low (near 0 volt). When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit senses a voltage other than what is expected, the fault line status will change causing the fault code to set.
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A/C COMPRESSOR RELAY
YAD1F520
Failure Code 228
Description A/C compressor relay short circuit to battery A/c compressor relay short circuit to ground or open
Trouble Area When malfunction of A/C compressor control
Maintenance Hint
Monitoring the actual operation through scan tool Inspection the Engine Control Module (ECM) pin 44 about short circuit or open with bad contact Inspection the relay short circuit or open Inspection the ECM
229
Circuit Description When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM.
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CRUISE CONTROL SWITCH
YAD1F530
Failure Code 129 130 131 132
Description Cruise control OFF due to message counter failure Vehicle speed signal failure Vehicle speed signal failure Cruise control lever failure Cruise control acceleration failure Cruise control deceleration failure
Trouble Area Cruise control system message counter fault When malfunction of auto-cruise system Implausible condition of vehicle speed signal. Cruise control lever defective Cruise control system Implausible condition of acceleration signal Cruise control system Implausible condition of deceleration signal
Maintenance Hint
Monitoring the actual recognition status and vehicle speed signal through scan tool Inspection the Engine Control Module (ECM) pin 52, 53, 54, 55, 57 about short circuit or open with bad contact Inspection the CAN and ABS Inspection the cruise control lever switch Inspection the ECM
133
134
Circuit Description Cruise control is an automatic speed control system that maintain adesired driving speed with out using the accelerator pedal. The vehicle speed must be greater than 40 km/h to engage cruise control.
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TRACTION CONTROL SYSTEM (TCS)
YAD1F540
Failure Code 150
Description TCS input signal short circuit to battery TCS input signal short circuit to ground or open
Trouble Area TCS short circuit to power TCS short circuit to ground or open
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 45 about short circuit or open with bad contact Inspection the TCS lamp of I/P cluster. Inspection the ECM
151
Circuit Description Battery voltage is supplied to the TCS warning lamp with the ignition in ON and START. The warning lamp can be activated only by the Electrical Brake Control Module (EBCM) internally supplying ground to terminal 21. If the TCS input circuit is open or short, this failure code will be set.
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STOP LAMP SWITCH
YAD1F550
Failure Code 135
Description Stop lamp switch failure
Trouble Area When malfunction of stop lamp switch-implausible condition of stop lamp signal input
Maintenance Hint
Monitoring the actual operational status and vehicle speed signal through scan tool Inspection the Engine Control Module (ECM) pin 49 about short circuit or open with bad contact Inspection the contact condition of stop lamp switch Inspection the ECM
Circuit Description The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released.
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ENGINE RPM
YAD1F560
Failure Code 32
Description Engine rpm output circuit short circuit to battery Engine rpm output circuit short circuit to ground or open
Trouble Area When short circuit to battery
Maintenance Hint
Monitoring the actual rpm in cluster Inspection the Engine Control Module (ECM) pin 60 about short circuit or open Inspection the cluster panel board circuit Inspection the ECM
33
When short circuit to ground or open
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EXHAUST SYSTEM
CATALYTIC CONVERTER
The purpose of the catalytic converter is to convert the three pollutants of carbon monoxide (CO), hydrocarbons (HC) and oxides of nitrogen (NOx) contained in the exhaust of gasoline engines, into the harmless compounds of water (H2O), carbon dioxide (CO2) and nitrogen (N2). The catalytic converter contains acatalyst, a word coming from the Greek and which designates the element essential for catalyst which triggers chemical reactions without itself being consumed. These catalysts in the 3-way catalytic converter are the rare metals platinum (Pt) and rhodium (Rh). The catalytic converter consists essentially of three main elements. The exhaust gases flow through the catalytic converter and, in so doing, coming into contact with rare metals (Pt and Rh). The following chemical reaction are produced. CO + O 2 CO2 HC + O2 CO2 + H 2O NO x N 2 + O2
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BLANK
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OXYGEN SENSOR
YAD1F570
The oxygen sensor is unique amongthe engine control sensors because is acts like a battery and is able to generate its own low voltage signal. It is located the exhaust system and monitors the amount of oxygen in the exhaust stream and provides feedback to the Engine Control Module (ECM). The electrically heated oxygen sensor warms up quickly and remains hot, even at idle when the exhaust manifold may cool down. The ECM applies a reference voltage of 450 mv to the oxygen sensor, the ECM compares this reference voltage with the voltage generated by oxygen sensor. The amount of voltage the oxygen sensor generates is proportionate to the difference between the amount of oxygen in the outside air and the exhaust gases. The atmosphere contains about 21% oxygen. The exhaust from a rich air/fuel ratio contains almost no oxygen. With a large difference betweenthe amounts of oxygen containing the two surface, the sensor generates less voltage.
When the exhaust gas is rich (below 14.7:1), the voltage output is high, above 450 mv. When the exhaust gas is lean (above 14.7:1 air/fuel ratio), the sensor s voltage output is low, below 450 mv. The ECM uses oxygen sensor information for: Open loop / closed loop criteria Ideal air / fuel ratio
YAD1F580
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YAD1F590
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YAD1F600
Failure Code 80
Description Oxygen sensor high voltage
Trouble Area When recognition the output that more than nominal threshold, malfunction of sensing voltage. When recognition the output that more than nominal threshold, malfunction of sensing voltage. When recognition the output that not active the sensor etc. When recognition the output that no lean signal after overrun fuel shut-off When slow response of sensor signal When recognition the heating circuit When recognition the heating currents that more or less than set values (less than 0.2 A or more than 2 A) When recognition the heating voltages than less than set values (less than 2 v)
Maintenance Hint
Monitoring the actual output signal through scan tool Inspection the ECM pin 16, 17 about short circuit or open with bad contact Inspection the oxygen sensor Inspection the ECM
89
Oxygen sensor low voltage
82
Oxygen sensor no activity detected Oxygen sensor not lean after overrun fuel shut-off Oxygen sensor slow response Oxygen sensor heater failure Oxygen sensor heater short circuit to battery
83 84 85
Monitoring the heating status through scan tool Inspection the ECM pin 9 about short circuit or open with bad contact Inspection the heating power source Inspection the heating circuit of oxygen sensor Inspection the ECM
86
87
Oxygen sensor heater short circuit to ground or open
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Failure Code Description Bank 1 system short term fuel trim adaptation below lean threshold Trouble Area When recognition the value less than nominal control threshold, it means that when big deviation in control range of adaptation values through fuel and air mixture formation When recognition the value more than nominal control threshold, it means that when big deviation in control range of adaptation values through fuel and air mixture formation When recognition the short term fuel trim that more than nominal threshold When recognition the short term fuel trim that less than nominal threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold Maintenance Hint
81
Inspection the intake air leakage Inspection the injection quantities with injector block or leakage Inspection the exhaust leakage Inspection the ECM
93
Bank 1 system short term fuel trim adaptation above rich threshold
96
Bank 1 system short term fuel trim at rich stop Bank 1 system short term fuel trim at lean stop Bank 1 system idle adaptationfailure (above rich threshold) Bank 1 system idle adaptation failure (below rich threshold) Bank 1 system learning control failure (rich, low load) Bank 1 system learning control failure (lean, low load) Bank 1 system learning control failure (rich, high load) Bank 1 system learning control failure (rich, low load)
97
98
99
100
101
102
103
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1F2-74 M161 ENGINE CONTROLS Circuit Description

In order to control emissions, a catalytic converter is used to covert harmful emissions into harmless water vapor and carbon dioxide. The ECM has the ability to monitor this process by using a oxygen sensor. The oxygen sensor produces and output signal which indicates the storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust emission effectively. If the oxygen sensor pigtail wiring, connector, or terminal is damaged. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly, it must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair the wires, connector, or terminal and degrade the oxygen sensor performance. Oxygen Sensor Signal Voltage Inspection 1. Maintain the engine speed is at idle while the coolant temperature is over 80 C. 2. Measure the oxygen sensor signal voltage between the ECM terminal No. 16 and No. 17. Specified Value 0.2 ~ 1.0 V
Notice: If the measured value is not within the specified value, the possible causemay bein cable, oxygen sensor or ECM Oxygen Sensor Heating Voltage Inspection 1. Maintain the engine speed is at idle while the coolant temperature is over 80 C. 2. Measure the oxygen sensor signal voltage between the ECM terminal No. 11 and No. 9. Specified Value 11 ~ 14 V
Notice: If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECM Oxygen sensor Heating Current Consumption Inspection 1. Turn the ignition switch to ON position. 2. Measure the oxygen sensor heating current consumption between the ECM terminal No. 9 and No. 5. Specified Value 0.2 ~ 2.0 V
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YAD1F610
1 2 3 4
Cover Plate Connector Plat Pin Vehicle Side : No. 1-12 Engine Side : No. 61-72
5 Pin Vehicle Side : No. 13-60 Engine Side : No. 73-120 A Vehicle Side Connector : Black B Engine Side Connector : Gray
The Engine Control Module (ECM), located inside the right side kick panel, is the control center of the fuel injection system. It constantly looks at the information fromvarious sensors and controls the systems that affect the vehicle s performance. Engine rpm and air mass are used to measure the air intake quantity resulting in fuel injection metering. The ECM also performs the diagnostic functions of the system. It can recognize operational problems, store failure code(s) which identify the problem areas to aid the technician in making repairs. There are no serviceable parts in the ECM. The calibrations are stored in the ECM in the Programmable Read Only Memory (PROM). The ECM supplies either 5 or 12 volts to power the sensors or switches. This is done through resistance in the ECM which are so high in value that a test light will not come ON when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give and accurate reading because its resistance is too low. You must use a digital voltmeter with a 10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as the ignition coils, the fuel injectors, the fuel pump relay, the camshaft actuator, the canister purge valve, etc., by controlling the ground circuit.
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BLANK
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SERIAL DATA COMMUNICATION
YAD1F620
Failure Code
Description CAN communication failure: ASR/MSR
Trouble Area When CAN signal message missing or implausibility for ASR/MSR unit or not initialized condition
Maintenance Hint
Inspection the ASR unit with CAN connection Inspection the Engine Control Module (ECM) pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the TCM unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM
23
CAN communication failure: ABS 24
When CAN signal message missing or implausibility for ABS unit or not initialized condition
CAN communication failure: TCU (A/T only) 26
When CAN signal message missing or implausibility for TCU unit or not initialized condition
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Failure Code Description CAN communication failure: ID 200h not plausible Trouble Area When CAN signal message missing or implausibility for ABS/ABD unit or not initialized condition Maintenance Hint
Inspection the ABS/ABD unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS/ABD unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the each control unit with CAN connection Inspection the ECM pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the MSR unit with CAN connection Inspection the Engine Control Module (ECM) pin 38, 37 about short circuit or open with bad contact Inspection the ECM Inspection the ASR unit with CAN connection Inspection the Engine Control Module (ECM) pin 38, 37 about short circuit or open with bad contact Inspection the ECM
29
30
31
CAN communication failure: communication initialization failure
When CAN signal message missing or implausibility for each unit (ABS, ASR, TCM, TOD etc.) or not initialized condition When CAN signal message missing or implausibility for MSR unit or not initialized condition
59
CAN communication failure: MSR data transmission not plausible
60
CAN communication failure: ASR data transmission not plausible
When CAN signal message missing or implausibility for ASR unit or not initialized condition
Circuit Description The provision for communicating with the ECM is the Data Link Connector (DLC). It is located in the instrument panel fuse block. The DLC is used to connect the scan tool. Battery power and ground is supplied for the scan tool through the DLC. CAN line is used to communicate with the other module such as the Transmission Control Module (TCM) and Transfer Case Control Unit (TCCU). Keyword 2000 Serial Data Communications Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmitting and receiving multiple signals over a singles wire. The message carried on KWP 2000 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will must wait.
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INTERNAL FAILURE
Failure Code Description Transmission coding failure 21 Trouble Area When faulty of variant coding of transmission Maintenance Hint
Inspection the coding condition through scan tool InspectiontheEngine ControlModule (ECM) Inspection the CAN line Inspection the TCM Inspection the ECM
ECM failure (RAM) 136 Uncoded/ unprogramed ECM ECM failure (EPROM) ECM failure (EEPROM/ Flash-EPPOM checksum failure) ECM failure (coding ID checksum failure) ECM failure (coding checksum failure) ECM failure (programming checksum failure)
When malfunction of random access memory - ECM internal error When malfunction of ECM coding-required ECM encoding When malfunction of ECM internal
Fulfill the ECM variant coding
142 137 143 144 145 146
Inspection the ECM
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BLANK
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ELECTRONIC THROTTLE CONTROLLER SAFETY MALFUNCTION

Failure Code 110 117 120 138 139 140 186 187 188 189 Description Throttle actuator learning data fault Exceed fuel-cut safety time Cruise control interruption memory failure Call Monitoring Servo motor control output interruption memory failure Servo motor open/short ECM failure (incompatible CPU) ECM failure (CPUs communication failure) ECM failure (CPU 2 configuration failure) ECM failure (CPU 2 fault) ECM failure (CPU run time failure between CPUs) ECM failure (CPU 2 cruise control message counter failure) Over deceleration limit (CPU 2) Over acceleration limit (CPU 2) Cruise control lever dual operation (CPU 2) Cruise control lever safety terminal failure (CPU 2) Unusual pedal position variation (CPU 2) Unusual throttle position variation (CPU 2) Unusual throttle controller monitoring data comparison fault (CPU 2) Trouble Area System internal failure Maintenance Hint
190
231
232 233 234
235
236 237
238
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Failure Code 239 Description Unusual accelerator pedal position sensor comparison fault (CPU 2) Throttle potentiometer comparison fault (CPU 2) Unusual CPU communication (CPU 2) Unusual CPU configuration (CPU 2) A/D converter failure (CPU 2) Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2 Position controller setpoint fault between CPU 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint fault between CPU 1 and CPU 2 A/D converter overflow (CPU 2) ROM fault (CPU 2) RAM fault (CPU 2) Cycle monitor fault (CPU 2) Trouble Area System internal failure Maintenance Hint
240 241 242 243
244
245
246
247 248 249 250 251
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IMMOBILIZER
YAD1F630
Failure Code
Description Communication with transponder missing
Trouble Area When missing the transponder signal
Maintenance Hint
Inspection the Engine Control Module (ECM) pin 13, 14 about short circuit or open with bad contact Inspection the power source or ground short circuit or open of immobilizer unit Inspection the transponder condition (broken etc.) Inspection the ECM Fulfill the immobilizer pairing
25
Unprogramed ECM with immobilizer 141
When malfunction of immobilizer Required immobilizer encoding, no paired condition of immobilizer even through start trial
Circuit Description Immobilizer is a device disabling vehicle ignition unless a specific key is used and designed to help prevent vehicle theft. Immobilizer is comprised of two devices, a key with encoded transponder and ECM with the same encoding of the transponder. When a key is inserted into the hole to start vehicle and turned to ON, the ECM reads and decodes the transponder code and, if the same, starts the engine, it is called immobilizer. It means immobilizer system disables starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other.
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DISCHARGING THE PRESSURE IN FUEL SYSTEM
1. Remove the fuel pressure test connector. Installation Notice Tightening Torque 25 N m (18 lb-ft)
YAA1F700
2. Remove the fuel pressure in fuel systemby pressing the service valve with a clean, pointy tool. Notice: Place a cloth so that the fuel doesnt stain around. 3. Installation should follow the removal procedure in the reverse order.
YAA1F710
FUEL PUMP
Tools Required 661 589 00 46 00 Fuel Tank Cap Wrench

Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Relieve the fuel system pressure. Refer to Discharging the Pressure in Fuel System in this section. 2. Disconnect the negative battery cable. 3. Put aside the floor carpet to remove the fuel pump access cover. 4. Remove the fuel pump access cover. 5. Remove the fuel pump wiring connectors. 6. Disconnect the fuel supply and return pipes. 7. Remove the fuel pump locking cap band.
YAA1F170
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8. Using the fuel tank cap wrench 661 589 00 46 00, remove the locking cap. 9. Remove the pump from the fuel tank. Notice: Check the condition of the seal and replace if necessary. Drain the fuel before removing the pump. 10. Perform an operational check of the fuel pump. 11. Installation should follow the removal procedure in the reverse order.
YAA1F550
FUEL FILTER
1. Disconnect the negative battery cable. Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 2. Relieve the fuel system pressure. Refer to Discharging the Pressure in Fuel System in this section. 3. Disconnect the fuel lines from the fuel filter. Installation Notice Tightening Torque 28 N m (21 lb-ft)
YAA1F190
4. Remove the fuel filter mounting bracket bolt . Installation Notice Tightening Torque 6 N m (53 lb-in)
Notice: Place the fuel pump pad. There may be acorrosion due to the contact between the fuel filter and the bracket. 5. 6. 7. 8. Remove the fuel filter. Install the fuel filter. Perform a leak test of the fuel filter. Installation should follow the removal procedure in the reverse order.
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FUEL TANK
Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Relieve the fuel pressure. Refer to Discharging the Pressure in Fuel System in this section. 2. Disconnect the negative battery cable. 3. Drain the fuel tank. 4. Put aside the floor carpet to remove the fuel pump access cover. 5. Remove the fuel pump access cover.
KAA1F370
6. Disconnect the return line. 7. Disconnect the supply line. 8. Disconnect the fuel tank-to-canister hose from the fuel tank. 9. Disconnect the fuel pump wiring connector.
YAA1F170
10. Disconnect thefuel filler hoseand air vent hosefrom the fuel tank. 11. Support the fuel tank. 12. Remove the fuel tank retaining nuts. Installation Notice Tightening Torque 38 N m (28 lb-ft)
13. Carefully lower the fuel tank.
YAA1F160
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14. Turn the rollover valves counterclockwise at an angle of 90 degrees. 15. Turn the lock ring counterclockwise. 16. Remove and discard the gasket. 17. Installation should follow the removal procedure in the reverse order.
YAA1F180

1. Disconnect the negative battery cable. 2. Remove the fuel pressure test connector. Installation Notice Tightening Torque 25 N m (18 lb-ft)
YAA1F700
Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 3. Relieve the fuel pressure in fuel supply systemby pressing the service valve.
YAA1F720
4. Disconnect the vacuum hose. 5. Disconnect the circlip and remove the fuel pressure regulator. 6. Apply the oil to O-ring lightly and then replace it. 7. Perform a leak test of the fuel pressure regulator with the engine off and the ignition on. 8. Installation should follow the removal procedure in the reverse order.
YAA1F730
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FUEL RAIL AND INJECTORS

Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Discharge the fuel pressure from the fuel pressure test connector. 2. Disconnect the negative battery cable. 3. Disconnect the vacuumhose from the fuel pressure regulator. 4. Remove the cable guide. 5. Disconnect the Hot Film Air Mass (HFM) sensor connector. 6. Remove the intake air duct mounting bolts. Installation Notice Tightening Torque 9 N m (80 lb-in)
YAA1F710
7. Remove the intake air duct clamps. 8. Remove the intake air duct.
YAA1F740
9. Remove the fuel return and supply line. Notice: For removal, cover around parts with cloths not to be stained by fuel. In case of checking the injector only, do not remove the fuel return and supply line. Installation Notice Tightening Torque 23 N m (17 lb-ft)
10. Remove the six injector connectors.
YAA1F750
11. Remove the two left and two right bolts and one center bolt of the fuel rail assembly from the intake manifold. Installation Notice Tightening Torque 25 N m (18 lb-ft)
YAA1F760
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Notice: Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service. Important: If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.
YAA1F770
12. Remove the injectors and the fuel rail carefully. 13. Remove the fuel injector retainer clips. 14. Remove the fuel injectors by pulling them down and out. 15. Discard the fuel injector O-rings. 16. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors. 17. Perform a leak check of the fuel rail and fuel injectors. 18. Installation should follow the removal procedure in the reverse order.

1. Relieve the coolant system pressure. 2. Disconnect the negative battery cable. 3. Disconnect the engine coolant temperature sensor connector. Notice: Take care when handling the engine coolant temperature sensor. Damage to the sensor will affect the proper operation of the fuel injection system. 4. Remove the engine coolant temperature sensor from the pump hosing. Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAA1F780
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THROTTLE BODY (INTEGRATED WITH THE ACTUATOR)

1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature (IAT) sensor connector. 3. Remove the intake air duct clamps.
KAC1F250
4. Remove the blow-by hose. 5. Remove the intake air duck.
KFC1F240
6. Disconnect the throttle body electrical connector. 7. Remove the throttle body bolts. Installation Notice Tightening Torque 8. Remove the vacuum hose. 12 N m (106 lb-in)
YAA1F790
9. Remove the throttle body and discard the gasket. Important: Use care in cleaning old gasket material. Sharp tools may damage sealing surfaces. 10. Installation should follow the removal procedure in the reverse order.
KAA1D240
SSANGYONG Y200

1. Disconnect the negative battery cable. 2. Disconnect the Hot Film Air Mass (HFM) sensor electrical connector. 3. Remove the HFM sensor retaining screws. 4. Turn the HFM sensor coupling in the direction shown in the figure in the left so that it gets separated from the contact surface. Notice: Make sure the HFM sensor coupling connects completely with the contact surface installation. 5. Remove the HFM sensor. 6. Installation should follow the removal procedure in the reverse order.
KAC1F270
KNOCK SENSOR
1. Disconnect the negative battery cable. 2. Disconnect the knock sensor electrical connector from the intake manifold bracket. 3. Remove the knock sensor mounting bolt from the knock sensor installed on the cylinder block. Installation Notice Tightening Torque
KAA1F180
25 N m (18 lb-ft)
4. Remove the knock sensor. 5. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
PEDAL POSITION SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the pedal position sensor connector. 3. Unscrew the bolts and nut. Installation Notice Tightening Torque 6 N m (53 lb-in)
4. Remove the pedal and sensor assembly.

KAA1F410
OXYGEN SENSOR
1. Disconnect the negative battery cable. Notice: The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or the connector could affect proper operation of the oxygen sensor. Do not drop the oxygen sensor. 2. Disconnect the electrical connector. 3. Carefully remove the oxygen sensor from the exhaust pipe. Installation Notice Tightening Torque 55 N m (41 lb-ft)
YAA1F820
Important: A special anti-seize compound is used on the oxygen sensor threads. This compound consists of aliquid graphiteand glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or serviced sensors will already have the compound applied to the threads. If a sensor is removed from any engine and is to be reinstalled, the threads must havean antiseize compound applied before reinstallation. 4. Coat the threads of the oxygen sensor with an antiseize compound, if needed. 5. Installation should follow the removal procedure in the reverse order.
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PURGE CONTROL VALVE

1. Disconnect the negative battery cable. 2. Disconnect the purge control valve connector. 3. Disconnect the throttle body-to-purge control valve hose from the purge control valve. 4. Disconnect the canister-to-purge control valve hose from the purge control valve. 5. Remove the purge control valve. 6. Installation should follow the removal provedure in the reverse order.
YAA1F800
CANISTER
Caution: Canister and vacuum hoses contain fuel vapors. Do not smoke in the area or permit an open flame. 1. Disconnect the fuel tank-to-canister hose form the canister. 2. Disconnect the canister-to-purge control valve hose form the canister.
YAD1F660
3. Remove the canister mounting bolts. Installation Notice Tightening Torque 6 N m (53 lb-in)
4. Remove the canister. 5. Installation should follow the removal procedure in the reverse order.
YAD1F670
CAMSHAFT POSITION SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the camshaft position sensor. 3. Remove the camshaft position sensor retaining bolt. Installation Notice Tightening Torque
YAA1F810
10 N m (89 lb-in)
SSANGYONG Y200

4. Check the O-ring for damage and replace it if necessary. 5. Installation should follow the removal procedure in the reverse order.
CRANKSHAFT POSITION SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the electrical connector at the crankshaft position sensor. 3. Remove the crankshaft position sensor retaining bolt. Installation Notice Tightening Torque 10 N m (89 lb-in)
KAA1F160

1. Disconnect the negative battery cable. 2. Remove the cowl side trim form passenger side. Re-er to Section 9G, Interior trim. 3. Remove the four securing nuts for the Engine Control Module (ECM) from the mounting bracket. Installation Notice Tightening Torque
KAA1F200
10 N m (89 lb-in)
4. Pull out the ECM from the bracket. 5. Disconnect the vehicle side coupling. 6. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
YAD1F010
SSANGYONG Y200
SSANGYONG Y200
YAD1F0A0
ECM WIRING DIAGRAM (2.3L DOHC - 3 OF 7) (MSE 3. 53D)
SSANGYONG Y200
YAD1F030
SSANGYONG Y200
YAD1F040
SSANGYONG Y200
YAD1F0B0
SSANGYONG Y200
YAD1F0C0
SSANGYONG Y200
YAD1F0D0
SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter Engine Coolant Temp. Intake Air Temp. Engine RPM Regular RPM Engine Load Mass Air Flow Meter Throttle Position Angle Spark Advance Indicated Engine Torque Injection Time Battery Voltage Front Axle Speed Rear Axle Speed Accel. Pedal Position 1 Accel. Pedal Position 2 Throttle Position 1 Throttle Position 2 Fuel Integrator Oxygen Sensor A/C S/W Condition Full Load State Shift Gear State (A/T) A/C Control State Clutch Switch (M/T) Cam Actuator State Knocking Control Protect Mission Purge Control Valve Lambda Function Catalyst Heating Overrun Fuel Cut Full Fuel Cut Brake Switch Cruise Control Status * Condition : Warmed up, idle, P/N or neutral mv 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF 1=ON/0=OFF Unit C C rpm rpm % Kg/h TA CA Nm ms V Km/h Km/h V V V V Value greater than 95 C after warm up -40 ~ 130 C (varies with ambient temp. or engine mode) 700 50 (P/N), 600 50 (D) 700 50 (P/N), 600 50 (D) 18 ~ 25 % 16 ~ 25 Kg/h 0 TA (up to 100 TA at the wide open throttle) CA (6 ~ 9 CA) Varies with engine condition 3 ~ 5 ms 13.5 ~ 14.1 V (engine running) 0 ~ 265 Km/h 0 ~ 265 Km/h 0.4 ~ 4.8 V 0.2 ~ 2.4 V 0.3 ~ 4.6 V 0.3 ~ 4.6 V 0.8 ~ 1.2 100 ~ 900 mv -
SSANGYONG Y200

Application Camshaft Position Sensor Retaining Bolts Canister Mounting Bolts Coolant Temperature Sensor Crankshaft Position Sensor Retaining Bolt Engine Control Module (ECM) Mounting Bracket Nuts Fuel Filter Mounting Bracket Bolt Fuel Filter Lines Fuel Pressure Test Connector Fuel Rail Assembly Bolts Fuel Return And Supply Lines Fuel Tank Retaining Nuts Knock Sensor Mounting Bolt Oxygen Sensor Pedal Position Censor Mounting Bolts And Nut Throttle Body Bolts Nm 10 6 30 10 10 6 28 25 25 23 38 25 55 6 12 Lb-Ft 22 21 18 18 17 28 18 41 Lb-In 89 53 89 89 53 53 106
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FUEL SYSTEM SPECIFICATION

Use Only Unleaded Fuel Rated at 89 Octane or Higher
Fuel quality and additives contained in fuel have a significant effect on power output, drivability, and life of the engine. Fuel with too low an octane number can cause engine knock. Caution: Use of fuel with an octane number lower than 89 may damage engine and exhaust system. Notice: To prevent accidental use of leaded fuel, the nozzles for leaded fuel are larger, and will not fit the fuel filler neck of your vehicle.
This type of fuel can reduce vehicle performance and damage components of the fuel system. Caution: Use of methanol may damage the fuel system.
Vehicle Fueling from Drums or Storage Containers

For safety reasons (particularly when using noncommercial fueling systems) fuel containers, pumps and hoses must be properly earthed. Static electricity build up can occur under certain atmospheric and fuel flow conditions if unearthed hoses, particularly plastic, are fitted to the fuel-dispensing pump. It is therefore recommended that earthed pumps with integrally earthed hoses be used, and that storage containers be properly earthed during all noncommercial fueling operations.
Do Not Use Methanol

Fuels containing methanol (wood alcohol) should not be used in vehicle.
TEMPERATURE VS RESISTANCE
C F ECT sensor ohms ( ) 88 111.6 143 202 261 340 452 609 835 1166 1662 2420 3604 5499 8609 13850 22960 39260 102 127 159 202 261 340 452 609 835 1166 1662 2420 3604 5499 8609 13850 22960 39260 IAT sensor
Temperature vs Resistance Values (Approximate) 130 120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 266 248 230 212 194 176 158 140 122 113 86 68 50 32 14 -4 -22 -40
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SPECIAL TOOLS TABLE
661 589 00 46 00 Fuel Tank Cap Wrench
103 589 00 21 00 Fuel Pressure Gauge
YAA1F890
KAA1F490
SSANGYONG Y200
SECTION 1F3 DIESEL ENGINE CONTROLS

Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
Description and Operation ................................. 1F3-2 Fuel System ...................................................... 1F3-2 Governor ........................................................... 1F3-4 Absolute Metering Manifold Pressure Compensator (ALDA) .....................................1F3-10 Pneumatic Idle Speed Increase (PLA) ............... 1F3-11 Pneumatic Shut-Off Device (PNAB) ................... 1F3-12 Exhaust Gas Recirculation (EGR) Valve .............1F3-13 Component Locator ......................................... 1F3-15 Fuel Injection Pump .......................................... 1F3-15 Vacuum Pump (Sectional View) .........................1F3-16 Diagnostic Information And Procedure ........... 1F3-17 Vacuum Control System Test ............................ 1F3-17 Vacuum Shut-Off Leak Test ............................... 1F3-21 Idle Speed Adjustment .....................................1F3-23 Fuel Pump Test ................................................. 1F3-25 Injection Nozzle Test ........................................1F3-28 Checking and Adjusting Start Of Delivery .......... 1F3-31 Repair Instructions ............................................ 1F3-41 On-Vehicle Service ........................................... 1F3-41 Vacuum Pump .................................................. 1F3-41 Vacuum Unit Replacement ................................ 1F3-43 Fuel Pump ........................................................ 1F3-44 Injection Nozzles ..............................................1F3-46 Injection Nozzle Repair .....................................1F3-48 Injection Timing Device Assembly .................... 1F3-51 Injection Timing Device .....................................1F3-56 Fuel Injection Pump .......................................... 1F3-58 Fuel Tank .......................................................... 1F3-64 Specifications ................................................... 1F3-66 General Specifications ...................................... 1F3-66 Fastener Tightening Specifications .................... 1F3-67 Schematic and Routing Diagrams ................... 1F3-68 EGR System................................................... 1F3-68 Special Tools and Equipment .......................... 1F3-69 Special Tools Table ...........................................1F3-69
1F3-2 DIESEL ENGINE CONTROLS

FUEL SYSTEM
Fuel Injection System
YAD1FAA0
1 2 3 4 5
Fuel Injection Pump Fuel Feed Pump Overflow Valve Injection Nozzle Pre-filter
6 7 8 9 10
Fuel Return Hoses Injection Line Fuel Tank Fuel Filter Choke Orifice
SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-3

Fuel Injection Pump Coding
PES 5M 55C 320 RS 167 P E S 5 M Injection Pump Self - Driven End Flange Mounting Number of Cylinders (5EA) Pump Size (Flange Stroke) M - 7 mm A - 8 mm M, W - 8 mm, 10 mm P - 10 mm, 11 mm, 12 mm Z - 12 mm O - 15 mm
YAD1FAB0
55 Element Diameter C 320 R S167 Modification Letter Assembly Number Direction of Rotation (clockwise) Special Version
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GOVERNOR
RSF Minimum-maximum-speed governor
The RSF mechanical governor was developed specifically as a minimum-maximum-speed governor. It is suitable for use in those on-road vehicles (passenger cars and commercial vehicles) in which
control requirements are restricted to low idle and high idle (maximum) speeds.control requirements are restricted to low idle and high idle (maximum) speeds. In the uncontrolled range between these two speed, the driver uses the accelerator pedal to directly adjust the setting of the injection-pump control rack so that the engine develops the right torque.
YAD1FAC0
a Idle Range (Working Range of the Idle Spring) b Extended Idle Range at No-Load and Minimum Part Load (Working Range of the Idle Spring and the Auxiliary Idle Spring) c Uncontrolled Range d Torque-Control Range (Working Range of the Torque-Control Spring) e Torque-Control Travel f Speed-Regulation Range (Working Range of the Governor Spring) g Full-Load Speed Regulation to the High Idle Speed h Start of the Auxiliary Idle-Spring Shutoff
S Start Setting With Accelerator Pedal fully Depressed (Cold-Start) S Start Setting With Accelerator Pedal Released (Hot/ Warm Start) L Low-Idle-Speed Setting O High-Idle-Speed Setting n1u n1o nvo n1 n2 Low Idle Speed High Idle Speed Maximum Full-Load Speed Speed at Start of Torque Control Speed at End of Torque Control
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Speed-sensing mechanism stage 1 (low idle) The force path starts at flyweights (22) and travels through sliding sleeve (20) and guide lever (9) to idle spring (12) and auxiliary idle spring (14). Both springs are leaf springs. Speed-sensing machanism, stage 2 (until full-load speed regulation) After completion of idle-speed sleeve travel, the force path is from governor sliding sleeve (20) through torque-control spring retainer (18) and tensioning lever (16) to governor spring (17). The flyweights (22) are fastened directly to the injectionpump camshaft and when they move outward, governor sliding sleeve (20) is moved axially. The sliding sleeve does not move except in the idle, fullload torque-control, and speed-regulation breakaway ranges. The fuel delivery quantity needed for the required engine torque is selected by the actuatormechanism control lever. The guide lever (9) is movably connected at pivot point B with the governor sliding sleeve. In addition, guide lever and tensioning lever (16) also pivot at point A.
YAD1FAD0
1 2 3 4 5 6 7 8 9 10 11 12 13
Stop(Shutoff) Lever Strap Stop Lever Control Rack Linkage Lever (Inner) Control Lever (Outer) Full-Load Stop Adjusting Screw For Idle Speed Guide Lever Idle Stop Reverse-Transfer Lever Idle-Speed Spring Variable-Fulcrum Lever
14 15 16 17 18 19 20 21 22
Auxiliary Idle Spring Adjusting Screw for Auxiliary Idle Spring Tensioning Lever Governor Spring Spring Retainer (Torque Control) Full-Load Adjusting Screw Governor Sliding Sleeve Auxiliary-Idle-Spring Switch-Off Device Flyweight
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Actuator mechanism Input of the desired valve is through control lever (6) linkage lever (5) and reverse-transfer lever (11) to variable fulcrum lever (13), and from there through strap (2) to injection-pump control rack (4). The strap is spring-loaded, and compensates for the extra movement of the fulcrum lever. Similar to the guide lever, the reverse-transfer lever is also flexibly mounted at pivot point B of the sliding sleeve, and is also attached to the fulcrum lever (13) via a shaft and bushing. Full-load delivery at the fulcrum levers lower bearing point, which also acts as the spring-loaded yield point for the fulcrum lever for absorbing the sliding sleeves additional travel in case of excessive speed. The bearing shaft of the stop lever (3) protrudes from the governor housing. Attached to its end is a stop (shutoff) lever (1) which switches off the engine, whereby the stop lever pulls the control rack in the stop (shoutoff) direction. Starting the engine The engine is to be started according to the vehicle manufacturers operating instructions. Normally, it can be started without pressing the accelerator pedal. Only with a cold engine at low temperatures is the accelerator pedal to be pushed to the floor so that control lever (6) is shifted up against full-load stop(7) a fixed stop on the governor housing. Reverse- transfer lever (11) swivels around pivot point B, and in doing so shifts fulcrum lever (13) in the Start direction. The result is that the control rack (4) is moved to the start setting and the engine receives the required start quantity. Rapid speed regulation from the governor start setting is made possible by lifting the auxiliary idle spring (14) away from fulcrum lever (9) by a switch-off device (21) when the control lever is in the full-load position.
YAD1FAE0
4 6 7 9
Control Rack Control Lever (Outer) Full-Load Stop Guide Lever
11 13 14 21
Reverse-Transfer Lever Variable-Fuicrum Lever Auxiliary-Idle Spring Auxiliary-Idle Spring Switch-Off
Cold-start setting (only the components concerned in the governing process shown.)
SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-7 Operating Characteristics

Low idle speed Once the engine starts and the accelerator pedal is released, a return spring pulls control lever (6) back to the low-idle position. Linkage lever (5) is now up against idle-speed stop screw(10). During warm-up, low idle speed follows the idle-speed control curve and stabilizes at Point L. When speed increases, flyweights (22) move outward, and shift governor sliding sleeve (20) to the right. During operation within the idle range, sliding sleeve movement is transmitted through reverse-transfer lever (11) and fulcrum lever (13); moving the control rack (4) toward Stop (shutoff). At the same time, sliding-sleeve movement causes guide lever (9) to swivel about pivot point A, compressing the idle leaf spring (12). This springs pretension (and thus the low idle speed) is set using adjusting screw(8). At a given speed, the fulcrum lever also comes up against the adjusting nut for auxiliary idle spring (14). Intermediate speed After passing through the idle stage (a), governor sliding sleeve (20) and spring retainer (18) for torque control come into contact with each other. In the uncontrolled range between idle and maximum speed, the position of the flyweights (22) remains constant up to high idle (maximum) speed, the only exception being for minor adjustments necessary for torque control. Control-rack setting and therefore delivery quantity are selected directly through control lever (6). That is, the driver uses the accelerator pedal to select the delivery quantity necessary to increase speed or climb hills (control-lever position between idle stop and full-load stop). If the driver depresses the accelerator pedal fully, the control rack shifts to the full-load delivery setting.
YAD1FAF0
4 5 6 8 9 10 11
Control Rack Linkage Lever (Inner) Control Lever Adjusting Screw For Idle Speed Guide Lever Idle Stop Reverse-Transfer Lever
12 13 14 15 18 20 22
Idle-Speed Spring Variable-Fulcrum Lever Auxiliary Idle Spring Adjusting Screw for Auxiliary Idle Spring Spring Retainer (Torque Control) Governor Sliding Sleeve Flyweight
Idle-speed setting. (only the components concerned in the governing process are shown)
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Torque control If torque control is fitted, full-load delivery quantity is reduced when a given speed n 1 is exceeded, because centrifugal force acting on sliding sleeve (20) exceeds the force of the torque-control spring fitted in spring retainer (18). The torque-control spring yields to this force. As a result, if speed increases further, control rack (4) shifts by the torque-control travel distance. Torque control ends at speed n 2. Instead of positive torque control, the RDF governor can have negative torque control. Here the control-rack setting is controlled by a spring combination. High idle (maximum) speed With the accelerator pedal pressed to the floor, the full-load quantity is injected until the maximum fullload speed nvo is reached. If engine speed increases beyond full-load speed, the force exerted by the flyweights (22) suffices to overcome the force of governor spring (17) and full-load-speed regulation starts. Engine speed increases slightly, and rack travel is reduced due to the rack being moved towards stop (shutoff) and the delivery quantity decreases. Breakaway depends upon governor spring pretension. The engine adjusts to high idle (maximum) speed n10 when all load is removed. When driving downhill with the accelerator released, the vehicle drives the engine (overrun) and accelerates it. No fuel is injected during this operating mode (overrun fuel shutoff).
YAD1FAG0
4 Control Rack 17 Governor Spring 18 Spring Retainer (Torque Control)
20 Governor Sliding Sleeve 22 Flyweight
Full-load setting (only the components concerned in the governing process are shown)
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Stopping the engine When Stop (shutoff) lever (1) is moved by hand, stop lever (3) shifts control rack (4) to the Stop (shutoff) position. The fuel supply is interrupted and the engine stops. A pneumatic shutoff device can also be used for engine switchoff. Switching off The vacuum unit (6) is connected to vacuum from the vacuum pump via the glow starter switch of the vehicle. As a result, the diaphragm of the vacuum unit is pulled against the compression spring. The vacuum unit (6) is connected with a stop lever (2r). This lever pivots around the fulcrum D pulling the control rod of the injection pump into the stop position. The bypass spring of the fulcrum lever is overcome in this process. Via the emergency stop lever (2s) the control rod can likewise be pulled into stop position on the outside of the governor.
YAD1FAM0
a Start b Stop
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ABSOLUTE METERING MANIFOLD PRESSURE COMPENSATOR (ALDA)

On a pressure-charged engine, the cylinder air charge depends upon the boost pressure, which in turn is influenced by the prevailing atmospheric pressure. The effects of variants in atmospheric pressure have an especially large influence when considerable differences in attitude are encountered in driving.
Because the engines turbocharger further compresses the prevailing atmospheric pressure, the absolute pressure in the engines intake manifold is a combination of the atmospheric pressure and the charge-air pressure. The absolute-metering manifoldpressure compensator registers this absolute pressure and adapts the fuel-delivery quantity accordingly.
YAD1FAJ0
1 Adjusting Screw 2 Aneroid Box 3 Connection for the Line to the Engine Manifold
4 Aneroid Capsule 5 Adaptation 6 Guide Plate
SSANGYONG Y200
PNEUMATIC IDLE SPEED INCREASE (PLA)

Application
The injected fuel quantity needed by a diesel engine at idle decreases along with increasing engine temperature. When the engine is cold, the temperature-dependent idle-speed increase fitted to the RSF governor raises the idle speed accordingly, there by improving the engines warm-up behaviour. It also prevents the cold engine stalling when additional loads are switched, such as power-assisted steering, air-conditioner, etc. The PLA ceases to function above a certain temperature.
the aneroid capsules diaphragm which in turn shifts a sliding bolt to change the pretension on the idle spring. The control rack now moves towards increased fuel quantity via the governor linkage and the control rack.
Operation
Coolant temparature <0c The thermovalve is open. The vacuum of approx. 700 mbar reaches the vacuum unit idle speed increase via the thermovalve. The idle speed is increased by approx 100/min. The choke in the ventilation filter causes a pressure loss of approx 100 mbar. Coolant temperature >0c The thermovalve is closed. Atmospheric pressure reaches the vacuum unit through the choke in the ventilation filter. The speed increase is cancelled.
Design and Function

Depending upon temperature, pressure is applied to
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PNEUMATIC SHUT-OFF DEVICE (PNAB)

To shut off the engine, the key in the steering lock is turned to stop. This applies vacuum to the shut-off device diaphragm which pulls the control rack to the stop setting.
This device can only be installed on vehicle which are equipped with a vacuum pump.
YAD1FAK0
1 Pneumatic Shut-Off Device 2 Shut-Off Lever for Manual Operation 3 Stop Lever
4 Spring-Loaded Strap 5 Control Rack
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EXHAUST GAS RECIRCULATION (EGR) VALVE

The Exhaust Gas Recirculation (EGR) system is the device to lower the NOx (oxides of nitrogen) emission level caused by high combustion temperature. Because the combustion process of the diesel engine always needs excessive air, the exhaust gas contains large amount of NOx. The EGR valve restricts NOx generation by recirculating some amount of the exhaust gas into the combustion chamber to reduce the combustion temperature. But the recirculated gas results in reduced charging efficiency of mixture so that the engine performance drops down. Because of this fact, EGR valve is tuned to operate in the area where oxidized substances are generated much.
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YAD1FAL0
Condition of working the EGR valve - 100 seconds after starting the engine - More than 200 RPM
YAD1FAM0
1 2 3 4 5
Injection Pump Micro Switch Bolt Screw ....................................... 5 Nm (44 lb-in) Cam
6 7 8 9
Lever Micro Switch Adjusting Disc A Setting Indicator (10 inch) Adjusting Disc B Setting Indicator (11 inch)
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1F3-14 DIESEL ENGINE CONTROLS EGR Micro Switch Setting Procedure

Tools Required 617 589 08 21 01 Micro switch Setting Device. In turbo equipped vehicle, the timing of injection pump must be adjusted after repairing or replacement as follows: 1. 2. 3. 4. 5. 6. 7. 8. Hold the injection with clamp (special) on the work bench. Install the micro switch setting device 017 589 08 21 01 in the injection pump. Adjust and fix the lever (6) at 10 1 Insert the harness into the micro switch setting device 617 589 08 21 01. Install the cam on the injection pump when the both lamps are on. Install the screw. At this moment, loosen the clamp and insert the adjusting disc A to the lever and check again. If the lamp A is on, the setting is correct, thus, timing of injection pump is OK. If the both lamps are on, perform the setting as above procedure.
SSANGYONG Y200
COMPONENT LOCATOR
FUEL INJECTION PUMP
YAD1FAN0
1 2 3 4 5 6 7 8
Delivery Valve Holder Control Lever Engine Stop Unit Idle Speed Adjustment (ALDA) Stop Lever Adjusting Screw for Idle Speed Guide Lever Adjusting Screw for Auxiliary Idle Speed
9 10 11 12 13 14 15
Governor Assembly Hinge Lever Spring Retainer (Torque Control) Fly Weight Clamping Piece Plunger Driving Cam Fuel Pump Driving Cam
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VACUUM PUMP (SECTIONAL VIEW)
YAD1FAP0
2 4 5 6 7 8 9 12 14 15
Suction Valve Piston Pressure Valve Safety Valve O-Ring Pump Housing Pump Cover Lever Outer Return Spring Inner Spring Retainer
16 17 21 23 28 30 31 32 SB SK
Roller Cam Piston Rod Inner Return Spring Upper Spring Retainer Piston Ring Seal Ring Oil Return Valve Restrictor To Brake Booster To Vacuum Lines
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VACUUM CONTROL SYSTEM TEST
YAD1FAQ0
1 2 3 4 5 6
Rubber Hose Air Filter Distributor Chock Rubber Hose Molding Hose
7 8 9 10 11
Distributor Molding Hose Connector Chock Filter Molding Hose
Service Data
Idle Speed Increase Permissible Pressure Drop of System At least 100 rpm at approx. 500 mbr 400 - 500 mbar approx. 1 min
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Tools Required 001 589 73 21 00 Vacuum Pump 201 589 13 21 00 Vacuum Tester 667 589 00 21 00 TDC pulse generator Commercial Tools Digital tester Temperature measuring instrument with test probe WB24 e.g Bosch MOT 001.03 Sun DIT 9000 e.g Ahlborm, Therm 2263 - 2 Eichenfeldstrabe 1 - 3 D - 8150 Holzkirichen
Tester Connection
YAD1FAR0
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Test step 1 (Coolant Temp. 0C) Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run engine at idle speed. Vacuum > = 500 mbar? YES NO Lines and connections leaking. Faulty PLA vacuum unit.
(Remove the connection hose from vacuum pump)
YAD1FAS0
Connect vacuum pump (14) direct to PLA vacuum unit (5) and pressurize with vacuum. Vacuum is built up and idle speed increases approx. 150-200 rpm ?
YES
NO Faulty PLA vacuum unit
YAD1FAT0
(Coolant Temperature 0 3 C)
Stop the engine and seal the air admission line with plug (arrow). Connect the vacuum pump to line to thermovalve and pressurize the line with vacuum. Vacuum is built up?
YES
NO Lines and connections leaking. Faulty thermovalve.
YAD1FAU0
Detach line downstream of air admission filter (13). Vacuum drops off?
YES
NO Faulty thermovalve
YAD1FAV0
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Fit the line onto air admission filter. Built up vacuum with vacuum pump. Detach the plug from air admission line. Vacuum drops off?
YES
NO Faulty filter with restriction.
YAD1FAU0
Go to test step 2.
Test step 2
Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run the engine at idle speed. Vacuum drops to 0 at approx. 3C of the thermovalve. YES NO Faulty thermovalve. Defective filter with restriction. Stop the engine. Detach the filter with restriction. Filter with restriction is clear.
YAD1FAS0
YES
NO
Defective filter with restriction.
YAD1FAW0
OK
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VACUUM SHUT-OFF LEAK TEST
YAD1FAX0
1 2 3 4
Vacuum Pump Fuel Injection Pump Engine Stop Unit Control Line
5 6 7 8
Check Valve (to Brake Booster) Engine Shut-Off Valve Suction Line Vacuum Tester
Service Data
Model Entire System at 400 + 50 mbar Vacuum Individual Part at 300 + 50 mbar Vacuum Permissible loss of vacuum 6 mbar / min. 5 mbar / min.
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Tools Required 201 589 13 21 00 Vacuum Tester 1. After fully warming up the engine, turn the ignition switch to LOCK position. 2. Disconnect the suction (7) line from vacuum pump. 3. Connect the vacuum teater 201 589 13 21 00 (8) to suction line (7) and apply vacuum of 400 + 50 mbar. Permissible loss of vacuum
YAD1FAY0
6 mbar / min
If a vacuum drop is more than sperified value, check the engine shut-off valve or vacuum unit. 4. Engine Shut-off valve test - Turn the ignition switch to ON position. - Connect the vacuum tester 201 589 13 21 00 to engine shut-off valve (6) and apply vacuum of 300 + 50 mbar. Permissible loss of vacuum 5 mbar / min
If a vacuum drop is more than specified value, replace the engine shut-off valve (6) Notice: Before replacing the valve for the glow starter system and the vacuum unit of the injection pump, check the hose lines and connections. 5. Vacuum Stop Unit Test. - Disconnect the control line (4) from the vacuum stop unit (3). - Connect the vacuum tester 201 589 13 21 00 to vacuum stop unit (3) and apply vacuum of 300 + 50 mbar. Permissible loss of vacuum 5 mbar / min
YAD1FAZ0
- If a vacuum drop is more than specified valve, replace the vacuum stop unit.
YAD1FB00
SSANGYONG Y200
IDLE SPEED ADJUSTMENT

Service Data
Engine OM662LA Engine Idle Speed 720 - 820 rpm
Commercial Tool
Digital tester e.g. Bosch, MOT 001.03 Sun, DIT 9000
Tools Required 001 589 73 21 00 Vacuum Pump 667 589 00 73 21 TDC Pulse Generator
Adjustment Procedure
1. Connect the digital tester (1) and TDC pulse generator 667 589 02 21 00 (11). 2. Run the engine and warm up the coolant to 60~80 C.
YAD1FB10
3. Disconnect the connecting rod (3) from control lever (2).
YAD1FDV0
4. Disconnect the vacuum hose (4) from the PLA unit to check idle speed with tester. 5. Check idle speed with tester. Idle Speed 720 - 820 rpm
Notice: To adjust idle speed, loosen the locking nut (6) of PLA unit.
YAD1FB20
SSANGYONG Y200

6. Ensure not to damage the idle spring in the governor and adjust idle speed by turning the PLA unit (5) slowly. Clockwise Counterclockwise RPM Decrease RPM Increase
Notice: Do not rotate the PLA unit over turn from the position marking. If do, idle spring in the governor will be severely damaged.
YAD1FB30
7. After adjustment, tighten the locking nut and place the position marking with different color of paint. Notice: If there are no changes in idle speed with PLA unit adjustment, perform the service at a BOSCH Service Center. 8. Connect the vacuum pump 001 589 73 21 00 to the PLA vacuum unit and build up vacuum approx. 500 mbar. If engine rpm increases by approx. 150 rpm. It is normal.
YAD1FB40
9. Connect the vacuum line (4). 10. Install the connecting rod. 11. Switch on all ancillaries and check the idle speed.
SSANGYONG Y200
FUEL PUMP TEST

Notice: Before test, replace the fuel filter cartridge and fuel prefilter.
Fuel Feed Test

Tools Required 001 589 73 21 00 Vacuum Pump 1. Disconnect the fuel return line (1) and seal up it with plug.
YAD1FB50
2. Insert the plastic hose (5) and put the end into the measuring beaker (6).
YAD1FB60
3. Disconnect the vacuum line from vacuum unit (engine stop) (5) and connect the vacuum pump 001 589 73 21 00 to the vacuum unit. 4. To avoid the engine starting, build up vacuum (approx. 500 mbar). 5. Operate the starter motor for exactly 30 seconds and measure fuel volume in the beaker. Min. volume 150 cm 3 for 30 seconds
YAD1FB70
SSANGYONG Y200
1F3-26 DIESEL ENGINE CONTROLS Fuel Pressure Test
YAD1FB80
1 2 3 4
Fuel Filter Housing Fuel Line Seal ........................................................ Replace Bolt ........................................... 13 N m (10 lb-ft)
5 Tester ............................ At Idle Speed > 0.3 bar ......................................... At Full Load > 0.5 bar 6 Fuel Injection Pump 7 Fuel Pump
SSANGYONG Y200

Tools Required 617 589 04 21 00 Tester
1. Disconnect the fuel line (2) from the fuel filter. 2. Remove the banjo bolt (4) from the fuel injection pump and remove the seals (3) and fuel line (2).
YAD1FB90
3. Connect the tester 617 589 04 21 00 (5). 4. Start the engine and read off the fuel pressure on tester 617 589 04 21 00 (5). At Idle Speed At Full Load > 0.3 bar > 0.5 bar
Notice: If out of standard, replace the fuel feed pump.
YAD1FBW0
5. Stop the engine. 6. Remove the tester 617 589 04 21 00. 7. Replace the seal and connect the fuel line (2). Inatallation Notice Tightening Torque 13 N m (10 lb-ft)
YAD1FBA0
SSANGYONG Y200
INJECTION NOZZLE TEST

Preceding Work: Removal of fuel injection nozzle
YAD1FBB0
1 Fuel Injection Nozzle ...........New : 135 - 143 bar ............................................ Used : min. 120 bar A Closed Spray = good B Stringy Spray = poor
2 Tester 3 Valve
SSANGYONG Y200

Tools Required 000 589 14 27 00 Fuel Injection Nozzle Tester
Notice: When testing the injection nozzle, do not place your hand into the spray of a nozzle. The spray will penetrate deep into the skin and destroy the tissue. 1. Connect the fuel injection nozzle to the fuel injection nozzle tester 000 589 14 27 00. 2. Close the valve (3) and pump 5 times strongly. 3. Chatter test : Slowly operate the hand lever at tester (approx. 1 stroke per second). The nozzle must spray with a gentle chattering. 4. Spray pattern test : Operate the hand lever at tester rapidly (approx. 2~3 strokes per second). Good The spray pattern shows closed and well atomized.
YAD1FBC0
YAD1FBD0
Poor The spray pattern shows split, too wide and stringy. (Repair the fuel injection nozzle)
YAD1FBE0
SSANGYONG Y200

5. Opening pressure test : Open the valve (3) and slowly operate the hand lever at tester (approx. 1 stroke / second) and measure opening pressure. New Nozzle Used Nozzle Difference Between Nozzles 135 - 143 bar Min. 120 bar Max. 5 bar
Notice: If out of standard, repair the injection nozzle.

YAD1FBC0
6. Leak test Slowly operate the hand lever at the tester until get a pressure of approx. 90 bar. Maintain this pressure for more than 20 seconds and within this period no drop of fuel should build up at the nozzle tip.
SSANGYONG Y200
CHECKING AND ADJUSTING START OF DELIVERY

Governor Impulse Method (RIV)
In order to be able to register the relationship of the injection pump relative to the engine two signals are required. TDC impulse from the crankshaft. Governor impulse from the injection pump. Both impulses are supplied by pulse generators. In order to obtain a measuring signal the sensor pins must be moved past the pulse generators with a minimum speed (idle speed). A measuring instrument measures the time interval of the two impulses, converting the result into an angular value which is then indicated.
YAD1FBF0
1 Fuel Injection Pump 2 Rl Sensor 3 Digital Testor
4 TDC Pluse Sender Unit 5 Battery
SSANGYONG Y200
1F3-32 DIESEL ENGINE CONTROLS Position Sensor, RIV Method
YAD1FBG0
1 Position Sensor 2 Battery 3 Fuel Injection Pump
4 Seal ........................................................ Replace 5 Screw Plug ............................... 30 Nm (22 lb-ft)
Service Data
Start of Delivery (RIV) ATDC 14 - 16
SSANGYONG Y200

Tools Required 617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel. Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAD1FBH0
2. Install the position sensor 617 589 08 21 00 (1) into the governor housing of the injection pump to be the guide pin of the position sensor facing up. 3. Connect the battery terminal of position sensor 617 589 08 21 00 (1) to positive terminal (+) of battery.
YAD1FBJ0
4. Rotate the crankshaft by hand (in direction of engine rotation) until the lamp B lights up. Rotate the crankshaft carefully further until both lamps A and B come on. In this position, check the Rl value on the crankshaft vibration damper. Specification
0 T 10 20 30 40
ATDC 14 - 16
Notice: If only lamp A lights up, repeat the test and if out of specification, adjust start of delivery.
YAD1BC10
SSANGYONG Y200
1F3-34 DIESEL ENGINE CONTROLS Digital Tester, RIV Method (Connection Diagram for Testers Without Adapter)
YAD1FBF0
1 Fuel Injection Pump 2 Rl Sensor 3 Digital Tester
4 TDC Pulse Generator 5 Battery
SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-35 (Connection Diagram for Testers With Adapter)
YAD1FBK0
1 Fuel Injection Pump 2 Rl Sensor 3 Digital Tester
4 TDC Pulse Sender Unit 5 Battery 6 Rl Pulse Generator
Service Data
Start of Delivery (RIV) Idle Speed ATDC 14 - 16 720 - 820 rpm
SSANGYONG Y200

Tools Required 617 589 09 21 00 Rl Adapter 617 589 10 21 00 RI Sensor 667 589 00 21 00 TDC Pulse Generator Commercial Tools Item Digital Tester With Pluse Generator Without Pulse Generator Tools Bosch, MOT 001.03 Hartmann & Braun. EOMT3 Bosch, ETD 019.00 Sun, DIT 9000 ALV, Diesel - Tester 875
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable vessel.
YAD1FBL0
2. Install the Rl sensor 617 589 10 21 00 into the governor housing of injection pump (1). 3. Connect the digital tester and TDC pulse generator 667 589 00 21 00 according to connection diagram. 4. Run the engine at idle speed and check the Rl value on the digital tester RI valve ATDC 14 - 16
Notice: If out of standard, adjust the start of delivery. 5. Stop the engine. 6. Remove the Rl sensor, digital tester and TDC pulse generator. 7. Replace the seal and tighten the plug. Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAD1FBM0
8. Check engine oil level and adjust if necessary.
SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-37 After Testing - Position Sensor (RIV Method)
Preceding Work: Start of delivery test
YAD1FBN0
1 Adjusting Screw 2 Bolt ........................................... 23 N m (17 lb-ft) 3 Fuel Injection Pump
4 Bolt ........................................... 23 N m (17 lb-ft) 5 Scale ....... Rl start of delivery = 14 - 16 ATDC
SSANGYONG Y200

Tools Required 617 589 08 21 00 Position Sensor
1. Position the No. 1 cylinder at ATDC 15
0 T 10 20 30 40
Notice: Do not rotate the engine in opposite direction of engine rotation.
YAD1BC10
2. Remove the bolt (2) at the supporting bracket. Installation Notice Tightening Torque 23 N m (17 lb-ft)
YAD1FBP0
3. Remove the bolt (4) at the timing case cover. Installation Notice Tightening Torque 23 N m (17 lb-ft)
YAD1FBQ0
4. Turn the adjusting screw (1) until both lamps A , B on the position sensor 617 589 08 21 00 light up. To the right To the left Start of Delievery Retarded Star of Delivery Advanced
Notice: If the adjustment range is not adequate, remove the injection pump and reinstall. 5. After adjusting, retighten all the bolt to the specified torque.
YAD1FBR0
SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-39 After Testing - Digital Tester (RIV Method)
YAD1FBS0
1 Bolt ........................................... 23 N m (17 lb-ft) 2 Adjusting Screw .... To the right : start of delivery retarded To the left : start of delivery advanced
3 Bolt ........................................... 23 N m (17 lb-ft)
Service Data
Start of Delivery (RIV) Ldling Speed ATDC 14 - 16 720 - 820 rpm
Tools Required 617 589 09 21 00 Rl Adaptor 617 589 10 21 00 RI Sensor 667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Item Digital Tester With Pulse Generator Without Pulse Generator Tools Bosch, MOT 001.03 Hartmann & Braun, EOMT3 Bosch, ETD 019.00 Sun, DIT 9000 ALV, Diesel - Tester 875
SSANGYONG Y200
1F3-40 DIESEL ENGINE CONTROLS Adjustment Procedure

1. Remove the bolt (3) at the supporting bracket. Installation Notice Tightening Torque 23 N m (17 lb-ft)
YAD1FBT0
2. remove the bolts (1) at the timing case cover. Installation Notice Tightening Torque 23 N m (17 lb-ft)
YAD1FBU0
3. Run the engine at idle speed. 4. Turn the adjusting screw (2) until the specification (15 1 ATDC) is indicated on the digital tester. To the Right To the Left Start of Delivery Retarded Start Delivery Advanced
YAD1FBV0
SSANGYONG Y200

VACUUM PUMP
Preceding Work: Removal the poly V-belt
YAD1FBX0
1 Bolt ........................................... 10 N m (89 lb-in) 2 Vacuum Pump
3 Vacuum Line 4 Gasket ................................................... Replace
SSANGYONG Y200
1F3-42 DIESEL ENGINE CONTROLS Removal & Installation Procedure

1. Remove the vacuum line.
YAD1FBY0
2. Remove the bolts (1) evenly. Notice: If necessary, rotate the engine until the pressure on the tappet of the vacuum pump is released.
YAD1FBZ0
3. Remove the vacuum pump (2). 4. Install the vacuum pump (2). Installation Notice Tightening Torque 10 N m (89 lb-in)
Clean the gasket residues of sealing surface of vacuum pump and replace the gasket (5). 5. Connect the vacuum line.
YAD1FC00
SSANGYONG Y200
VACUUM UNIT REPLACEMENT
YAD1FC10
1 Bracket 2 Bolt 3 Vacuum Unit
4 Vacuum Line 5 Seal ........................................................ Replace
SSANGYONG Y200
FUEL PUMP
YAD1FC20
1 2 3 4
Fuel Injection Pump Pressure Line ........................... 13 N m (10 lb-ft) Suction Line Hose Clip ............................................... Replace
5 6 7 8
Gasket ................................................... Replace Spring Lock Washer Hexagon Nuts .......................... 18 N m (13 lb-ft) Fuel Pump
SSANGYONG Y200

Removal & Installation procedure
1. Disconnect the fuel pressure and suction line. Installation Notice Tightening Torque 13 N m (10 lb-ft)
YAD1FC30
2. Remove the fuel pump mounting bolts. Installation Notice Tightening Torque 17 N m (10 lb-ft)
3. Remove the fuel pump and gasket.
YAD1FC40
YAD1FC50
SSANGYONG Y200
INJECTION NOZZLES
YAD1FC60
1 Fuel Injection Nozzle . 35 - 40N m (26 - 30 lb-ft) 2 Fuel Return Hose 3 Plug
4 Nozzle Washer ..................................... Replace 5 Fuel Injection Pipe ................... 18 N m (13 lb-ft)
SSANGYONG Y200

Tools Required 001 589 65 09 00 Serration Wrench

1. Remove the plastic clip from the injection pipe 2. Remove the fuel return hose (5). 3. Remove the plug(3).
YAD1BFC70
4. Disconnect the injection pipes from the injection nozzles and push them to the side. Installation Notice Tightening Torque 18 N m (13 lb-ft)
YAD1BFC80
5. Remove the fuel injection nozzle (4) with serration wrench 001 589 65 09 00. Installation Notice Tightening Torque 35 - 40 N m (26 - 30 lb-ft)
YAD1BCU0
6. Replace the washers (6). 7. Installation should follow the removal procedure in the reverse order. Notice: Pay attention to the installation position of new nozzle washer and tightening torque.
YAD1BFC90
SSANGYONG Y200
INJECTION NOZZLE REPAIR

Preceding Work: Removal of fuel injection nozzle
YAD1FCA0
1 2 3 4
Nozzle Holder Steel Washer Compression Spring Thrust Pin
5 6 7 8
Intermediate Disc Nozzle Needle Nozzle Body Nozzle Tensioning Nut ............ 80 N m (59 lb-ft)
SSANGYONG Y200

Tools Required 000 589 00 68 00 Cleaning Set
Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzle tensioning nut (8). Notice: Use protective jaws for clamping. 2. Disassemble the fuel injection nozzle.
YAD1FCB0
3. Clean the nozzle needle (6) and nozzle body (7) with an abradant. 4. Clean the nozzle seat with cleaning cutter.
YAD1FCC0
5. Immerse nozzle needle (6) and nozzle body (7) in filtered diesel fuel. When the nozzle body is held vertical, the weight of the nozzle needle must cause it to slide down toward the nozzle needle seat.
YAD1FCD0
6. Assemble the injection nozzle so that the tip of the thrust (4) pin is facing toward the nozzle holder. Installation Notice Tightening Torque 80 N m (59 lb-ft)
Nozzle needle (6) and nozzle body (7) should always be replaced as a pair.
YAD1FCE0
SSANGYONG Y200

7. Check the fuel injection nozzle and adjust opening pressure if necessary. Opening pressure adjustment Disassemble the fuel injection nozzle and replace the steel washer (2). Notice: Each 0.05 mm thickness of the washer results in a pressure difference of approx. 3 bar.
SSANGYONG Y200
INJECTION TIMING DEVICE ASSEMBLY

Preceding Work : Removal of vacuum pump
YAD1FCF0
1 2 3 4 5 6 7 8 9
Cylinder Head Cover Bolt ........................................... 10 N m (89 lb-in) Gasket ................................................... Replace Fuel Injection Pump Seal ........................................................ Replace Screw Plug ............................... 30 N m (22 lb-ft) Oil Pan Locking Pin Injection Timing Device
10 11 12 13 14
Washer Bolt (Left-Hand Thread) ........... 46 N m (34 lb-ft) Camshaft Sprocket Washer 12-Sided Stretch Bolt .......................................... ........................... Check, 25 Nm (18 lb-ft)+ 90 15 Timing Chain 16 Seal 17 Chain Tensioner ....................... 80 N m (59 lb-ft)
SSANGYONG Y200

Tools Required 116 589 02 34 00 Threaded Bolt 116 589 20 33 00 Sliding Hammer 601 589 00 08 00 Flange 601 589 05 21 00 Locking Screw 667 589 04 63 00 Retaining Plate

1. Remove the bolts (2) and then remove the cylinder head cover (1) and gasket (3). Installation Notice
YAD1BCV0
Tightening Torque
10 N m (89 lb-in)
Replace the gasket. Rotate the engine 1 revolution by hand and check TDC marking of the crankshaft and camshaft.
2. Loosen the camshaft sprocket bolt (14). Installation Notice Tightening Torque 25 N m (18 lb-ft)+ 90
Do not remove the bolt. If max. length of bolt exceeds 53.6 mm, replace it.
YAD1FCG0
3. Loosen the bolt (11) (left-hand thread). Installation Notice Tightening Torque Do not remove the bolt. 46 N m (34 lb-ft)
YAD1FCH0
SSANGYONG Y200

4. Position the no.1 cylinder at ATDC 15 . Notice: Do not rotate the engine with camshaft sprocket bolt or opposite direction of the engine rotation.
0 T
10
20
30
40
YAD1BC10
5. Remove the plug (6) and seal (5) from the fuel injection pump and collect oil in a suitable vessel. Installation Notice Tightening Torque Replace the seal. 30 N m (22 lb-ft)
YAD1FCJ0
6. Install the locking screw 601 589 05 21 00 (18) into the injection pump. Notice: Before tightening the bolts for the injection timing device and the camshaft sprocket, always remove the locking screw 601 589 05 21 00 from the injection pump and reinstall the plug.
YAD1FCK0
7. Place alignment marks (arrow) on the timing chain (12) and camshaft sprocket (15).
YAD1BC20
SSANGYONG Y200

8. Remove the chain tensioner (17). Installation Notice Tightening Torque Replace the seal (16). 80 N m (59 lb-ft)
YAD1FCL0
9. Pull out the 12-sided stretch bolt (14) and washer and remove the camshaft sprocket (12).
YAD1FCM0
10. Pull out the bolt (11) and washer (10). Notice: Be careful that the bolt is left-hand thread.
YAD1FCN0
11. Using special tool (Sliding Hammer 116 589 20 33 00 - 24,Threaded bolt 116 589 02 34 00 - 25), remove the locking pin (8).
YAD1FCP0
SSANGYONG Y200

12. Push back the timing chain with retaining plate 667 589 04 63 00 (26) and remove the injection timing device (9). 13. Installation should follow the removal procedure in the reverse order. 14. After assembling the engine, check start of delivery and adjust if necessary.
YAD1FCQ0
SSANGYONG Y200
INJECTION TIMING DEVICE

Preceding Work: Removal of injection timing device assembly
YAD1FCR0
1 Cam Sprocket ............................................ Check 2 Bushing ...................................................... Check 3 Governor Weights
4 Segment Flange and Drive Hub 5 Compression Springs
SSANGYONG Y200

1. Remove the governor weights (3).
YAD1FCS0
2. Pull out the compression springs (5) and cam sprocket (1) from the segment flange (4).
YAD1FCT0
3. Knock out the bushing (2) with a proper drift. 4. Installation should follow the removal procedure in the reverse order.
YAD1FCU0
SSANGYONG Y200
FUEL INJECTION PUMP

Preceding Work: Removal of vacuum pump Removal of air cleaner housing Removal of intake manifold
YAD1FCV0
18 19 20 21 22 23
Chain Tensioner ....................... 80 N m (59 lb-ft) Seal ........................................................ Replace Bolt(Left-Hand Thread) ............ 46 N m (34 lb-ft) Washer Bolt ........................................... 23 N m (17 lb-ft) Seal ........................................................ Replace
24 25 26 27 28
Oil Pan Fuel Injection Pump Seal ........................................................ Replace Screw Plug ............................... 30 N m (22 lb-ft) Square Nut
SSANGYONG Y200

Tools Required 000 589 77 03 00 Box Wrench Insert 601 589 00 08 00 Flange 601 589 05 21 00 Locking Screw 601 589 05 14 00 Assembly Cage
Removal Procedure
1. Position the no.1 cylinder at 15 ATDC. Notice: Do not rotate the engine in opposition direction of engine rotation.
YAD1BC10
2. Remove the connecting rod (9). 3. Disconnect the vacuum lines (13, 14). 4. Remove the accelerator control damper (10). (Manual transmission vehicle)
YAD1FCW0
5. Remove the suction line (16) and pressure line (4). 6. Remove the banjo bolt (1) and then remove the seal (2) and fuel line (3). 7. Remove the plastic clip (8) on the injection line.
YAD1FCX0
8. Disconnect the injection lines (15) from the injection pump (25). 9. Remove the banjo bolt (6) and then remove the seal (7) and return line (5).
YAD1FCY0
SSANGYONG Y200

10. Install the assembly cage 601 589 05 14 00 (29) and remove the bolt (20) and pull off the washer (21). Notice: Be careful that the bolt (20) is left hand thread.
YAD1FCZ0
11. Remove the chain tensioner (18) and seal (19).
YAD1FD00
12. Remove the bolt (12) and pull off the washer (11).
YAD1FD10
13. Remove the bolt (22) and pull off the square nut (28). 14. Pull out the fuel injection pump (25) and seal (23).
YAD1FD20
SSANGYONG Y200

Installation Procedure
1. Remove the screw plug (27) and seal (26) and collect oil in a vessel.
YAD1FD30
2. Insert flange 601 589 00 08 00 (31) onto the injection pump camshaft and turn until the cam of the governor is visible in the hole.
YAD1FD40
3. Tighten the locking screw 601 589 05 21 00.
YAD1FD50
4. Ensure that the no.1 cylinder is positioned at ATDC 15 .
0 T
10
20
30
40
YAD1BC10
SSANGYONG Y200

5. Coat the new seal (23) with engine oil and install it. 6. Insert the fuel injection pump (25) and tighten the bolts (22). Installation Notice Tightening Torque 23 N m (17 lb-ft)
7. Remove the locking screw (32).
YAD1FD60
8. Tighten the bolt (12). Installation Notice Tightening Torque 23 N m (17 lb-ft)
YAD1FD70
9. Insert the washer (21) and tighten the bolts (20) and then remove the assembly cage 601 589 05 14 00 (29). Installation Notice Tightening Torque 46 N m (34 lb-ft)
YAD1FD80
10. Connect the fuel pipes Installation Notice Return Line (5) Fuel Injection Line (15) Fuel feed Line (3) Suction and Pressure Line (4) Replace the seal. 11. Assemble the plastic clip (8).
YAD1FD90
13 Nm (10 lb-ft) 18 Nm (13 lb-ft) 13 Nm (10 lb-ft) 13 Nm (10 lb-ft)
SSANGYONG Y200

12. Connect the vacuum line (13, 14). 13. Connect the connecting rod (15). 14. connect the accelerator control damper (16). (Manual transmission vehicle) 15. 16. 17. 18. Install the chain tensioner. Install the vacuum pump. Check the start of delivery. Adjust the idle speed.
YAD1FDA0
SSANGYONG Y200
FUEL TANK
YAD1FDB0
1 2 3 4 6
Fuel Tank Mounting Bracket Fuel Return Line Fuel Supply Line Fuel Filter Fuel Tank
7 8 9 10
Fuel Pump Fuel Tank Rear Pipe Fuel Tank Air Cap Fuel Filler Assembly
SSANGYONG Y200

Caution: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines. 1. Disconnect the negative battery cable. 2. Disconnect the fuel filler hoses.
YAD1FDC0
3. Put aside the floor carpet to remove the fuel pump access cover. 4. Remove the fuel pump access cover. 5. Disconect the fuel return and supply line. 6. Disconnect the fuel pump wiring connector.
YAD1FDD0
7. Remove the fuel pump moumting bolts and bracket. 8. Carefully lower the fuel tank. 9. Installation should follow the removal precedure in the reverse order.
YAD1FDE0
SSANGYONG Y200
SPECIFICATIONS
Fuel Distribution Type Number of Cylinders Mounting Type Drive Type Flange Stroke Flange Outside Diameter Rack Movement Max. Speed Injected Fuel Quantity / Stroke Lubrication Type Individual Injection Type (Same Number of Cylinder and Plunger) 5 Cylinder End Flange Mounting Inside Chain Connected with Camshaft 7 mm 5.5 mm 21 mm 2,500 rpm 35 mm3 / Stroke Sump Lubrication Type (Connected with Engine Oil Passage)
SSANGYONG Y200

Application Camshaft Sprocket Bolt Chain Tensioner Cylinder Head Cover Bolt Fuel Feed Line (at Fuel Injection Pump) Fuel Injection Nozzle Fuel Injection Pipe Fuel Injection Pump Mounting Bolt (at the Timing Cast Cover) Fuel Injection Pump Supporting Bracket Bolt Fuel Line Bolt (at Fuel Filter) Fuel Pressure Line (at Fuel Pump) Fuel Return Line (at Fuel Injection Pump) Injection Timing Device Bolt Nozzle Tensioning Nut Screw Plug Vacuum Pump Mounting Bolt Nm 25 + 90 80 10 13 35 - 40 18 23 23 13 13 13 46 80 30 10 Lb - Ft 18 + 90 59 10 26 - 30 13 17 17 10 10 10 34 59 22 Lb - In 89 89
SSANGYONG Y200
EGR SYSTEM
YAD1FDF0
SSANGYONG Y200

SPECIAL TOOLS TABLE
000 589 00 68 00 Cleaning Set
000 589 14 27 00 Fuel Injection Nozzle Tester
YAD1FDU0
YAD1FDK0
000 589 77 03 00 Box Wrench Insert
001 589 65 09 00 Serration Wrench
YAD1FDT0
YAD1BKB0
001 589 73 21 00 Vacuum Pump
116 589 02 34 00 Threaded Bolt
YAD1A190
YAD1BLH0
201 589 13 21 00 Vacuum Tester
YAD1B580
YAD1FDG0
SSANGYONG Y200
601 589 05 14 00 Assembly Cage
601 589 05 21 00 Locking Sensor
YAD1FDS0
YAD1FDQ0
610 589 00 08 00 Flange
617 589 00 21 00 Ri Sensor
YAD1FDP0
YAD1FDN0
617 589 04 21 00 Tester
617 589 08 21 01 Micro Switch Setting Device
YAD1FDJ0
YAD1FDL0
617 589 08 21 00 Position Sensor
617 589 09 21 00 Ri Adapter
YAD1FDL0
YAD1FDM0
SSANGYONG Y200
667 589 00 21 00 TDC Pulse Generator
667 589 04 63 00 Retaining Plate
YAD1FDH0
YAD1FDR0
SSANGYONG Y200
SECTION 1G
ENGINE INTAKE & EXHAUST

TABLE OF CONTENTS
Description and Operation ............................... 1G-2 Exhaust System................................................ 1G-2 Muffler ............................................................... 1G-2 Catalytic Converter (Gasoline Engine) ............. 1G-2 DOC (Diesel Oxidation Catalyst) ..................... 1G-2 Resonance Flap (Gasoline Engine) .................. 1G-5 Repair Instructions ............................................ 1G-6 On-Vehicle Service .............................................. 1G-6 Air Cleaner and Intake Air Duct (Gasoline Engine) .......................................... 1G-6 Air Cleaner (Diesel Engine) .............................. 1G-9 Intake Manifold (Gasoline Engine) ................. 1G-11 Intake Manifold (Diesel Engine) ..................... 1G-13 Resonance Flap (Gasoline Engine) ................ 1G-15 Exhaust Line (Gasoline Engine) ..................... 1G-16 Exhaust Line (Diesel Engine) ......................... 1G-19 Specifications .................................................. 1G-21 Fastener Tightening Specifications................ 1G-21
1G-2 ENGINE INTAKE & EXHAUST

EXHAUST SYSTEM
Notice: When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials. Check the complete exhaust system and the nearby body areas and trunk lid for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections, or other deterioration which could permit exhaust fumes to seep into the trunk may be an indication of a problem in one of these areas. Any defects should be corrected immediately.
DOC (DIESEL OXIDATION CATALYST)

System and Principle
Oxidation catalytic technology for diesel engine is basically the same with it of gasoline engine used before development of 3 primary catalyst (2 primary catalyst), and its effect and performance were already proved. DOC (Diesel Oxidation Catalyst) reduces HO and CO contained exhaust gas over 80%, and removes SOF (Soluble Organic Fraction) over 50~80%, but because its portion in total PM is low, it reduces approx, 20~40% of TPM (Total Particulate Material). Because of low reducing rate for PM of DOC, in order to guarantee safety rate of PM regulation, this technology is being used mainly. And it should keep over 80% of PM reducing rate, and at present it plays a role as a transition stage. And also it reduces diesel odor and black smoke, platinum or palladium are being used as a catalyst. On the other hand, it is a problem that it makes the reaction of oxidation, which SO 2 produce SO3 and H 2 SO4 by reacting to oxygen in exhaust gas, if temperature of exhaust gas becomes over 300C, and this produced gas is very harmful to human body. To prevent is, previously it is requested that the sulfur content rate of fuel should be below 0.05%, and in the future it is being expected to keep it below 0.01%.
MUFFLER
Aside from the exhaust manifold connection, the exhaust system uses a flange and seal joint design rather than a slip joint coupling design with clamp and U-bolts. If hole, open seams, or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the complete assembly should be replace, the complete assembly should be replaced. The same procedure is applicable to the rear muffler assembly. Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops.
CATALYTIC CONVERTER (GASOLINE ENGINE)

Notice: When jacking or lifting the vehicle from the body side rails, be certain that the lift pads do not contact the catalytic converter, as this could damage the catalytic converter. Notice: Use of anything other than unleaded fuel will damage the catalyst in the catalytic converter. The catalytic converter are emission-control devices added to the exhaust system to reduce pollutants from the exhaust pipes. The oxidation catalyst is coated with a catalytic material containing platinum and palladium, which reduces levels of hydrocarbon (HC) and carbon monoxide (CO) from the exhaust gas. The three-way catalyst has coatings which contain platinum and rhodium, which additionally lower the levels of oxides of nitrogen (NOx).
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ENGINE INTAKE & EXHAUST 1G-3 Catalytic Converter Structure

The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite. The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith. Washer coat operates first, and catalytic metal elements (Pt, Pd, Rh) operates to washer coat next. Monolith type is lighter than other types, easy to manufacture and quickly approaches to proper temperature. Washer coat is used to make a contact surface with exhaust gas bigger by adhering closely to small holes of inner layer. If a lead compound or phosphorus adheres to the surface and the temperature rises, its surface is decreased. The total area of general monolith converter is about 45,000~500,000ft 3. (10 times of a football field) Generally Alumina (AL2 O 3) is used as a raw material and its 7 phases of gamma, delta, theta have big areas and high stability for the temperature, and nowadays gamma Alumina is used usually.
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YAD1G010
Catalytic Converter and Temperature

Catalytic converter has the normal function of purification at a range of the temperature. Because it has a weak point of decreasing of the purification rate in the condition of continuous high temperature, it should keep the temperature range of 400 to 500C for normal condition. HC purification rate becomes better according to the increase of temperature in the normal range of temperature. CO purification rate becomes the best near the temperature of 450C, and NO x does so near the temperature of 400 to 500C.
YAD1G020
Purification of Catalytic Converter
YAD1G030
Adhesion of soluble organic fraction (SOF) below 180C Purification of soluble organic fraction (SOF) over 180C Chemical reaction formula SOF(HC)+O2 CO 2+H 2O 2CO2 2CO+O2 4CO2+6H20 2C2H6+7O2 By catalytic action of two primary catalytic converter, oxidation occurs in order to decrease HC and CO.
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Oxygen adheres to catalytic material : below 180C
YAD1G040
Catalytic material supplies each CO and HC with O 2 for their oxidation : above 180C
YAD1G050
Catalytic material conversion process by DOC
YAD1G060
Method for Reduction of NOx

NOx is generated a great deal in case that combustion temperature and excess air factor are high. EGR valve can decrease NOx (30 to 35% decrease) by making temperature of combustion chamber fall by means of exhaust gas re-circulation. EGR valve is installed on the diesel engine of Musso, Korando, Istana and Rexton. And micro switch is installed together to control EGR valve.
The setting method of micro switch is identical with the existing one.
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ENGINE INTAKE & EXHAUST 1G-5
RESONANCE FLAP (GASOLINE ENGINE)

Function
A pneumatically actuated resonance flap (5) is located on the intake manifold, and will be opened and closed by load, which operates resonance flap according to engine and controlled by ECU and rpm.
YAD1G070
Resonance flap closed (at idle/partial load : less than 3,800/rpm) The switch valve (7) will be adjusted by ECU and resonance falp will be colosed. By increasing air flow passage through dividing intaking air flow toward both air collection housing (8). This leads to a signficant increase in the torque in the lower speed range.
YAD1G080
Resonance flap open (at full load : over 3,800/rpm) The switch valve (7) will not be adjusted by ECU and resonance falp (5) will be open. The collected air in the air collection housing (8) will not be divided and intaking air passage will be shorten.
YAD1G090
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AIR CLEANER AND INTAKE AIR DUCT (GASOLINE ENGINE)
YAD1G100
1 2 3 4 5 6 7
Air Cleaner Upper Housing Air Cleaner Lower Housing Element Air Duct Inlet Insulator Bolt Clamp
8 9 10 11 12 13
Sleeve HFM Sensor Intake Air Duct Blow-by Hose Clamp (2 Pieces) Intake Air Duct Mounting Clamp
SSANGYONG Y200

1. Remove the air cleaner upper housing clamp and mounting bolts and remove the air cleaner upper housing and element.
YAD1G110
2. remove the air cleaner lower housing bolt and air cleaner lower housing and insulators.
YAD1G120
3. Disconnect the HFM sensor connector.
YAD1G130
4. Remove the intake air duct housing clamp and intake air duct assembly.
YAD1G140
SSANGYONG Y200

5. Install the intake air duct to intake manifold and intake air duct mounting clamp. 6. Connect the HFM sensor connector.
YAD1G150
7. Install the air cleaner housing assembly.
YAD1G160
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AIR CLEANER (DIESEL ENGINE)
YAD1G170
1 2 3 4
Air Cleaner Upper Housing Air Cleaner Lower Housing Element Air Duct Inlet
5 6 7 8
Insulator Air Cleaner to T/C Hose Clamp Bolt
SSANGYONG Y200

1. Remove the air cleaner upper housing clamp and mounting bolts and remove the air cleaner upper housing and element.
YAD1G180
2. Remove the air cleaner lower housing bolt, air cleaner lower housing, air duct inlet and insulators.
YAD1G120
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INTAKE MANIFOLD (GASOLINE ENGINE)

Preceding Work : Removal of fuel distributor and injection valve
YAD1G190
1 Bolt (M6 X 40, 4 pieces) .........................................9-11 Nm (80-97 lb-in) 2 Softcap 3 Resonance Flap 4 Gasket.................................................... Replace 5 Upper Intake Manifold 6 Bolt (M8 X 50, 9 pieces) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft) 7 Gasket.................................................... Replace 8 Blow-by Hose 9 Blow-by Hose 10 Clamp 11 Blow-by Nipple 12 Inlet Air Housing
13 Bolt (M6 X 40, 4 pieces) ......................................... 9-11 Nm (80-97 lb-in) 14 Throttle Body-Electric 15 Gasket.................................................... Replace 16 Lower Intake Manifold 17 Bolt (M8 X 40, 4 pieces) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft) 18 Nipple 19 Seal Ring 20 Connector 21 Connection House 22 Clamp 23 Noise Damper Assembly 24 Tapping Screw
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Upper Intake Manifold 1. Disconnect the vacuum hose (8, 9). 2. Loosen the clamp (22). 3. Remove the upper intake manifold (5) after unscrewing the bolt (6). Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Check the gasket and replace it if necessary.

YAD1G200
Lower Intake Manifold Preceding work : removal of upper intake manifold 1. Remove the hose of brake booster vacuum line and idle speed connector. 2. Disconnect the water inlet pipe from the bottom of lower intake manifold. 3. Unscrew the bolt (17) and remove the lower intake manifold (16). Installation Notice Tightening Torque
YAD1G210
22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
4. Installation should follow the removal procedure in the reverse order. 5. Start the engine and check for leaks at each connection part.
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INTAKE MANIFOLD (DIESEL ENGINE)
YAD1G220
1 2 3 4 5 6 7 8 9 10
Gasket Nut ..................... 22.5-27.5 Nm (16.6-20.3 lb-ft) Exhaust Manifold Support Assembly Washer Nut ..................... 22.5-27.5 Nm (16.6-20.3 lb-ft) Gasket Bolt ..................... 22.5-27.5 Nm (16.6-20.3 lb-ft) Intake Manifold Stud Bolt
11 12 13 14 15 16 17 18 19 20
Seal Ring Expansion Plug Ball Pivot Intake Air Duct Gasket Bolt ..................... 22.5-27.5 Nm (16.6-20.3 lb-ft) Bracket Bolt Bolt Nut
SSANGYONG Y200

1. Loosen the air hose clamp from the intake air duct and remove the air hose.
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YAD1G230
2. Disconnect the blow-by hose. 3. Disconnect the air cleaner and turbo charger hoses. 4. Disconnect the intercooler hoses.
YAD1G240
5. Remove the intake air duct mounting bolts and intake air duct. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1G250
6. Remove the intake manifold mounting bolts and intake monifold. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1G260
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RESONANCE FLAP (GASOLINE ENGINE)
YAD1G270
1 Soft Cap (2) 2 Bolt (M6 X 40, 4 piecesc) ........................................... 9-11 Nm80-97 lb-in) 3 O-ring
4 Vacuum Hose 5 Resonance Flap 6 Gasket.................................................... Replace

1. Remove the 2 soft caps (1). 2. Remove the upper resonance flap coupling after removing 4 bolt (2). Installation Notice Tightening Torque 3. 4. 5. 6. 9 - 11 N m (80 - 97 lb-ft)
Check the O-ring (3) and replace it if necessary. Remove the lower resonance flap (5). Replace the gasket (6). Installation should follow the removal procedure in the reverse order.
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EXHAUST LINE (GASOLINE ENGINE)
YAD1G280
1 2 3 4 5 6 7 8
Front Exhaust Pipe Muffler Tail Exhaust Pipe Gasket.................................................... Replace Gasket.................................................... Replace Hanger Hanger Heat Protector No. 1
9 10 11 12 13 14 15 16
Heat Protector No. 2 Heat Protector No. 3 Heat Protector No. 4 Bolt ................................. 15-28 Nm (11-21 lb-ft) Nut ................................. 28-47 Nm (21-35 lb-ft) Nut ..................................... 8-18 Nm (6-13 lb-ft) Screw Oxygen Sensor
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1. Disconnect the oxygen sensor electrical connectors. 2. Remove the exhaust manifold to front exhaust pipe nuts. Installation Notice Tightening Torque 15 - 28 N m (11 - 21 lb-ft)
YAD1G290
3. Remove the oxygen sensor and hanger from the front exhaust pipe. 4. Remove the front exhaust pipe to muffler nuts. Installation Notice Tightening Torque 28 - 47 N m (21 - 35 lb-ft)
YAD1G300
5. Remove the muffler to tail exhaust pipe nuts. Installation Notice Tightening Torque 28 - 47 N m (21 - 35 lb-ft)
YAD1G310
6. Remove the Mounting hunger and muffler.
YAD1G320
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7. Remove the mounting hanger and tail exhaust pipe. 8. Check the muffler and pipes for holes, damage, open seams, or other deterioration. Which could permit exhaust fumes to seep into the passenger compartment or the trunk. 9. Installation should follow the removal procedure in the reverse order.
YAD1G330
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EXHAUST LINE (DIESEL ENGINE)
YAD1G340
1 2 3 4 5 6 7
Front Exhaust Pipe Diesel Oxidation Catalyst Converter Muffler Tail Exhaust Pipe Gasket Hanger Hanger
8 9 10 11 12 13
Heat Protector No. 1 Heat Protector No. 3 Nut ................................. 15-28 Nm (11-21 lb-ft) Nut ................................. 28-47 Nm (21-35 lb-ft) Nut ..................................... 8-18 Nm (6-13 lb-ft) Screw
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1. Remove the exhaust manifold to front exhaust pipe nuts and mounting hanger. Installation Notice Tightening Torque 15 - 28 N m (11 - 21 lb-ft)
YAD1G350
2. Remove the front exhaust pipe to diesel oxidation catalyst converter nuts and front exhaust pipe. Installation Notice Tightening Torque 28 - 47 N m (21 - 35 lb-ft)
YAD1G360
3. Remove the diesel oxidation catalyst converter to muffler nuts and diesel oxidation catalyst converter. Installation Notice Tightening Torque 28 - 47 N m (21 - 35 lb-ft)
4. Remove the muffler to tail exhaust pipe nuts. Installation Notice Tightening Torque
YAD1G370
28 - 47 N m (21 - 35 lb-ft)
5. Remove the mounting hangers and then remove the muffler and tail exhaust pipe. 6. Check the muffler and pipes for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk. 7. Installation should follow the removal procedure in the reverse order.
YAD1G320
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SPECIFICATIONS
Application DOC to Muffler Nut Exhaust Manifold to Front Exhaust Pipe Nut Front Exhaust Pipe to DOC Nut Front Exhaust Pipe to Muffler Nut Intake Air Duct Mounting Bolt Intake Manifold Mounting Bolt Muffler to Tail Exhaust Pipe Nut Resonance Flap Mounting Bolt Nm 28 - 47 15 - 28 28 - 47 28 - 47 22.5 - 27.5 22.5 - 27.5 28 - 47 9 - 11 Lb-Ft 21 - 35 11 - 21 21 - 35 21 - 35 16.6 - 20.3 16.6 - 20.3 21 - 35 Lb-In 80 - 97
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SECTION 1
ENGINE
SECTION 1A
ENGINE GENERAL INFORMATION

TABLE OF CONTENTS
Description and Operation ............................... 1A-2 Cleanliness and Care ....................................... 1A-2 On-Engine Service ............................................ 1A-2 Component Locator .......................................... 1A-3 M162 Engine ..................................................... 1A-3 M161 Engine ..................................................... 1A-5 Diesel Engine .................................................... 1A-7 Diagnostic Information and Procedure .......... 1A-9 Oil Leak Diagnosis ........................................... 1A-9 Compression Pressure Test (Gasoline Engine) ........................................ 1A-10 Compression Pressure Test (Diesel Engine) ............................................ Cylinder Pressure Leakage Test (Gasoline Engine) ........................................ Cylinder Pressure Leakage Test (Diesel Engine) ............................................ General Diagnosis .......................................... 1A-12 1A-14 1A-16 1A-18
Specifications .................................................. 1A-23 Engine Specifications ..................................... 1A-23 Performance Curve ......................................... 1A-24 Special Tools and Equipment ....................... 1A-27 Special Tools Table ........................................ 1A-27
1A-2 ENGINE GENERAL INFORMATION

CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.
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ENGINE GENERAL INFORMATION 1A-3
COMPONENT LOCATOR
M162 ENGINE
Front View
YAD1A010
1 2 3 4 5 6 7 8 9 10 11
HFM Sensor Intake Air Duct Resonance Flap Cylinder Head Cover Exhaust Camshaft Intake Camshaft Cylinder Head Spark Plug Connector Valve Tappet Injector Exhaust Valve
12 13 14 15 16 17 18 19 20 21 22
Intake Manifold Connecting Rod Exhaust Manifold Crankshaft Engine Mounting Bracket Starter Crankcase Oil Pump Sprocket Oil Strainer Oil Pan Drain Plug
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Side View
YAD1A020
23 24 25 26
Camshaft Adjuster Cooling Fan and Viscous Clutch Piston Flywheel of Drive Plate
27 28 29 30
Oil Pump Drive Chain Oil Return Pipe Timing Chain Oil Pump
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M161 ENGINE
Front View
YAD1A030
1 2 3 4 5 6 7 8 9 10 11
HFM Sensor Intake Air Duct Cylinder Head Cover Ignition Coil Spark Plug Connector Fuel Distributor Injector Exhaust Camshaft Intake Camshaft Valve Tappet Intake Valve
12 13 14 15 16 17 18 19 20 21 22
Intake Manifold Cylinder Head Exhaust Manifold Dipstick Guide Tube and Gauge Connecting Rod Crankshaft Engine Mounting Bracket Starter Crankcase Oil Pump Sprocket Oil Pan
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1A-6 ENGINE GENERAL INFORMATION Side View
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YAD1A040
23 24 25 26 27 28
Camshaft Adjuster Oil Filler Cap Engine Hanger Bracket Cooling Fan and Viscous Clutch Oil Filter Timing Chain
29 30 31 32 33
Oil Pump Drive Chain Oil Strainer Oil Pump Ring Gear and Flywheel of Drive Plate Piston
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DIESEL ENGINE
Front View
YAD1A050
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1A-8 ENGINE GENERAL INFORMATION Side View
YAD1A060
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OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks.
Black Light and Dye Method

A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit. 1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle normal operating conditions as directed in the kit. 3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.
Finding the Leak

1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc. 2. Identify where the fluid is leaking from. 2.1 After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2.2 Wait a few minutes. 2.3 You should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. 4.1 Clean the area well. 4.2 Dry the area. 4.3 Operate the vehicle for several miles at normal operating temperature and varying speeds. 4.4 After operating the vehicle, visually check the suspected component. 4.5 If you still cannot locate the leak, try using the powder or black light and dye method.
Repairing the Leak

Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.
Gaskets
The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning. The fasteners are tightened improperly or the threads are dirty or damaged. The flanges or the sealing surface is warped. There are scratches, burrs or other damage to the sealing surface. The gasket is damaged or worn. There is cracking or porosity of the component. An improper seal was used (where applicable).
Seals
The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning. The seal bore is damaged (scratched, burred or nicked). The seal is damaged or worn. Improper installation is evident. There are cracks in the components. The shaft surface is scratched, nicked or damaged. A loose or worn bearing is causing excess seal wear.
Powder Method
1. Clean the suspected area. 2. Apply an aerosol-type powder (such as foot powder) to the suspected area. 3. Operate the vehicle under normal operating conditoins. 4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.
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COMPRESSION PRESSURE TEST (GASOLINE ENGINE)
YAD1A070
1 Compression Pressure Tester 2 Diagram Sheet
3 Adaptor 4 Sealing Cone
Standard Service Data

Application Compression Ratio Normal Engine Temperature Normal Compression Pressure Permissible Pressure Difference Between Individual Cylinders M162 Engine 10 : 1 80 C (176 F) Min. 10 bar, Max. 14 bar Max. 1.5 bar M161 Engine 10.4 : 1 Min. 11 bar, Max. 15 bar
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Tools Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench 5. Crank the engine approx. eight revolutions by using the start motor. 6. Compare the measurements of compression pressure tester 001 589 76 21 00 with the specifications. 7. Measure the compression pressure of the other cylinders in the same way. 8. If measured value is not within the specifications, perform the cylinder pressure leakage test. Notice: Discharge the combustion residues in the cylinders before testing the compression pressure. Apply the parking brake before cranking the engine.
Measuring Procedure
1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs using the spark plug wrench 119 589 01 09 00. 3. Place the diagram sheet to compression pressure tester 001 589 76 21 00. 4. Connect the adaptor to compression pressure tester 001 589 76 21 00 and install it into the spark plug hole.
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COMPRESSION PRESSURE TEST (DIESEL ENGINE)
YAD1A080
1 Test Adaptor 2 Flexible Connector
3 Compression Pressure Tester
Standard Service Data

Compression Ratio Normal Engine Temperature Normal Compression Pressure Minimum Compression Pressure Permissible Pressure Difference Between Individual Cylinders 22 : 1 80 C (176 F) 28bar Approx.18bar Max. 3bar
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Tools Required 001 589 76 21 00 Compression Pressure Tester 001 589 73 21 00 Hand Vacuum Pump 601 589 65 09 00 Socket
Measuring Procedure
Notice: Ensure that no gear is engaged and that the vehicle is protected from rolling. 1. Run the engine to be the coolant temperature 80 C (176 F). 2. Remove the fuel injection nozzle. 3. Install the test adapter (1) and connect the flexible connector (2) to the compression pressure tester 001 589 76 21 00.
YAD1A090
4. Disconnect the vacuum line from the stop unit and connect the hand vacuum pump 001 589 73 21 00 to the stop unit. 5. Pump the hand vacuum pump 001 589 73 21 00 and make the fuel injection pump in stop position. Operating Pressure Approx. 500bar
6. Using a starter motor, crank the engine 8 revolutions. 7. Measure the remaining cylinder compression pressure in the same manner and compare it with service data.
YAD1A100
Notice: If out of standard, do cylinder pressure leakage test. 8. Remove the compression pressure tester 001 589 76 21 00. 9. Install the fuel injection nozzle.
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CYLINDER PRESSURE LEAKAGE TEST (GASOLINE ENGINE)
YAD1A110
1 Engine Oil Filler Cap 2 Vibration Damper
3 Cylinder Pressure Leakage Tester with Connecting Hose
Permissible Pressure Leakage

At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max. 25 % Max. 10 % Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark (M162 Engine) Cylinder Number TDC Mark (M161 Engine) Cylinder Number OT (TDC) 1, 6 OT (TDC) 1, 4 a (120 ) 2, 5 b (240 ) 3, 4 UT (BDC 180 ) 2, 3
Universal Tool
Cylinder Pressure Leakage Tester Bosch, EFAW 210A Sun, CLT 228
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ENGINE GENERAL INFORMATION 1A-15 Leakage Test

1. Warm the engine up to normal operating temperature. 2. Disconnect the negative battery cable. 3. Remove the spark plugs. 4. Check the coolant level by opening the coolant reservoir cap and replenish if insufficient. 5. Open the engine oil filler cap. 6. Connect the tester to air pressure line and adjust the scale of tester. 7. Install the connecting hose to spark plug hole. M162 Engine 8. Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
YAD1A120
9. Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air. Notice: Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable. 10. Perform the pressure test according to the firing order. Notice: Firing Order M162 Engine: 1 - 5 - 3 - 6 - 2 - 4 M161 Engine: 1 - 3 - 4 - 2 11. Compare the leakage pressure with the specifications.
M161 Engine
YAD1A130
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CYLINDER PRESSURE LEAKAGE TEST (DIESEL ENGINE)
YAD1A140
1 Connector 2 Connection Piece
3 Connection Hose
Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80C)

At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max. 25 % Max. 10 % Max. 20 %
Universal Tools
Cylinder Pressure Leakage Tester Connection Piece Bosch, EFAW 210 A or Sun CLT 228 Bosch order no. 1 687 010 016
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Leakage Test
1. Run the engine to be the coolant temperature 80 C (176 F). 2. Remove the fuel injection nozzle. 3. Open the coolant reservoir. 4. Check the coolant level and replenish if necessary. 5. Open the oil filler cap. 6. Remove the air cleaner cover and element. 7. Position the piston at TDC. 8. Install the connector (1) and connection piece (2).
YAD1A150
9. Calibrate the tester and connect the connection hose (3) 10. Pressurize with compressed air and compare the pressure changes with permissible pressure leakage. 11. If permissible pressure leakage is out of standard, check followings : - Intake and exhaust lines. - Sounds in oil filler area. - Air bubbles in radiator coolant. Do pressure leakage test for the remaining cylinders according to the firing order. firing order: 1-2-4-5-3 Remove the tester. Close the coolant reservoir cap and oil filler cap. Install the air cleaner element and cover. Install the fuel injection nozzle.
12.
13 . 14 . 15. 16.
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GENERAL DIAGNOSIS
Condition Hard Starting Malfunction of (With normal Ignition System cranking) Probable Cause Correction
Faulty fuse. Faulty spark plug. Electric leakage at the high tension cable. Poor connection of the high tension cable or lead wires. Improper ignition timing. Faulty ignition coil. Lock of fuel in the fuel tank. Dirty or clogged fuel filter. Clogged fuel pipe. Malfunction of the fuel pump. Malfunction of the fuel injector. The foreign material in the fuel tank. Poor tightening spark plug. Cracked cylinder head gasket. Inadequate the valve clearance. Leakage of the valve clearance. Interference of the valve stem. Low elasticity or damage of the valve spring. Abnormal interference of pistons and cylinders. Excessive wear of pistons, rings, or cylinders. Broken timing belt. Loosening, damage or leakage of the vacuum hose. Leakage of intake system. Refer to above in this page.
Replace the fuse. Clean, adjust the plug gap or replace. Replace the cable. Replace the cable or wires. Adjust the ignition timing. Replace the ignition coil. Feed the fuel. Replace the filter. Clean the fuel pipe. Replace the fuel pump. Replace the injector. Clean the fuel tank. Tighten to the specified torque. Compression Replace the gasket. Adjust the clearance. Repair the valve. Replace the valve or the valve guide. Replace the valve spring. Replace the piston ring. Replace the ring or the piston and boring or replace the cylinder. Replace the belt. Connect the hose correctly or replace it. Replace intake system. Refer to above in this page.
Malfunction of Fuel System
Decline of Compression Pressure
Others
Lack of Engine Power
Decline of Compression Pressure Malfunction of Ignition System
Improper ignition timing. Faulty spark plug. Electric leakage or poor connection of the high tension cable.
Adjust the ignition timing. Adjust or replace the spark plug. Connect the cable correctly or replace it.
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ENGINE GENERAL INFORMATION 1A-19 General Diagnosis (Contd)

Condition Lack of Engine Malfunction of Power Fuel System Others Probable Cause Correction
Clogged fuel pipe. Clogged or contaminated fuel filter. Clogged exhaust system. Clogged or contaminated air cleaner element. Leak of the intake manifold gasket. Dragging brakes. Refer to Page 1A-10.
Clean the pipe. Replace the filter. Check and repair the system. Clean or replace the air cleaner element. Replace the gasket. Repair or replace the brakes. Refer to Page 1A-10.
Rough Engine Idling
Decline of Compression Pressure Malfunction of Fuel System
Clogged fuel pipe. Clogged or contaminated fuel filter. Malfunction of the fuel pressure regulator. Malfunction of the spark plug. Electric leakage or poor connection of the high tension cable. Poor ignition timing. Malfunction of the ignition coil. Clogged or contaminated air cleaner element. Leak of the intake manifold gasket. Poor connection or damage or leakage of the vacuum hose. Refer to Page 1A-10.
Clean the pipe. Replace the filter. Replace the regulator. Adjust or replace the spark plug. Connect the cable correctly or replace it. Adjust the ignition timing. Replace the ignition coil. Clean or replace the air cleaner element. Replace the gasket. Connect the hose correctly or replace it. Refer to Page 1A-10.
Malfunction of Ignition System
Others
Engine Hesitate (Upon pressing accelerating pedal, the engine makes delayed response This situation is remarkable when cruising or starting.)
Decline of Compression Pressure Malfunction of Ignition System
Poor ignition timing. Poor spark plug or Poor adjustment of the plug gap. Electric leakage or poor connection of the high tension cable. Malfunction of the air cleaner system. Leak of the intake manifold gasket.
Adjust the ignition timing. Replace the plug or adjust the gap. Connect the cable correctly or replace it. Clean or replace the air cleaner system. Replace the gasket.
Others
SSANGYONG Y200
1A-20 ENGINE GENERAL INFORMATION General Diagnosis (Contd)

Condition Engine Surging Decline of (Engine power Compression makes Pressure fluctuation in a Malfunction of fixed speed Fuel System and speed changes without operating the accelerating Malfunction of pedal.) Ignition System Probable Cause Correction
Refer to Page 1A-10.
Clogged fuel pipe. Clogged or contaminated fuel filter. Malfunction of the fuel pressure regulator. Malfunction of the spark plug. Electric leakage or poor connection of the high tension cable. Poor ignition timing. Leak of the intake manifold gasket. Leakage of the vacuum hose. Refer to Overheat in this page. Abnormal spark plug. Poor ignition timing. Electric leakage or poor connection of the high tension cable. Clogged or contaminated fuel filter and fuel pipe. Leak of the intake manifold gasket. Excessive carbon deposit due to abnormal combustion. Lack of coolant. Malfunction of the thermostat. Malfunction of the cooling fan. Poor water pump performance. Clogged or leaky radiator. Poor engine oil. Blocking oil filter or strainer. Lack of engine oil. Poor oil pump performance. Leakage of oil Damaged cylinder head gasket.
Clean the pipe. Replace the filter. Replace the fuel pressure regulator. Adjust or replace the spark plug. Connect the cable correctly or replace it. Adjust the ignition timing. Clean or replace the gasket. Connect the hose correctly or replace it. Refer to Overheat in this page. Replace the spark plug. Adjust the ignition timing Connect the cable correctly or replace it. Clean or replace the fuel filter and the fuel pipe. Replace the gasket. Remove the carbon. Refill coolant. Replace the thermostat. Check or replace the cooling fan. Replace the pump. Clean, repair or replace the radiator. Replace engine oil with the specified one. Clean or repair the oil filter or the strainer. Refill oil. Replace or repair the pump. Repair. Replace the gasket.
Others
Excessive Detonation (According to the opening range of Malfunction of metallic is made with abnormal explosion )
Overtheated Engine Malfunction of Fuel System
Malfunction of Ignition System Others
Overheat
Malfunction of Cooling System
Malfunction of Lubrication System
Other
SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-21 General Diagnosis (Contd)

Condition Poor Fuel Decline of Consumption Compression Pressure Malfunction of Fuel System Malfunction of Ignition System Probable Cause Correction
Leakage of the fuel tank or the fuel pipe. Improper ignition timing. Abnormal spark plug (Excessive carbon deposit, inadequate gap, burnt electrode). Electric leakage or poor connection of the high tension cable. Malfunction of the thermostat. Improperly installed valve. Low pressure of tires. Loosened oil drain plug. Loosened oil pan bolt. Loosened oil filter. Loosened oil pressure switch. Leakage of camshaft front oil seal. Leakage of crankshaft front oil seal. Leakage at the cylinder head cover gasket. Damage of the cylinder head gasket. Stuck piston ring. Worn piston or cylinder. Worn piston ring or ring groove. Inadequate position of the piston ring cutting part. Abrasion or damage of the valve system. Inadequate oil viscosity. Loosening of the oil pressure switch. Lack of engine oil. Blocking oil strainer. Lowered function of the oil pump. Abrasion or damage of the oil pump relief valve.
Repair or replace the fuel tank or the fuel pipe Adjust the ignition timing. Replace the plug.
Malfunction of Cooling System Others Excessive Consumption of Engine Oil Leakage of Engine Oil
Connect the cable normally or replace it. Repair the thermostat. Repair or replace the valve. Adjust the pressure of tires. Tighten the plug. Tighten the bolt. Engine Oil Tighten the filter. Tighten the switch. Replace the seal. Replace the seal. Replace the gasket. Replace the gasket. Remove carbon and replace the ring. Replace the piston or the cylinder. Replace the piston or ring. Adjust the position. Replace the valve system. Replace with the specified one. Tighten the switch. Refill oil. Clean the strainer. Replace the pump. Replace the valve.
Oil Mixing in Combustion Chamber
Low Oil Pressure
Malfunction of Lubrication System
SSANGYONG Y200
1A-22 ENGINE GENERAL INFORMATION General Diagnosis (Contd)

Condition Engine Noise Valve Noise Probable Cause Correction
Inadequate valve clearance Abrasion of valve stem or guide. Weak valve spring. Abrasion of the piston, the ring or the cylinder. Abrasion of the connecting rod bearing. Loosened the connecting rod nut. Abrasion of the crankshaft bearing. Abrasion of the crankshaft journal. Loosened bearing cap bolt. Excessive clearance of the crankshaft thrust bearing. Low oil pressure.
Adjust the valve clearance. Replace the valve stem or the guide. Replace the spring. Boring the cylinder or replace the piston, the ring or the cylinder. Replace the bearing. Tighten to the specified torque Replace the bearing. Grind or replace the crankshaft journal. Tighten to the specified torque. Adjust or replace. Refer to Page 1A-21 in this section.
Piston, Ring, Cylinder Noise Connecting Rod Noise
Crankshaft Noise
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SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Engine Model Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max. Output (ps/rpm) Max. Torque (kgm/rpm) Firing Order Ignition Type Ignition Timing Valve Timing Intake Exhaust Open/ Close Open/ Close M162 Engine M162.990 3199 89.9 x 84.0 MSE 3.63D 10 : 1 6 DOHC Chain-Driven 220 / 6000 31.6 / 3900 1-5-3-6-2-4 Distributorless Double Ignition BTDC 8 ATDC 11 / ABDC 34 BBDC 31 / BTDC 14 Automatic Control 700 50 3-4 8.2 Forced by Gear Pump Full Flow with Paper Filter Unleaded Gasoline M161 Engine M161.970 2295 90.9 x 88.4 MSE 3.53D 10.4 : 1 4 DOHC 149 / 5500 22.4 / 4000 1-3-4-2 BTDC 6 2 ATDC 13.15 / ABDC 13.57 BBDC 16.58 / BTDC 17.05 750 50 3.2 - 4.2 7.5 Diesel Engine Four-Stroke Diesel 2874 89 x 92.4 PES 5 M55 C320 RS 168 22 : 1 5 SOHC 120 / 4000 25.5 / 4000 1-2-4-5-3 BTDC 18 10 ATDC 11.33 / ABDC 17 BBDC 28 / BTDC 15.25 720 - 820 138 - 146 8.0 - 9.5 Combined Full-Flow and Partial Flow Filter Diesel
Valve Clearance Adjustment Idle Speed (rpm) Fuel Injection Pressure (kg/cm) Oil Capacity (liter) Lubrication Type Oil Filter Type Fuel
MSE : Engine Control Module 3.63D : 6 Cylinder Version 3.53D : 4 Cylinder Version
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PERFORMANCE CURVE
M162 Engine
YAD1A160
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ENGINE GENERAL INFORMATION 1A-25 M161 Engine
YAD1A170
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1A-26 ENGINE GENERAL INFORMATION Diesel Engine
YAD1A180
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SPECIAL TOOLS TABLE
001 589 73 21 00 Hand Vacuum Pump
001 589 76 21 00 Compression Pressure Tester
YAD1A190
YAD1A210
120 589 02 09 00 Spark PlugWrench
610 589 65 09 00 Socket
YAD1A220
YAD1A200
SSANGYONG Y200
SECTION 1B1
M162 ENGINE MECHANICAL

TABLE OF CONTENTS
Repair Instructions .............................................. 1B1-2 On-Vehicle Service ............................................. 1B1-2 Engine Assembly ................................................. 1B1-2 Poly V-Belt and Tensioning Device ...................... 1B1-10 Poly V-Belt ...................................................... 1B1-10 Poly V-Belt Inspection ...................................... 1B1-12 Tensioning Device ........................................... 1B1-14 Crankcase and Cylinder Head ............................. 1B1-16 Crankcase Ventilation System .......................... 1B1-16 Generator ........................................................ 1B1-18 Power Steering Pump and A/C Bracket ............ 1B1-19 Engine Mount .................................................. 1B1-22 Cylinder Head Cover ........................................ 1B1-24 Cylinder Head Front Cover ............................... 1B1-26 Cylinder Head ................................................. 1B1-28 Oil Pan ............................................................ 1B1-31 Timing Gear Case Cover .................................. 1B1-33 Crankshaft Sealing Rear Cover ........................ 1B1-35 Crankshaft Assembly ......................................... 1B1-37 Belt Pulley and Vibration Damper ..................... 1B1-37 Crankshaft Front Radial Seal ............................ 1B1-40 Crankshaft Rear Radial Seal ............................. 1B1-42 Crankshaft ....................................................... 1B1-44 Connecting Rod ............................................... 1B1-50 Piston .............................................................. 1B1-52 Piston Ring ...................................................... 1B1-55 Flywheel / Driven Plate ..................................... 1B1-57 Timing Device and Valve .................................... 1B1-60 Camshaft Adjuster ........................................... 1B1-60 Camshaft Sprocket Bolt ................................... 1B1-65 Camshaft ........................................................ 1B1-66 Camshaft Timing Position ................................ 1B1-71 Valve Spring .................................................... 1B1-74 Valve Stem Seal .............................................. 1B1-78 Chain Tensioner ............................................... 1B1-79 Timing Chain ................................................... 1B1-83 Tensioning Rail ................................................ 1B1-88 Cylinder Head Guide Rail ................................. 1B1-89 Crankcase Guide Rail ...................................... 1B1-90 Crankshaft Sprocket ........................................ 1B1-91 Lubrication System ............................................. 1B1-93 Engine Oil Specification ................................... 1B1-93 Oil Circulation .................................................. 1B1-94 Engine Oil and Oil Filter Element ...................... 1B1-95 Oil Filter ........................................................... 1B1-97 Oil Pump ......................................................... 1B1-99 Oil Pressure Relief Valve ................................ 1B1-100 Oil Non-Return Valve ...................................... 1B1-101 Oil Dipstick Guide Tube ................................. 1B1-102 Unit Repair ...................................................... 1B1-103 Oil Gallery in Crankcase ................................ 1B1-103 Oil Gallery in Cylinder Head ........................... 1B1-105 Core Plugs in Crankcase ................................ 1B1-108 Cylinder Bore ................................................ 1B1-110 Crankcase Mating Surface ............................. 1B1-112 Cylinder Head Mating Surface ........................ 1B1-114 Specifications ................................................. 1B1-116 Fastener Tightening Specifications ................. 1B1-116 Special Tools and Equipment ........................ 1B1-118 Special Tools Table ........................................ 1B1-118
SSANGYONG Y200
1B1-2 M162 ENGINE MECHANICAL

ENGINE ASSEMBLY
YAD1B010
1 Engine Assembly
Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-3

1. Disconnect the negative terminal of battery. 2. Remove the hood. 3. Remove the under cover. Installation Notice Tightening Torque 28 - 47 Nm (21 - 35 lb-ft)
YAD1B020
4. Disconnect the Hot Film Air Mass (HFM) sensor connector. 5. Disconnect the HFM sensor from the air filter housing. 6. Remove the intake air duct mounting nuts. Installation Notice Tightening Torque 9 - 11 Nm (80 - 97 lb-in)
KAA1C010
7. Remove the air cleaner cover. Remove the mounting bolts and air cleaner housing and element assembly.
YAD1B030
8. Loosen the radiator drain cock and drain the coolant. Notice : Open the coolant reservoir cap.
YAD1B040
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9. Loosen the cylinder block drain plug and then drain the coolant completely. Installation Notice Tightening Torque 30 Nm (22 lb-ft)
Replace the seal before installation of the drain plug.
YAD1B050
10. Remove the cooling fan shroud. Refer to Section 1D, Engine Cooling.
YAD1B060
11. Disconnect the each hose from radiator.
YAD1B070
12. Remove the upper mounting bolts of radiator and then remove the radiator.
YAD1B080
SSANGYONG Y200

13. Remove the hydraulic pipe of power steering. Installation Notice Tightening Torque Completely drain the oil. 40 - 50 N m (30 - 37 lb-ft)
YAD1B090
14. Discharge the refrigerant from A/C system, and disconnect the discharge pipe and suction pipe from the compressor. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System. Installation Notice Tightening Torque 20 - 30 N m (15 - 22 lb-ft)
YAD1B100
15. Remove the acceleration control cable and automatic transmission pressure cable.
YAD1B4M0
16. Remove the fuel feed and return line. Installation Notice Tightening Torque 21 - 25 N m (15 - 18 lb-ft)
Before removing the fuel lines, release the pressure in the fuel system.
KAA1F070
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17. Disconnect the terminals from the generator.
YAD1B110
18. Disconnect the terminal from starter motor and remove the starter motor. 19. Disconnect the engine main harness ground.
YAD1B120
20. Disconnect the engine ground wire.
YAD1B130
21. Disconnect following sensors connector. Coolant temperature sensor. 2 knock sensors. Camshaft and crankshaft sensors.
YAA1F150
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22. After removing the ignition coil cover, disconnect the ignition coil connector. 23. Remove the harness cover and disconnect the 6 injection valve connectors. Disconnect the main harness.
YAD1B140
24. Separate the hose toward engine from canister purge solenoid valve.
YAD1B4N0
25. Remove the automatic transmission oil cooler line. Installation Notice Tightening Torque 25 - 35 N m (18 - 26 lb-ft)
YAD1B150
26. Separate the vacuum hose for brake booster. 27. Separate the other vacuum hoses.
YAD1B160
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28. Remove the service hole cover in the engine block. 29. Put the alignment mark for installation, and remove the six mounting bolts for torque converter from drive plate through the service hole by rotating the engine and remove the torque converter. Installation Notice Tightening Torque 42 N m (31 lb-ft)
Screw the six bolts mounting the torque converter through the service hole by using a mirror and rotating the engine.
KAA5A2N0
30. Remove the exhaust manifold and exhaust pipe. Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAD1B180
31. Remove the transmission mounting bolts and separate the transmission from the engine. Installation Notice Tightening Torque 54 - 68 N m (40 - 50 lb-ft)
YAD1B190
32. Install a chain to the bracket of engine, by using a hoist or crane. 33. Remove the engine mounting bracket nuts. Installation Notice Tightening Torque Upper : 70 N m (52 lb-ft) Lower : 38 N m (28 lb-ft)
YAD1B200
SSANGYONG Y200

34. Carefully separate the engine assembly from the vehicle. 35. Installation should follow the removal procedure in the reverse order.
YAD1B210
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POLY V-BELT AND TENSIONING DEVICE

POLY V - BELT
Preceding Work : Removal of cooling fan
YAD1B330
1 Poly V-belt
2 Belt Tensioning Pulley

1. Release the belt tension by turning the belt tensioning pulley nut clockwise. Installation Notice Tightening Torque 40.5 - 49.5 N m (29.9 - 36.5 lb-ft)
YAD1B250
2. Remove the poly v-belt. Notice: Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary. 3. Install the belt by turning the nut of tensioning pulley clockwise.
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M162 ENGINE MECHANICAL 1B1-11 Poly V-Belt Arrangement
YAD1B340
1 2 3 4
Belt Tensioning Pulley Crankshaft Belt Pulley A/C Compressor Pulley Cooling Fan Pulley
5 6 7 8
Generator Pulley Idler Power Steering Pump Pulley Cooling Fan and Water Pump Pulley
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POLY V - BELT INSPECTION

Make marks on the belt with chalk. Rotate the engine and check the belt for damage. Notice: If one of the following types of damages is found, replace the belt.
YAD1B370
1. Rubber lumps in the base of rib. 2. Dirt or grit ingrained.
YAD1B380
3. Pointed rib. 4. Belt cord visible in the base of rib.
YAD1B390
5. Cord torn out at the side. 6. Outer cords frayed.
YAD1B400
SSANGYONG Y200

7. Rib detached from the base of belt.
YAD1B410
8. Splits across the rib. 9. Sections of rib torn out.
YAD1B420
10. Splits across several ribs.
YAD1B430
11. Splits across the back of the belt.
YAD1B440
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TENSIONING DEVICE
Preceding Work : Removal of poly v-belt
YAD1B350
1 Belt (L = 2245) 2 Bolt Combi (M8 x 14, 3 pieces) + Washer ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft)
3 Water Pump Pulley 4 Nut 5 Belt Tensioning Pulley
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1. Remove the poly v-belt. 2. Remove the tensioning pulley by turning its mounting nut counter clockwise as shown in figure. Installation Notice Tightening Torque 40.5 - 49.5 N m (29.9 - 36.5 lb-ft)
YAD1B250
3. Remove the bolts and remove the water pump pulley. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
4. Remove the mounting bolts(M8 x 30, 3 pieces) at the tensioning device, and remove the tensioning device. Installation Notice Tightening Torque
YAD1B360
26 - 32 Nm (19 - 24 lb-ft)
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CRANK CASE AND CYLINDER HEAD

CRANKCASE VENTILATION SYSTEM
YAD1B220
1 2 3 4 5 6 7 8 9 10 11 12
Crankcase Air Admission Port in Crankcase Oil Drain Port Filter Gasket A/C Bracket Oil Drain Pipe Oil Pan Air Admission Line Vent Line Restriction Hole (Diameter = 2 mm) Intake Manifold
13 14 15 16 17 18 19 20
Intake Air Duct (Cross Pipe) Cylinder Head Cover Oil Separator Oil Separator Air Admission and Vent Connection Air Admission and Vent Connection Throttle Valve Vent Line
A Fresh Air B Blowby Gas in Partial Load C Blowby Gas in Full Load
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-17 Operation at Idling and Mid-Load
It show that the throttle valve (19) is closed or very partially opened and the vacuum pressure in intake manifold is high. The blowby gas in the crankcase in partial load flows into the intake manifold through the vent line (20) after passing the air conditioner bracket (6) and the filter (4). The air reentered into the intake manifold will be dilluted on the flow through the restriction hole (11) in the vent line (10). The circulated engine oil is separated at the air conditioner bracket (6) and then returns into the oil pan through the drain pipe (7). The vacuum pressure generated at the crankcase sucks fresh air from intake air line(13) through the air admission and vent connection (17, 18). The fresh air prevents engine oil from being contaminated and the air admission and vent connection (17, 18) is designed to control the rapid pressure changes in intake air line (13).
Operation at Full-Load
The throttle valve (19) is fully opened. All the blowby gases flow into the intake air duct (13) after passing through the oil separator (15,16) of the cylinder head cover (14) when fully loaded. This dilluted air will be supplied to the combustion chamber through the intake manifold (12).
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GENERATOR
YAD1B230
1 Nut (M8) .............22.5-27.5 Nm (16.5-20.5 lb-ft) 2 Bolt (M8 x 30, 3 pieces) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft) 3 Bolt (M8 x 40, 1 piece) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft)
4 Bolt (M8 x 70, 1 piece) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft) 5 Bolt (M8 x 75, 1 piece) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft)

1. Remove the drive belt. 2. Remove the generator. 3. Unscrew the generator carrier bolts and remove the carrier. Installation Notice Tightening Torque 25 N m (18 lb-ft)

YAD1B240
SSANGYONG Y200
POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud
YAD1B5A0
1 Vent Hose 2 Bolt (M8 x 91, 2 pieces) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft) 3 Power Steering Pump 4 Bolt (M8 x 105, 4 pieces) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft) 5 Washer 6 A/C Compressor 7 Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft)
8 9 10 11
A/C Bracket Gasket.................................................... Replace Bracket Bolt (M8 x 22, 2 pieces) ........................... 22.5-27.5 Nm (16.5-20.5 lb-ft) 12 Tensioning Pulley 13 Nut ..................... 40.5-49.5 Nm (29.9-36.5 lb-ft)
SSANGYONG Y200

1. Remove the belt tensioning pulley. Installation Notice Tightening Torque 40.5 - 49.5 N m (29.9 - 36.5 lb-ft)
Pull the tensioning pulley clockwise as shown in the figure.
YAD1B250
2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
YAD1B090
3. Unscrew the bolts and remove the steering pump. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1B260
4. Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A/C compressor. Notice: Discharge all the refrigerant before removing the pipes.
YAD1B270
SSANGYONG Y200

5. Disconnect the vent hose from the A/C bracket. Installation Notice Tightening Torque 20 - 30 N m (15 - 22 lb-ft)
YAD1B280
6. Unscrew all the mounting bolts and remove the A/C bracket and the gasket.
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YAD1B290
Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
7. Clean the sealing surface. 8. Replace the gasket with new one. 9. Installation should follow the removal procedure in the reverse order. 10. Check the oil leakage by operating the engine after installation.
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ENGINE MOUNT
YAD1B300
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M162 ENGINE MECHANICAL 1B1-23 Removal and Installation Procedure

1. Unscrew the upper engine mounting nut. Installation Notice Tightening Torque 70 N m (52 lb-ft)
YAD1B310
2. Unscrew the lower engine mounting nut. Installation Notice Tightening Torque 38 N m (28 lb-ft)
3. Remove the hydraulic engine mounting insulator. Notice: If the insulator is spotted with oil, replace the hydraulic insulator asseambly. 4. Installation should follow the removal procedure in the reverse order.
YAD1B320
SSANGYONG Y200
CYLINDER HEAD COVER
YAD1B450
1 Ignition Cable Dust Cover 2 Bolt (M6 x 65, 8 pieces) ....................................... 9-11 N m (80-97 lb-in) 3 Bolt (M6 x 50, 4 pieces) ....................................... 9-11 N m (80-97 lb-in) 4 Spacer Sleeve
5 6 7 8 9
Thrust Piece Cylinder Head Cover Gasket.................................................... Replace Spart Plug Hole Seal ............................. Replace Camshaft Seal ....................................... Replace
Composition of The Cylinder Head Cover Bolts

A. M6 x 50, 4 Pieces - Bolts + Washers B. M6 x 65, 8 Pieces - Bolts + Washers
YAD1B460
SSANGYONG Y200

1. Remove the intake air duct. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
YAD1B470
2. Remove the spark plug cover. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
Unscrew the seven (M6 x 60) bolts and remove the spark plug cover.
YAD1B480
3. Remove the spark plug connector and ignition cable.
YAD1B490
4. Unscrew all the bolts (2,3) and remove the head cover and the gasket. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
Replace the gasket with a new one if necessary. 5. Installation should follow the removal procedure in the reverse order. 6. Check for oil leaks by operating the engine.
YAD1B500
SSANGYONG Y200
CYLINDER HEAD FRONT COVER

Preceding Work : Removal of cylinder head cover Removal of coolant connection fitting
YAD1B510
1 2 3 4
Camshaft Position Sensor Camshaft Actuator Upper Guide Rail Bolt (M6 x 60, 3 pieces) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft)
5 Bolt (M8 x 80, 3 pieces) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft) 6 Front Cover 7 Rubber Gasket ...................................... Replace 8 Bolt (M6 x 16, 3 pieces) ......................................... 9-11 N m (80-97 lb-in)

1. Remove the camshaft actuator. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
YAD1B520
SSANGYONG Y200

2. Remove the cylinder head front cover (6). Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Apply the sealant at the mating surface of the cylinder head and the front cover. 3. Remove the upper guide rail pin and the guide rail (3). Notice: Install it while the chain tensioner is loose.
YAD1B530
4. Remove the gasket (arrow). Notice: Replace the gasket with new one and apply the sealant. 5. Installation should follow the removal procedure in the reverse order.
YAD1B540
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CYLINDER HEAD
Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover Removal of upper intake manifold
YAD1B550
1 Cylinder Head Bolt (14 pieces) ........................ 1st step 55 N m (141 lb-ft) 2nd step 90 3rd step 90 2 Washers (14 pieces) 3 Flange Bolts (3 pieces) ........................ 1st step 18-22 Nm (13-16 lb-ft) 2nd step 90 5
4 5 6 7
Exhaust Camshaft Sprocket Cylinder Head Gasket.................................................... Replace Dowel Sleeve
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Tools Required 116 589 01 34 00 Threaded Pin 116 589 20 33 00 Sliding Hammer 617 589 00 10 00 Allen Wrench Socket

1. Rotate the crankshaft so that the piston of number 1 cylinder is at TDC. Notice: Rotate the crankshaft in the normal engine direction.
YAD1B590
2. Put the alignment marks (arrows) on the timing chain and camshaft sprocket. 3. Drain the coolant from the crankcase.
4. Remove the three flange bolts in the exhaust camshaft sprocket. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5
Do not reuse the removed bolts.
YAD1B600
5. Separate the chain from the camshaft sprockrt. Notice: Be careful not to drop the chain into the timing case.
YAD1B610
SSANGYONG Y200

6. Remove the guide rail fixing pin from the cylinder head using the threaded pin 116 589 01 34 00 (1) and sliding hammer 116 589 20 33 00 (2).
YAD1B620
7. Remove the cylinder head bolts in numerical order using allen wrench socket 617 589 00 10 00. Installation Notice 1st step: 55 N m (41 lb-ft) 2nd step : 90 3rd step : 90
Tightening Torque
YAD1B630
8. Check the length of the cylinder head bolt. Installation Notice Length (L) New 160 0.8 mm Max. 162 0.7 mm
Replace the bolt if the measured length exceed the max. length. Apply the oil to the thread surface of bolt.
YAD1B640
9. Carefully remove the cylinder head and check the mating surface. 10. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
OIL PAN
YAD1B5B0
1 Gasket.................................................... Replace 2 Bolt (M6 x 22, 6 pieces) ....................................... 9-11 Nm (80-97 lb-in) 3 Drain Plug ........ 22.5-27.5 Nm (16.6-20.3 lb-ft) 4 Bolt (M6 x 20, 22 pieces) ....................................... 9-11 Nm (80-97 lb-in)
5 Bolt (M6 x 85, 3 pieces) ....................................... 9-11 Nm (80-97 lb-in) 6 Bolt (M8 x 40, 4 pieces) ...........................22.5-27.5 Nm (16.6-20.3 lb-ft) 7 Bolt (M10) ................................ 40 Nm (30 lb-ft) 8 Oil Pan
SSANGYONG Y200

1. Remove the drain plug and drain the oil completely. 2. Unscrew the bolts and remove the oil pan and gasket. Notice: Arrange the bolts according to each size. 3. Clean the inside of oil pan and sealing surface, then apply the sealant. 4. Replace the gasket with new one. 5. Install the oil pan with gasket, and tighten each bolt in specified torque. 6. Check for oil leaks while running the engine.
YAD1B5C0
M8 M6 M6 M6 Others M6
X 40, 4 pieces X 85, 3 pieces X 35, 3 pieces X 22, 6 pieces X 20, 28 pieces
SSANGYONG Y200
TIMING GEAR CASE COVER

Preceding Work : Removal of cylinder head front cover Removal of generator bracket Removal of tensioning device Removal of belt pulley and vibration damper
YAD1B690
1 Bolt (M8 x 60, 3 pieces) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft) 2 A/C Bracket 3 Bolt (M8 x 65, 3 pieces) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft) 4 Bolt (M8 x 40, 1 piece) ........................... 22.5-27.5 Nm (16.6-20.3 lb-ft)
5 Bolt (M8 x 60, 1 piece) ...........................22.5-27.5 Nm (16.6-20.3 lb-ft) 6 Seal 7 Timing Gear Case Cover 8 Roll Pin 9 Bolt (M6 x 22, 6 pieces) .........................................9-11 N m (80-97 lb-in)
SSANGYONG Y200
1B1-34 M162 ENGINE MECHANICAL Removal & Installation Procedure

1. Put the alignment marks (arrows) on the timing chain and camshaft sprocket. 2. Unscrew the A/C bracket bolts (1) and remove the bracket. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1B590
3. Remove the cooling fan and the viscous clutch. Unscrew the three bolts from the cooling fan bracket and remove the bracket. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1B700
4. Remove the timing gear case cover after unscrewing the bolts (3) and (4) from the timing gear case cover and the bolt (9) from the oil pan. Notice: Be careful not to damage the oil pan gasket. Installation Notice Bolt (3, 4) : 22.5 - 27.5 N m (16.6 - 20.3 lb-ft) Bolt (9) : 9 - 11 N m (80 - 97 lb-in)
Tightening Torque
Apply the sealant after cleaning the timing gear case cover surface. Be careful not to stain the oil chamber of chain tensioner with the sealant. 5. Installation should follow the removal procedure in the reverse order. 6. Warm up the engine and check for oil leaks.
SSANGYONG Y200
CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate
YAD1B710
1 Bolt (M6 x 20, 6 pieces) .........................................9-11 Nm (80-97 lb-in) 2 Radial Shaft Seal 3 Rear Cover
4 Sleeve 5 Bolt (M6 x 85, 2 pieces) .........................................9-11 N m (80-97 lb-in) 6 Washer
SSANGYONG Y200

Tools Required 601 589 03 43 00 Crankshaft Rear Seal Installer

1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice: Be careful not to damage the oil pan gasket.
YAD1B740
2. Clean the sealing surface of the crankcase and the rear sealing cover. 3. Check the radial shaft seal and replace it if necessary. 4. Apply the Loctite 573 to the rear cover sealing surface. 5. Apply the engine oil to the dust lip of the radial shaft seal. Notice: Do not use the grease.
YAD1B750
6. Install the crankshaft rear radial seal and the crankshaft sealing rear cover, using crankshaft rear seal installer 601 589 03 43 00.
YAD1B760
7. Install the crankshaft sealing rear cover mounting bolts and remove the crankshaft rear seal installer 601 589 03 43 00. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
YAD1B770
SSANGYONG Y200
CRANKSHAFT ASSEMBLY
BELT PULLEY AND VIBRATION DAMPER
Preceding Work : Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt
YAD1B650
1 Center Bolt (M18 x 50) .......... 1st step 180- 220 N m (133-162 lb-ft) .......... 2nd step 90 +10 2 Vibration Damper Disk 3 Bolt (M6 x 20, 6 pieces) ............................ 7.7-9.5 Nm (68.1-84.1 lb-in)
4 Vibration Damper Assembly 5 Woodruff Key 6 Bolt (M6 x 12, 4 pieces) ....................................... 9-11 N m (80-97 lb-in) 7 Cooling Fan Pulley
SSANGYONG Y200
1B1-38 M162 ENGINE MECHANICAL Components
YAD1B660
1 2 3 4 5 6
Center Bolt (M18 x 50) Vibration Damper Disk Vibration Damper and Pulley Assembly Woodruff Key Crankshaft Front Seal Timing Gear Case Cover
7 8 9 10 11 12
Crankshaft Sprocket (Camshaft Driven) Crankshaft Sprocket (Oil Pump Driven) Crankshaft Oil Pan Oil Pan Gasket Oil Pan Mounting Bolt (M6 x 22)
Service Data Standard

Permissble Deviation of The Vibration Damper Radial Runout Axial Runout 0.6 mm 0.6 mm
SSANGYONG Y200

Tools Required 602 589 00 40 00 Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.
YAD1B670
2. Remove the start motor and install the engine lock 602 589 00 40 00 to the flywheel ring gear. 3. Remove the vibration damper center bolt. Installation Notice Tightening Torque 1st step: 180 - 220 Nm (133 - 162 lb-ft) 2nd step: 90 + 10
YAD1B680
4. Remove the vibration damper assembly using the puller. 5. Installation should follow the removal procedure in the reverse order. Notice: If possible, don t separate the vibration damper and the pulley.
YAD1B250
SSANGYONG Y200
CRANKSHAFT FRONT RADIAL SEAL

Preceding Work : Removal of belt pulley and vibration damper
YAD1B780
1 Center Bolt (M18 x 50) .......... 1st step 180- 220 Nm (133-162 lb-ft) 2nd step 90+10 2 Center Bolt Washer
3 Sleeve (Special Tool) 4 Crankshaft Front Seal 5 Key
SSANGYONG Y200

Tools Required 601 589 03 14 00 Crankshaft Front Seal Installer
1. Remove the radial seal with a screw driver. Notice: Use a clean cloth not to damage the radial seal mounting hole and the crankshaft. 2. Coat the radial sealing lip with engine oil. 3. Using the crankshaft front seal installer 601 589 03 14 00, assemble the radial seal. 4. Align the sleeve groove and the woodruff key and tighten the center bolt until the center bolt and the damper disk stop in the movement. Installation Notice Tightening Torque 1st step: 180 - 220 Nm (133 - 162 lb-ft) 2nd step: 90 + 10 5. Remove the crankshaft front seal installer 601 589 03 14 00, and install the belt pulley and the vibration damper. 6. Check for leaks while operating the engine.
YAD1B800
SSANGYONG Y200
CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate
YAD1B840
1 Special Tool 2 Special Tool
3 Crankshaft Rear Seal
SSANGYONG Y200

Replacement Proceudre
1. Remove the radial seal with a screw driver. Notice: Use a clean cloth not to damage the radial seal mounting hole and the crankshaft. 2. Install the crankshaft rear seal installer 601 589 03 43 00 (2) to the crankshaft. 3. Apply the engine oil on the crankshaft rear seal installer 601 589 03 43 00 (2).
YAD1B850
Notice: Do not use the grease. 4. Install the radial seal on the inner parts assembler. 5. Press in the crankshaft rear seal installer 601 589 03 43 00 (1) until the radial seal is stopped. 6. Check for leaks while operating the engine.
SSANGYONG Y200
CRANKSHAFT
Preceding Work : Removal of engine assembly Removal of timing gear case cover Removal of cylinder head Removal of crankshaft sealing rear cover Removal of oil pan Removal of oil pump Removal of baffle plate
YAD1B860
1 Crankshaft Bearing Cap Bolt (M8 x 55, 14 pieces) .......... 1st step 50- 60 N m (37-44 lb-ft) 2nd step 90+5
2 3 4 5
Crankshaft Bearing Cap Crankshaft Lower Main Bearing Crankshaft Lower Thrust Bearing Crankshaft
SSANGYONG Y200
Arrangement of the Thrust Bearing and the Main Bearing
YAD1B870
1 2 3 4 5 1
Upper Main Bearing Upper Thrust Bearing Crankshaft Lower Main Bearing Lower Thrust Bearing - 12 Weight Balance/Color Marking Point Journal Main Bearing #1 - #7 Color Dot Marking
A B C D
Crankcase Side Bearing Cap Side (Oil Pan Side) Axial Fit Bearing (Number 5 Bearing Point) Radial Bearing
j1 - j7
The color dot marking are put on the 1 , 2 , 4 , 6 , 8 , 10 , 12 and it indicates the diameter of crankshaft journal by color as below.
SSANGYONG Y200

Color Dot Marking Crankshaft Journal Diameter (mm) Blue Yellow Red White Violet 57.960 - 57.965 57.955 - 57.960 57.950 - 57.955 57.945 - 57.950 57.940 - 57.945
Selection of Crankshaft Main Bearing 1. Crankcase Side There are seven punching marks on the mating surface to oil pan. This mark is correspondent to the bearing distinguished by color. Select the relevant bearing according to the punching mark when repaired. Punching Mark
YAD1B880
Bearing Color Selected Blue Yellow Red
2. Crankshaft Bearing Cap Side Select the crankshaft main bearing according to the marking letter on the crankshaft main journal when repaired. Marking Letter B Y R W V
YAD1B890
Bearing Color Selected Blue Yellow Red White Violet
Service Data
Crankshaft Standard and Repair Size Standard size 1st repair size 2nd repair size 3rd repair size 4th repair size Crankshaft Crankshaft Thrust Washer Bearing JourJournal Width Thickness nal Diameter at fit bearing 57.950 - 57.965 57.700 - 57.715 57.450 - 57.465 57.200 - 57.215 56.950 - 56.965 2.15 or 2.20 2.25 or 2.35 or 2.40 24.50 - 24.533 Connecting Rod Bearing Journal Diameter 47.94 - 47.96 47.75 47.50 47.25 47.00 -
Unit : mm
Connecting Rod Bearing Jourmal Width 27.958 - 28.042
SSANGYONG Y200

1. Unscrew the connecting rod bearing cap bolt and remove the bearing cap. Installation Notice Tightening Torque 1st step: 40 + 5 N m (30 + 3.7 lb-ft) 2nd step: 90 + 10
Make sure that the upper and lower bearing shells do not change each other. Coat the bearing shell with engine oil. Install the bearing cap according to the consecutive number.
YAD1B900
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice Tightening Torque 1st step: 50 - 60 Nm (37 - 44 lb-ft) 2nd step: 90
YAD1B910
Part Part Part Part Part
No. No. No. No. No.
: 601 : 601 : 601 : 601 : 601
030 030 030 030 030
00 01 02 03 04
62 62 62 62 62
2.15 2.20 2.25 2.30 2.40
mm mm mm mm mm
Remove the bearing cap from front (pulley side) to rear. Make sure that the upper and lower bearing shells do not change each other and coat with engine oil. The oil grooves (arrows) in the thrust washers must face outward and insert the thrust bearing into the bearing cap. There are five kinds of thrust washers by thickness. Select the proper washer when repaired. 3. Remove the crankshaft. 4. Installation should follow the removal procedure in the reverse order. 5. After completion of the installation, check for the rotating condition of the crankshaft.
Notice:
Make sure the crankshaft bearing cap properly seated in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the left side (intake manifold side). Assemble so that the projected part of the cap and crankcase face the same direction.
YAD1B920
SSANGYONG Y200
Inspection
1. If the length L of the crankshaft bearing cap bolt exceeds 63.8 mm, replace it.
YAD1B930
2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows).
YAD1B940
3. Measure and record the inner diameter of the crankshaft bearing. Notice: Measure at 2 points (1, 2). Measure A , B and C as shown. If average value of B and C is less than value A , then the average value of B and C is actual average value. If average value of B and C is more than value A, then the value A is actual average value.
YAD1B950
4. Measure and record the diameter of the crankshaft bearing journal. Notice: Record the mean value when measured at 3 points (A, B, C). Measure the inner diameter of bearing and the diameter of journal and if it is out of the standard data, replace the bearing shell.
YAD1B960
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-49 Service Data Standard (Crankshaft Main Bearing Gap)
Item Main Bearing Journal ( NO. 1, 5, 7) Radial Axial Main Bearing Journal ( NO. 3, 4, 6) Radial Axial Measuring Position Gap (mm) Static condition :0.015 - 0.039 Dynamic condition: 0.031 - 0.051 (Consider the expansion 0.011 - 0.016) 0.010 - 0.254 Static condition :0.011 - 0.039 Dynamic condition: 0.031 - 0.051 (Consider the expansion 0.015 - 0.022) 0.010 - 0.254
(Connecting Rod Bearing Gap)

Item Connecting Rod Bearing Measuring Position Radial Gap (mm) 0.030 - 0.050
SSANGYONG Y200
CONNECTING ROD
Preceding Work : Removal of piston
YAD1B970
1 2 3 4
Connecting Rod Bushing Oil Gallery Balance Weight Connecting Rod Bolt (M9 x 52, 12 pieces) .......... 1st step 40+5 N m (30+3.7 lb-ft) 2nd step 90+10
5 6 7 8 9
Fit Sleeve Upper Connecting Rod Bearing Lower Connecting Rod Bearing BearingShell Lug Marking [Indication(//) or Numbers]

Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing Bore Center Width of The Connecting Rod (B) at Bearing Bore Width of The Connecting Rod (b) at Bushing Bore Basic Bore at The Bearing Shell (D1) Basic Bore at The Bushing (d1) Bushing Inner Diameter (d) Clearance Between The Piston Pin and The Bushing Peak-to-valley Height of Connecting Rod Bushing on Inside Permissible Twist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting Rod Bushing Core Permissible Deviation of Connecting Rod Bearing Bore from Concentricity Permissible Difference of Each Connecting Rod in Weight 0.01 mm 0.4 g 145 0.05 mm 21.940 - 22.000 mm 21.940 - 22.000 mm 51.600 - 51.614 mm 24.500 - 24.571 mm 22.007 - 22.013 mm 0.007 - 0.018 mm 0.005 mm 0.15 mm 0.07 mm
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-51 Inspection

1. Measure the basic bore of the connecting rod bearing. Notice: If the basic bore exceeds the value of 51.614 mm, replace the bearing or check the connecting rod.
YAD1B980
2. Check connecting rod bolts. Length When New (L) Max. Length (L) Tightening Torque 51.7 - 52 mm 52.9 mm 1st step: 40 + 5 Nm (30 + 3.7 lb-ft) 2nd step: 90+10 Notice: If the length exceeds max. length, replace it.
YAD1B990
3. Check the assembly mark(indication//or number: arrow) of the connecting rods and the bearing cap when installing. Notice: Make sure it doesnt exceed over 4g with other connecting rods when replacing the connecting rods. Check if the connecting rod and the bearing cap are accurately seated on the groove when replacing the bearing.
YAD1B0A0
SSANGYONG Y200
PISTON
Preceding Work : Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate
YAD1B2P0
1 Connecting Rod Bearing Cap 2 Connecting Rod 3 Connecting Rod Bearing Cap Bolt (M9 x 52, 12 pieces) .......... 1st step 40+5 N m (30+3.7 lb-ft) 2nd step 90+10
4 Piston 5 Snap Ring 6 Piston Pin
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-53 Removal Procedure

1. Unscrew the connecting rod bearing cap bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice: Make sure that the bearing cap and shell are not changed each other. 3. Remove the snap ring (5) and pull out the piston pin (6). Notice: Remove the snap ring using a clean cloth as shown in the right picture so that the piston, piston ring, and the snap ring dont get damaged.
YAD1B2Q0
SSANGYONG Y200
1B1-54 M162 ENGINE MECHANICAL Installation Procedure
YAD1B2R0
YAD1B2S0
1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3. Clean the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and the piston and coat them with engine oil. 4. Install the piston ring. 5. Install the piston so that the arrow on the piston head faces to the forward of the vehicle. 6. After aligning the connecting rod and the bearing cap mark (// or a number), tighten the bolts. Installation Notice Tightening Torque 1st step: 40 + 5 N m (30 + 3.7 lb-ft) 2nd step: 90 + 10
Apply the engine oil to the bearing cap upper and lower bearing shells. 7. Check if the crankshaft rotates without any trouble by rotating it.
SSANGYONG Y200
PISTON RING
Preceding Work : Removal of piston
YAD1B2T0
1 Piston Compression Ring 2 Piston Compression Ring 3 Piston Oil Ring
4 Coil Spring and Control Ring 5 Hook Spring
SSANGYONG Y200
1B1-56 M162 ENGINE MECHANICAL Replacement Procedure

1. Measure the piston ring s gap. Groove 1 0.20 - 0.40 mm End Gap of The Piston Ring Gap Between The Piston and The Piston Ring Groove 2 0.20 - 0.40 mm Groove 3 0.20 - 0.45 mm Groove 1 0.015 - 0.050 mm Groove 2 0.020 - 0.040 mm Groove 3 0.010 - 0.045 mm
Notice: If out of specification, replace the piston ring. 2. Remove the piston ring with a pliers.
YAD1B2U0
3. For installation, position the piston ring to be the TOP mark on the piston ring upward and arrange the piston ring ends to be 120 apart. 4. Adjust the hook spring joint in the oil ring 180 away from the ring end.
YAD1B2V0
SSANGYONG Y200
FLYWHEEL / DRIVEN PLATE

Preceding Work : Removal of manual or automatic transmission
YAD1B810
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) .......... 1st step 45+5 N m (33+3.7 lb-ft) 2nd step 90+10 2 Plate
3 Driven Plate (A/T) 4 Dowel Pin 5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)

Nominal Size Stretch Side Diameter Bolt Length Tightening Torque D d L When New Min. Diameter When New 1st step 45 + 5 Nm (33 + 3.7 lb-ft), 2nd step 90 + 10 M x 1.5 8.5 - 0.2 mm 8.0 mm 21.8 - 22.2 mm
SSANGYONG Y200

1. Unscrew the flywheel mounting bolt. Installation Notice Tightening Torque 1st step: 40 + 5 N m (30 + 3.7 lb-ft) 2nd step: 90 + 10

YAD1B820
Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0 mm. For the stretch bolt tightening, keep the socket wrench and Tommy-bar to be 90 and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for automatic transmission vehicle. 3. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
Sectional View
YAD1B830
1 2 3 4 5 6 7
Oil Pan Cover Crankshaft Front Seal Flywheel Mounting Bolt Crankshaft Dowel Pin Washer (thickness = 3.5 mm)
8 9 10 11 12 13 14
Washer Bolt Front Drive Plate Rear Drive Plate Rivet Segment Ring Gear
SSANGYONG Y200
TIMING DEVICE AND VALVE

CAMSHAFT ADJUSTER
Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover
YAD1B0B0
1 Bolt (M6 x 16, 3 pieces) ....................................... 9-11 Nm (80-97 lb-in) 2 Camshaft Actuator (2 Pin Connector) 3 Bolt ........................................... 35 Nm (26 lb-ft) 4 Armature 5 Roll Pin 6 Nut (M20 x 1.5) .............. 60-70 Nm (44-52 lb-ft) 7 Front Cover 8 Seal 9 Camshaft Position Sensor 10 Bolt (M6 x 16, 2 pieces) .........................................9-11 Nm (80-97 lb-in) 11 -
12 13 14 15
16 17 18 19 20 21 22
Seal Cover Camshaft Sprocket and Position Indicator (b) Adjuster Piston Flange Bolt (M7 x 13, 3 pieces) ........................ 1st step 18-22 Nm (13-16 lb-ft) 2nd step 90 5 Flange Shaft Compression Spring Control Piston Circlip Oil Gallery Pin Intake Camshaft
SSANGYONG Y200
Functions
When the engine is running, the camshaft rotates the intake camshaft hydrauically/mechanically relative to the camshaft sprocket by 34 crankangle to the advanced position and back to the retarded position. The camshaft adjuster is actuated electromechanically by the ECU. The positioning time of approx. 1 second is dependent on the engine oil pressure at the camshaft adjuster and on the oil viscosity and oil temperature, respectively. The position indicator (b) on the camshaft sprocket (13) provides the camshaft rotational speed to the position sensor (9) as an input parameter for the engine ignition control unit. Retarded Position 1. Ignition suitch OFF (retarded) The compression spring (17) pushes the control piston (18) against the circlip (19). The engine oil pressure in the camshaft is eliminated. 2. From 0 to 1000 - 2000 rpm (retarded) The torque of the internally helically toothed camshaft sprocket (13) acting in the direction of rotation of the engine pushes the externally helically toothed positioning piston(14) against the cover(12) as a result of the screw action. Consequently, the likewise internally helically toothed positioning piston (14) holds the externally helically toothed flanged shaft (16) together with the bolted-on camshaft (22) in the retarded position. The compressing spring (17) pushes the control piston(18) against the circlip (19). The engine oil flows through 2 oblique drillings in the camshaft flange and in the flanged shaft (16) in to the working chamber (A) and holds the positioning piston (14) additionally in the retarded position with the available engine oil pressure. Leak oil flows off over control and positioning piston surface, through the control piston drilling and 2 drillings (23) in the camshaft flange.
YAD1B0C0
12 13 14 16 17 18 19 22 23
Seal Cover Camshaft Sprocket Adjust Piston (Stops Towards The Front) Flange Shaft Compression Spring Control Piston (Stops Towards The Rear) Circlip Intake Camshaft Oil Outlet Drilling
A Working Chamber (Oil Pressure) Y49 Electromagnetic Actuator (Not Functioning)
SSANGYONG Y200

Advanced Position 3. From 1000 - 2000 to 4000 rpm (advanced) The control piston (18) is pulled forward as far as the stop in the flanged shaft (16) by the actuator (Y49) against the force of the compression spring (17). The control piston (18) closes the oil feed to the working chamber A and at the same time allows oil to flow to the working chamber B through 2 drillings each in the flanged shaft (16) and adjusting piston (14). The engine oil pressure moves the adjusting piston (14) as for as the stop on the flanged shaft (16). As a result of the axial movement of the flanged shaft (16) is turned into the advanced position. The turning action is achieved as a result of the effect of the helical teeth on the camshaft sprocket (13), positioning piston (14) and flanged shaft (16). The engine oil in working chamber A flows off, assisted by the pushing action of the adjusting piston (14), over the flanged shaft (16) and through 2 drillings (23) in the camshaft flange.
YAD1B0D0
12 13 14 16 17 18 19 22 23
Seal Cover Camshaft Sprocket Adjust Piston (Stops Towards The Front) Flange Shaft Compression Spring Control Piston (Stops Towards The Rear) Circlip Intake Camshaft Oil Outlet Drilling
A Working Chamber (Oil Pressure) Y49 Electromagnetic Actuator (Not Functioning)
4. From 4000 rpm (retarded) The electromagnetic actuator (Y49) is not actuated and allows the control piston to move. The compression spring (17) pushes the control piston (18) against the circlip (19). The oil feed to the working chamber B is closed off and oil is able to flow to working chamber A along 2 drillings in the flanged shaft (16). As a result of the engine oil pressure, the control piston (18) is moved as far as the cover (12). This axial movement of the adjusting piston (14) rotates the camshaft (22) bolted to the flanged shaft (16) in to the retarded position. The rotational movement is a result of the screw effect of the helical teeth on the camshaft sprocket (13), positioning piston (14) and flanged shaft (16). The engine oil in the working chamber (B) flows off, assisted by the pushing action of the adjusting piston (14), through 2 drillings each in the adjusting piston (14), flanged shaft (16) and control piston (18) through the control piston (18) and 2 drillings in the camshaft flange (23). Leak oil flows off over the control and adjusting piston surfaces through the control piston drilling and 2 drillings in the camshaft flange (23).
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-63 Removal & Installation Procedure

1. Turn the crankshaft to the direction of engine rotation and position the no.1 cylinder piston at TDC which the camshaft is positioned at OT.
YAD1B670
2. Remove the cylinder head front cover. Refer to Cylinder Head Front Cover in this section. 3. Paint the alignment marks (arrows) on the intake and exhaust camshaft sprocket and the timing chain.
YAD1B590
4. Unscrew the bolt (3) from the armature (4) and remove the armature. Installation Notice Tightening Torque 35 N m (26 lb-ft)
5. Unscrew the nut (6) and remove the ring and seal cover (11). Installation Notice Tightening Torque
YAD1B0E0
60 - 70 N m (44 - 52 lb-ft)
3 4 6 12
Bolt Amarture Nut (M20 x 1.5) Seal Cover
13 Camshaft Sprocket 18 Control Piston 22 Intake Camshaft
SSANGYONG Y200

6. Unscrew the sprocket bolt from the exhaust camshaft and remove the sprocket. Installation Notice Tightening Torque 1st step: 18 - 22 Nm (13 - 16 lb-ft) 2nd step: 90 5
The sprocket bolt is designed to be used only once, so always replace with new one.
7. Remove the camshaft sprocket (13) and adjust piston (14), and remove the flange shaft (16) from the intake camshaft (22) after removing the bolt (15). Installation Notice Tightening Torque 1st step: 18 - 22 Nm (13 - 16 lb-ft) 2nd step: 90 5
YAD1B0F0
The sprocket bolt is designed to be used only once, so always replace with new one. 8. Installation should follow the removal procedure in the reverse order. 9. Adjust the camshaft timing.
SSANGYONG Y200
CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5
The sprocket bolts are designed to be used only once, so always replace with new one.
YAD1B0G0
C e 16 18 22
M7 x 13 Collar Bolt Torx-T30 6.8 mm Flange Shaft Control Piston Intake Camshaft
Exhaust Camshaft Sprocket Bolt

Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5
The sprocket bolts are designed to be used only once, so always replace with new one.
YAD1B0H0
E e 13a 22a
M7 x 13 Collar Bolt Torx-T30 6.8 mm Camshaft Sprocket Exhaust Camshaft
SSANGYONG Y200
CAMSHAFT
Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover Removal of coolant connection fitting
YAD1B0J0
1 Chain Tensioner Assembly ....................................... 72-88 Nm (53-65 lb-ft) 2 Exhaust Camshaft Sprocket 3 Upper Guide Rail
4 5 6 7
Cylinder Head Front Cover Intake Camshaft Sprocket Chain Wrench
SSANGYONG Y200

Tools Required DW 110-120 Holding Pin
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30. 2. Remove the generator. 3. Remove the chain tensioner. Refer to Chain Tensioner in this section.
YAD1B240
4. Remove the cylinder head front cover and the upper guide rail.
YAD1B530
5. Put the alignment marks (arrows) on the camshaft sprocket (2, 5) and the timing chain (6).
YAD1B0L0
6. Unscrew the exhaust camshaft sprocket bolt and remove the sprocket. 7. Separate the chain from the intake camshaft sprocket and put the chain not to be dropped into timing case.
YAD1B600
SSANGYONG Y200

8. Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust side bolts (1, 4, 6, 7). 9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice: Number the camshaft bearing cap bolts when removing them, so that they dont get mixed up. 10. Remove the intake and exhaust camshafts.
YAD1B0M0
1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30. Notice: Turn the crankshaft in the direction of engine rotation.
2. Install the exhaust camshaft bearing caps (2, 3, 5) and the intake camshaft bearing caps (9, 10, 12). Tighten the bolts with specified torque and install the remaining bearing caps. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Install the bearing caps according to the numbers on the bearing caps.
YAD1B0N0
3. Turn the camshaft using the wrench so that the intake camshaft adjustment hole lines up with the cylinder head upper side (3 oclock direction at the intake, 9 o clock direction at the exhaust). Notice: Turn the crankshaft and adjust it to OT so that No. 1 cylinders piston would be at TDC.
YAD1B0P0
SSANGYONG Y200

4. Align the holes on intake and exhaust camshaft to the hole on cylinder head. Insert the holding pin DW 110-120 into the holes.
YAD1B0Q0
5. Turn the intake camshaft adjuster to the direction of camshaft rotation by hard until it stops and then install the chain. Notice:
Make sure that the camshaft sprocket and timing chain are aligned with marks. Intake camshaft adjuster should be in retarded position.
YAD1B0R0
6. Install the chain on the exhaust sprocket and tighten the sprocket bolts. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5

YAD1B600
Make sure that the camshaft sprocket and timing chain are aligned with marks. Replace the sprocket bolt with new one.
7. Install the chain tensioner screw plug (1) and chain tensioner assembly (2) and tighten it as specified. Installation Notice Tightening Torque (1) : 40 N m (30 lb-ft) (2) : 72 - 88 N m (53 - 65 lb-ft)
YAD1B0S0
SSANGYONG Y200

8. Rotate the crankshaft 2 revolutions and check followings: - TDC of no. 1 cylinder : OT - Alignment between camshaft adjustment hole and cylinder head surface. - Alignments between timing chain and sprocket marks. Notice: Turn the crankshaft in the direction of engine rotation. Read just if not aligned.
YAD1B670
9. Install the upper guide rail and cylinder head front cover. 10. Install the generator.
YAD1B530
SSANGYONG Y200
CAMSHAFT TIMING POSITION

Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover
YAD1B0T0
1 Chain Tensioner Assembly 2 Exhaust Camshaft Sprocket 3 Upper Guide Rail
4 Cylinder Head Front Cover 5 Wrench 6 Holding Pin DW 110-120
SSANGYONG Y200

Tools Required DW 110-120 Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning the crankshaft. Notice: When the OT mark on vibration damper is aligned with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up. In this way, the adjustment hole of the intake and exhaust camshaft will match in line with the cylinder head upper end, at 3 o clock, and 9 o clock direction each other. 2. Check the timing as below procedure; - Check if the camshaft adjustment hole is positioned to 3 oclock direction at the intake side and to 9 oclock direction at the exhaust side, respectively and align with the cylinder head mating surface. - At this condition, check if the OT mark on vibration damper aligns with the marker on the timing gear case.
YAD1B670
YAD1B0U0
1. 2. 3. 4. Position the No.1 cylinder to BTDC 30 . Remove the chain tensioner. Remove the exhaust camshaft sprocket. Align the intake and exhaust camshaft flange hole with the cylinder head upper surface.
Intake Side : 3 o clock direction Exhaust Side : 9 o clock direction

5. Align the holes on intake and exhaust camshaft to the hole on cylinder head. Insert the holding pin DW 110-120 into the hole. 6. Secure the intake and exhaust camshaft. 7. Position the piston of No.1 cylinder at TDC (OT) by turning the crankshaft. 8. Turn the camshaft adjuster of the intake camshaft to the left as much as possible (cam adjuster retarded position). 9. Install the chain to the intake camshaft sprocket. Notice: Timing chain must be placed on the guide rail in gear case cover.
SSANGYONG Y200

10. Install the chain to the exhaust camshaft sprocket and install it to the camshaft. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5
The sprocket bolt is designed to be used only once, so replace with new one. 11. Install the chain tensioner. Installation Notice Tightening Torque Screw Plug Tensioner Assembly 40 N m (30 lb-ft) 72 - 88 N m (53 - 65 lb-ft)
12. Check the camshaft timing.
SSANGYONG Y200
VALVE SPRING
Preceding Work : Removal of camshaft Removal of spark plug
YAD1B0V0
1 2 3 4 5
Valve Cotter Upper Retainer Valve Spring ......... Check, Replace if necessary Valve Stem Seal Lower Retainer
6 7 8 9
Connecting Hose Thrust Piece Lever Pusher Supporting Bar
DW 110-090 111 589 25 63 00 111 589 18 61 00 111 589 01 59 00
SSANGYONG Y200

Tools Required 111 589 01 59 00 111 589 18 61 00 111 589 25 63 00 602 589 00 40 00 DW 110-090 DW 110-100 Supporting Bar Lever Pusher Thrust Piece Engine Lock Connecting Hose Valve Tappet Remover

1. Place the supporting bar 111 589 01 59 00 (12) at the camshaft bearing cap and tighten them with the bearing cap bolt. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1B1B0
2. Turn the crankshaft to position the each cylinder piston at TDC. Mark on The Vibration Damper OT 120 240 Cylinder 1, 6 2, 5 3, 4
YAD1B1C0
Notice: Remove the valve spring only at TDC. Always rotate the crankshaft by holding the chain to prevent from timing chain damage and tangling, and for smooth rotation. 3. Remove the valve tappet (1) using the valve tappet remover DW 110-100. 4. Install the connecting hose DW 110-090 to the spark plug hole.
YAD1B1D0
SSANGYONG Y200

5. Install the engine lock to the ring gear to prevent the crankshaft from rotating. 6. Blow up with compressed air.
YAD1B680
7. Install the lever pusher 111 589 18 61 00 (8) and the thrust piece 111 589 25 63 00 (7). 8. Mount the thrust piece 111 589 25 03 00 (7) vertically to the valve spring retainer (2). 9. Press the valve spring (3) by using the lever pusher 111 589 18 61 00 (8). 10. Remove the valve cotter (1) using the pincette. 11. Remove the upper retainer (2) and the valve spring (3).
YAD1B1E0
12. Remove the valve stem seal (4). Notice: Check the valve stem seal for damage and replace if necessary. 13. Remove the lower retainer (5). Notice: Check the retainer for damages and replace with a new one if necessary. 14. Installation should follow the removal procedure in the reverse order.
YAD1B1F0
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-77 Test (Upper and Lower Valve Tappet and Valve Cotter)
Upper Valve Spring Retainer Size (mm) (d) (D) 8.5 12.3
YAD1B1G0
Lower Valve Spring Retainer Thickness (mm) (a) 0.8 - 1.0
YAD1B1H0
Valve Cotter Size (mm) (B) (H) 9.0 9.2 - 9.8
YAD1B1J0
SSANGYONG Y200
VALVE STEM SEAL

Preceding Work : Removal of valve spring
YAD1B1K0
1 Drift 119 589 00 43 00 2 Valve Stem Seal
3 Protective Sleeve
Tools Required 119 589 00 43 00
Drift
1. Remove the valve stem seal (2) using the pliers. Notice: Check the valve stem seal for damage and replace if necessary. 2. Coat the valve stem seal with oil and assemble it with the protective sleeve. 3. Insert the valve stem seal by pressing it with the drift 119 589 00 43 00.
YAD1B1M0
SSANGYONG Y200
CHAIN TENSIONER
YAD1B1N0
1 2 3 4 5
Screw Plug ............................... 40 N m (30 lb-ft) Seal Filler Pin Compression Spring Snap Ring
6 Thrust Pin 7 Chain Tensioner Housing ....................................... 72-88 Nm (53-65 lb-ft) 8 Seal
SSANGYONG Y200
1B1-80 M162 ENGINE MECHANICAL Removal Procedure

1. Position the No.1 cylinder to TDC (OT). Notice: Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam s lobe (arrow) stays in the upper side. 2. Cover the generator with a clean cloth. 3. Release the tension by unscrewing the screw plug once. Notice: In case that the tension is reduced by unscrewing the screw plug, reinstall after completely removing the chain tensioner. If the chain tensioner is tightened again without completely reducing its tension, then the detent spring doesnt return to the original position and the tension gets exceeded.
YAD1B1P0
4. Carefully unscrew the screw plug (1), and remove the seal (2). Notice: For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring. Remove the screw plug only when the seal and compression spring are damaged.
YAD1B1Q0
5. Carefully remove the filler pin (3), compression spring (4), snap ring (5), and the thrust pin (6). 6. Remove the chain tensioner housing (7) and the seal (8).
YAD1B1R0
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-81 Installation Procedure

1. Connect the thrust pin (6) and the snap ring (5) to the chain tensioner housing (7). Notice: When connecting the thrust pin, push in the thrust pin far enough so that it doesnt protrude at the chain tensioner housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap ring (5), and the seal (8). Installation Notice Tightening Torque 72 - 88 N m (53 - 65 lb-ft)
3. Insert the compression spring (4) with the filler pin (3) into chain tensioner housing.
YAD1B1S0
4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 N m (30 lb-ft)
5. Check for leaks by operating the engine.
YAD1B1T0
SSANGYONG Y200
1B1-82 M162 ENGINE MECHANICAL Sectional View
YAD1B1U0
1 2 3 4 5 6 7 8 9 10 11 12
Screw Plug Ball (Nonreturn Valve) Compression Spring Ball Guide Seal (Aluminum) Filler Pin Compression Spring Snap Ring Thrust Pin Ball (Nonreturn Valve) Compression Spring Thrust Piece
13 14 15 16 17 18 19 20 21 A B
Chain Tensioner Housing Seal Timing Gear Case Cover Cylinder Head Bolt / Washer Tensioning Rail Cylinder Head Gasket Timing Chain Tensioning Rail Base (Sliding Surface) Oil Supply Hole Chain Tensioner Oil Storage Hole
SSANGYONG Y200
TIMING CHAIN
Preceding Work : Removal of cylinder head cover Removal of spark plug
YAD1B1V0
1 2 3 4
Pin New Timing Chain Timing Chain (Used) Wedge
5 Link 6 Center Plate 7 Outer Plate
SSANGYONG Y200

Tools Required 000 589 58 43 00 Chain Assembly DW 110-120 Holding Pin
1. Position the No.1 cylinder to TDC (OT).
YAD1B670
2. Insert the holding pin DW 110-120 to the intake and exhaust camshaft flange not to rotate camshaft. 3. Remove the chain tensioner.
YAD1B0Q0
4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure.
YAD1B1X0
5. Cover the chain housing with a clean cloth, and grind off the timing chain pin from the intake camshaft sprocket with the grinder.
YAD1B1Y0
SSANGYONG Y200

6. Remove the outer plate (7) with the screw driver and remove the link.
YAD1B1Z0
7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6 mm), and the outer plate (7). 8. Rotate the crankshaft in the direction if engine revolution by pressing the new timing chain against the exhaust camshaft sprocket to prevent it to be tangled. Notice: Be sure to remove the wedge before cranking the engine. 9. Take out the used timing chain out from the chain housing. 10. Connect both separators of the new timing chain with the link (5) and the center plate (6). 11. Install the jaw (a) and the thrust piece (b) to the assembly tool as shown in the figures.
YAD1B2A0
YAD1B2B0
YAD1B2C0
SSANGYONG Y200

12. Place the outer plate (7, thickness 1.2 mm) inside the thrust piece (b).
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13. Install the chain assembly 000 589 58 43 00 above the link and tighten the spindle (c) until a block is felt. 14. Place the chain assembly 000 589 58 43 00.
YAD1B2E0
15. Replace the thrust piece (b) as shown in the figure.
YAD1B2F0
16. Install the chain assembly 000 589 58 43 00 to the link pin and tighten the spindle (c). Tightening Torque 30 N m (22 lb-ft)
YAD1B2E0
SSANGYONG Y200

17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Tightening Torque Screw Plug Tensioner Assembly 40 N m (30 lb-ft) 72 - 88 N m (53 - 65 lb-ft)
19. Check the camshaft timing position.
YAD1B2G0
SSANGYONG Y200
TENSIONING RAIL
Preceding Work : Removal of timing gear case cover
YAD1B2H0
1 Tensioning Rail 2 Plastic Guide
3 Tensioning Rail Pin 4 Guide Rail

1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow). 2. Remove the exhaust camshaft sprocket. 3. Remove the tensioning rail (1) from the tensioning rail pin (3). Notice: Replace the plastic guide (2) if it is damaged. For installation, exactly align the plastic guide (2) with the tensioning rail (1). 4. Installation should follow the removal procedure in the reverse order. 5. Check the camshaft timing position.
SSANGYONG Y200
CYLINDER HEAD GUIDE RAIL

Preceding Work : Removal of cylinder head cover
YAD1B2J0
1 Chain Tensioner 2 Upper Guide Rail
3 Upper Guide Rail Pin 4 Wrench (Special Tool)

1. Remove the chain tensioner (1). 2. Turn the exhaust camshaft to the camshaft rotating direction using the wrench (4) and loosen the timing chain at upper guide rail (2). 3. Pull out the upper guide rail pin from the guide rail (2). 4. Turn the exhaust camshaft to the opposite direction of rotation using the wrench. 5. Check for damages at the upper sliding rail and replace it if necessary. Install the upper guide rail pin. 6. Install the chain tensioner. Installation Notice Tightening Torque Screw Plug Tensioner Assembly 40 Nm (30 lb-ft) 72 - 88 Nm (53 - 65 lb-ft)
SSANGYONG Y200
CRANKCASE GUIDE RAIL

YAD1B2K0
1 Guide Rail 2 Plastic Guide
3 Guide Rail Pin 4 Tensioning Rail

1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow). 2. Remove the exhaust camshaft sprocket. 3. Remove the guide rail (1) from the guide rail pin (3). Notice: Replace the plastic guide (2) if damaged. Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when installing. 4. Installation should follow the removal procedure in the reverse order. 5. Check the camshaft timing position.
SSANGYONG Y200
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan Removal of tensioning rail Removal of crankcase guide rail
YAD1B2L0
1 2 3 4 5
Oil Pump Chain Tensioner Oil Pump Chain Bushing Oil Pump Chain Spring Crankshaft Sprocket Key
6 Bolt (M8 x 20, 1 piece) / Washer ..................................... 29-35 N m (21-26 lb-ft) 7 Oil Pump Sprocket 8 Oil Pump 9 Oil Pump Roller Chain 10 Timing Chain
SSANGYONG Y200

Tools Required 615 589 01 33 00 Crankshaft Sprocker Puller

1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Notice: Align the assembly marks on cranshaft sprocket and timing chain. Also, align the assembly marks on camshaft sprocket and timing chain when installing. 2. Unscrew the bolt (6) and remove the oil pump sprocket (7) from the oil pump. Installation Notice Tightening Torque 29 - 35 N m (21 - 26 lb-ft)
YAD1B2N0
3. Remove the oil pump roller chain (9). 4. Remove the oil pump chain tensioner (1), oil pump chain bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the crankshaft sprocket puller 615 589 01 33 00. Notice: Make sure not to lose the crankshaft pulley key (5) when removing. Install the crankshaft sprocket (4) after warming it up. 6. Installation should follow the removal procedure in the reverse order.
YAA1C850
SSANGYONG Y200
LUBRICATION SYSTEM
ENGINE OIL SPECIFICATION
YAD1B2W0
1 Drain Plug ................................ 25 N m (18 lb-ft) 2 Oil Filter
3 Engine Oil Filler Cap 4 Dipstick Gauge
Specifications
Application Capacity Quality Descrition Min : 6.7 L, Max : 8.2 L
Viscosity Replacemant
API SH or above grade ACEA : A2 or A3 Approved oil by MB Sheet 229.1 Approved oil by MB Sheet 224.1 Initial at 1000-1500 km, Replace every 15000 km
SSANGYONG Y200
OIL CIRCULATION
YAD1B2X0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Oil Pump Oil Gallery (to oil filter) Oil Filter Oil Pressure Switch Main Oil Gallery Cylinder Head Closing Cover Oil Gallery (At Chain Tensioner) Oil Non-return Valve Chain Tensioner Vent (Chain Tensioner) Front Closing Cover ( 17 mm) Oil Gallery (Perpendicular to The Shaft) Ball ( 6 mm) Oil Spray Nozzle (Timing Chain) Oil Gallery (At Cylinder Head) Ball ( 15mm) Oil Restriction Inner ( 4mm) Oil Supply (To Exhaust Camshaft) Oil Supply (To Intake Camshaft)
20 Oil Supply (To Exhaust Camshaft Bearing) 21 Oil Supply (To Intake Camshaft Bearing) 22 Oil Gallery (Oil Supply to Exhaust Valve Tappet) 23 Oil Gallery (Oil Supply to Intake Valve Tappet) 24 Camshaft Closing Cover 25 Ball ( 8 mm) 26 Screw Plug 27 Camshaft Adjuster 28 Front Closing Cover (Intake Camshaft) 29 Front Treaded Bushing (Exhaust Camshaft) 30 Valve tappet a Oil Gallery (From Oil Pump to Oil Filter) b Main Oil Gallery c Oil Return Line (Oil Returns to the Oil Pan when Replacing the Filter Element)
SSANGYONG Y200
ENGINE OIL AND OIL FILTER ELEMENT

Tools Required 103 589 02 09 00 Oil Filter Remover
1. Install the oil filter remover 103 589 02 09 00 on the oil filter cover. Notice: Make the screw cover removable by tightening the bolt at the side of the oil filter remover 103 589 02 09 00.
YAD1B2Z0
2. Install the wrench to the upper bolt in the oil filter remover 103 589 02 09 00 and remove the oil cover by turning it. 3. Remove the oil filter element. Notice: Work with a cloth under the vehicle when removing the oil filter element to not drain the oil.
4. Remove the drain plug (1) and drain the engine oil. Notice: Leave the oil filler cap open to ease the engine oil discharge. 5. Tighten the engine oil drain plug after cleaning it. Installation Notice Tightening Torque 25 N m (18 lb-ft)
Replace the seal washer with new one. 6. Replace the O-ring in the oil filter cover with new one. Notice: Apply the engine oil to the O-ring. 7. Insert new oil filter element into the oil filter housing. 8. Temporarily tighten the oil filter cover. Install the oil filter remover 103 589 02 09 00, and then completely tighten it. Installation Notice Tightening Torque 25 N m (18 lb-ft)
YAD1B3A0
SSANGYONG Y200

9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary.
YAD1B3B0
SSANGYONG Y200
OIL FILTER
Preceding Work : Removal of starter motor Removal of upper intake manifold
YAD1B3C0
1 2 3 4
Coolant Line O-ring ..................................................... Replace Clip Hose
5 Bolt .................... 22.5-27.5 Nm (16.6-20.3 lb-ft) 6 Oil Filter 7 Gasket ................................................... Replace
SSANGYONG Y200

1. Drain the coolant from the crankcase. 2. Remove the each coolant line and hose.
YAD1B3D0
3. Remove the oil filter bolt and then remove the oil filter. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Replace the oil filter gasket. 4. Installation should follow the removal procedure in the reverse order. 5. Check engine oil level. 6. Run the engine at idle and check the engine for leaks.
SSANGYONG Y200
OIL PUMP
Preceding Work : Removal of oil pan
YAD1B3E0
1 Bolt (M8 x 20, 1 piece) ..................................... 29-35 N m (21-26 lb-ft) 2 Sprocket (Oil Pump Drive)
3 Bolt (M8 x 35, 3 pieces) .......................... 22.5-27.5 Nm(16.6-20.3 lb-ft) 4 Spring Pin 5 Oil Pump

1. Remove the bolt (1) from the oil pump drive sprocket (2) and separate the gear and the oil pump drive chain. Installation Notice Tightening Torque 29 - 35 N m (21 - 26 lb-ft)
2. Unscrew the oil pump mounting bolts (3). Installation Notice

YAD1B3F0
Tightening Torque
22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Tighten the baffle plate and the oil pump with the two bolts in right side first, and then tighten the other bolt. 3. Remove the oil pump and oil strainer assembly. 4. Replace the strainer in oil pump if necessary. 5. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
OIL PRESSURE RELIEF VALVE

Preceding Work : Removal of oil pan
YAD1B3G0
1 Screw Plug ............................... 50 N m (37 lb-ft) 2 Compression Spring
3 Guide Pin 4 Piston

1. Remove the screw plug (1). Installation Notice Tightening Torque 50 N m (37 lb-ft)
2. Remove the spring (2), guide pin (3) and the piston (4). 3. Installation should follow the removal procedure in the reverse order. Notice: Don t use the seal for the screw plug.
SSANGYONG Y200
OIL NON-RETURN VALVE

YAD1B3H0
1 Oil Non-return Valve
Functions
The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oilreturning in order to prevent the oil in the chain tensioner from getting dry. As a result, the chain tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers. 2. Insert new non-return valve with hand.
YAD1B3J0
SSANGYONG Y200
OIL DIPSTICK GUIDE TUBE
YAD1B3K0
1 Oil Dipstick Level Gauge 2 Oil Dipstick Guide Tube
3 O-ring 4 Bolt (M6 x 12, 1 piece) ....9-11 Nm (80-97 lb-in)

1. Pull out the oil dipstick level gauge (1). 2. Remove the bolt (4) in the upper intake manifold and remove the oil dipstick guide tube. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-in)
YAD1B3L0
3. Install new O-ring to the dipstick guide tube. 4. Installation should follow the removal procedure in the reverse order. 5. Check for leaks by starting the engine.
SSANGYONG Y200
UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work : Removal of crankshaft Removal of oil spray nozzle
YAD1B3M0
1 Plug 2 Steel Ball
3 Round Bar .................................... 11 x 750 mm
Cleaning Procedure
1. Remove the plug (1) with a screwdriver. 2. Using a round bar (3) and hammer, remove the steel ball (2). 3. Using the compressed air, blow into the oil galleries and clean it off.
YAD1B4L0
SSANGYONG Y200
YAD1B3N0
1 Plug ........................................................ Replace 2 3 -
4 Main Oil Gallery 5 Screw Plug
Tools Required 102 589 12 15 00
Drift
Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of 16mm, depth of 15mm. 2. Using an M16 x 1.5 thread (tap), make the thread at the end of main oil gallery (4). 3. Throughly clean the oil gallery with compressed air and tighten the screw plug (M16 x 1.5) after applying sealing bond on it. 4. Apply Loctite 270 on new plug and tighten to the hole until the drift 102 589 12 15 00 is stopped after inserting new plug into the drift.
SSANGYONG Y200
OIL GALLERY IN CYLINDER HEAD

Preceding Work : Removal of cylinder head Removal of camshaft Removal of tappet
YAD1B3Q0
1 Screw Plug ............................... 15 N m (11 lb-ft) 2 Seal
3 Steel Ball ( 8mm)
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2). Installation Notice Tightening Torque 15 N m (11 lb-ft)
Replace the seal with new one. 2. Clean the oil gallery using the compressed air.
SSANGYONG Y200
1B1-106 M162 ENGINE MECHANICAL Sealing Procedure

1. Remove the screw plug (1) and the seal. Installation Notice Tightening Torque 15 N m (11 lb-ft)
YAD1B3R0
2. Remove the steel ball from the oil gallery (4), (5), (6) and (7) using the round bar (12, 6 x 700 mm).
YAD1B3S0
3. Remove the plug (8) using the screw driver.
YAD1B3T0
4. Enlarge the oil gallery at the rear of the cylinder head to be diameter 9mm, depth 8mm. 5. Tap in the steel ball (3) from the side to the oil gallery using the punch (13). 6. Pull out the steel ball (3) using the round bar (12). 7. Enlarge the oil gallery to be diameter 9mm, depth 8 mm.
YAD1B3U0
SSANGYONG Y200

8. Make a screw hole at the oil gallery using M10 x 1 thread. 9. All the oil gallery should be cleaned with the compressed air. 10. Apply the Loctite 270 to new plug and press in using a suitable drift (arrow).
YAD1B3V0
11. Tighten the screw plug with the seal (arrow).
YAD1B3W0
SSANGYONG Y200
CORE PLUGS IN CRANKCASE

Preceding Work : Draining of the coolant
YAD1B3X0
1 Core Plug ............................................... Replace
SSANGYONG Y200

Tools Required 102 589 00 15 00 Drift
1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver.
YAD1B3Z0
3. Pull out the plug carefully using a pliers.
YAD1B4A0
4. Clean the sealing surface and apply Loctite 241.
YAD1B4B0
5. Press in new plug using a drift 102 589 00 15 00. Notice: Wait for about 45 minutes before filling the coolant so that the Loctite hardens. 6. Warm up the engine and check the coolant for leaks.
YAD1B4C0
SSANGYONG Y200
CYLINDER BORE
YAD1B4D0
Group Code Letter and Cylinder Bore Size

Group Code Letter of Cylinder A X B X+5 X + 10 Piston Type to be Used A or X A, X or B X or B X+5 X + 10 Cylinder Bore Size (mm)
89.900 - 90.906 89.906 - 89.912 89.912 - 89.918 89.950 - 89.968 90.000 - 90.018
Repair Size
Type Standard Size 89.9 Group Code Letter1) A X B 1st Repair Size (Standard Size + 0.25) 2nd Repair Size (Standard Size + 0.5)
1)
Cylinder Bore Size (mm)
89.900 - 90.906 89.906 - 89.912 89.912 - 89.918 90.150 - 90.156 89.156 - 90.162 90.162 - 90.168 90.400 - 90.406 90.406 - 90.412 90.412 - 90.418
A X B A X B
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-111 Service Data Standard

Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out-of-round When new Wear limit Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) Basic Peak-to-valley Height After Final Honing and Brushing Chamfer Angle Honing Angle 0.1 mm 0.007 mm 0.05 mm 0.05 mm 0.003 - 0.006 mm 60 50 10
Measurement of Cylinder Bore

1. Clean the cylinder wall. 2. Using a internal diameter gauge, measure the bore size in axial and transverse direction at three points (1, 2, 3).
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1,2,3. A. B. a. b. c.
Measuring Points Axial Direction Transverse Direction Location of the No.1 Piston Ring at TDC Location of the Piston BDC Location of the Oil Ring at BDC
Chamfer Angle
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CRANKCASE MATING SURFACE
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Height of The Crankcase H (When new) Minimum Height After Milling Flatness Permissible Deviation of Parallelism of The Upper to Lower Mating Surface Peak-to-valley Height Crankcase Upper Mating Surface Crankcase Lower Mating Surface Axial Direction Transverse Direction Crankcase Upper Mating Surface Crankcase Lower Mating Surface 282.25 - 282.35 mm 281.95 mm 0.03 mm 0.04 mm 0.1 mm 0.05 mm 0.005 - 0.020 mm 0.025 mm
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M162 ENGINE MECHANICAL 1B1-113 Chamfering Procedure

1. Chamfer angle : 60
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2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).
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CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of valves
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Overall Height of Cylinder Head Minimum Height After Machining Flatness Distance T (Between Camshaft Bearing and Valve Stem) Axial Direction Transverse Direction Standard Size Repair Size Intake Exhaust Intake Exhaust 135.9 - 136.0 mm 135.5 mm 0.08 mm 0.0 mm 24.21 - 24.75 mm 22.21 - 22.75 mm 23.96 - 24.51 mm 21.96 - 22.51 mm
Notice: Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.
SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-115 Measurement of Mating Surface

1. Measure the height (H) of the cylinder head (refer to Service data standard). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4. Re-measure the height (H) of the cylinder head. 5. Seal the intake and exhaust valves. 6. Measure the dimension (T) between the camshaft bearing and the valve system (refer to Service data standard). 7. Mill the cylinder head valve seat (refer to Service data standard).
Universal Tool
Sceledum, Type RTY Surface Grinding Machine Roaro Schio/Italy
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SPECIFICATIONS
Application A/C Bracket Bolt Armature Bolt in Camshaft Actuator Belt Tensioning Pulley Nut Camshaft Actuator Bolt Camshaft Adjuster Mounting Nut Camshaft Bearing Cap Bolt Chain Tensioner Assembly Chain Tensioner Screw Plug Connecting Rod Bearing Cap Bolt Cooling Fan Bracket Bolt Crankshaft Bearing Cap Bolt Crankshaft Sealing Rear Cover Mounting Bolt Cylinder Block Drain Plug Cylinder Head Bolt Nm 22.5 - 27.5 35 40.5 - 49.5 9 - 11 60 - 70 22.5 - 27.5 72 - 88 40 40 + 5 90 + 10 22.5 - 27.5 50 - 60 90 + 5 9 - 11 30 55 +90 +90 Cylinder Head Cover Bolt Cylinder Head Front Cover Bolt Engine Mounting Bracket Nut Exhaust Camshaft Sprocker Bolt Exhaust Manifold and Pipe Flywheel Mounting Bolt Fuel Feed and Return Hose to Fuel Rail Generator Carrier Bolt Intake Air Duct Nut Intake Flange Shaft Bolt Lower Engine Mounting Nut Oil Dipstick Guide Tube Bolt Oil Drain Plug Oil Filter Bolt Oil Filter Cover Oil Gallery Screw Plug in Cylinder Head Oil Pan Bolt M10 M8 M6 9 - 11 22.5 - 27.5 70 18 - 22 90 5 30 45 + 5 90 + 10 21 - 25 25 9 - 11 18 - 22 90 5 38 9 - 11 22.5 - 27.5 22.5 - 27.5 25 15 40 22.5 - 27.5 9 - 11 Lb-Ft 16.6 - 20.3 26 29.9 - 36.5 44 - 52 16.6 - 20.3 53 - 65 30 30 + 3.7 90 + 10 16.6 - 20.3 37 - 44 90 + 5 22 41 +90 +90 16.6 - 20.3 52 13 - 16 90 5 22 33 + 3.7 90 + 10 15 - 18 18 13 - 16 90 5 28 16.6 - 20.3 16.6 - 20.3 18 11 30 16.6 - 20.3 80 - 97 80 - 97 80 - 97 80 -97 Lb-In 80 - 97 80 - 97 -
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Application Oil Pressure Relief Valve Screw Plug Oil Pump Drive Sprocket Bolt Oil Pump Mounting Bolt Oil Pump Sprocket Bolt Spark Plug Cover Bolt Steering Pump Bolt Tensioning Device Bolt Timing Gear Case Cover Bolt Torque Converter Mounting Bolt Transmission Mounting Nut Under Cover Upper Engine Mounting Nut Vibration Damper Center Bolt Water Pump Pulley Bolt M8 M6 Nm 50 29 - 35 22.5 - 27.5 29 - 35 9 - 11 22.5 - 27.5 26 - 32 22.5 - 27.5 9 - 11 42 54 - 68 28 - 47 70 180 - 220 90 + 10 22.5 - 27.5 Lb-Ft 37 21 - 26 16.6 - 20.3 21 - 26 16.6 - 20.3 19 - 24 16.6 - 20.3 31 40 - 50 21 - 35 52 133 - 162 90 + 10 16.6 - 20.3 Lb-In 80 - 97 80 - 97 -
SSANGYONG Y200

SPECIAL TOOLS TABLE
000 589 58 43 00 Chain Assembly
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102 589 00 15 00 Drift
111 589 18 61 00 Lever Pusher
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102 589 12 15 00 Drift
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103 589 02 09 00 Oil Filter Remover
111 589 25 63 00 Thrust Piece
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116 589 01 34 00 Threaded Pin
601 589 03 43 00 Crankshaft Rear Seal Installer
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119 589 00 43 00 Drift
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601 589 03 14 00 Crankshaft Front Seal Installer
615 589 01 33 00 Crankshaft Sprocket Puller
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602 589 00 40 00 Engine Lock
617 589 00 10 00 AllenWrench Socket
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DW110-090 Connecting Hose
DW110-120 Holding Pin
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DW110-100 Valve Tappet Remover
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SSANGYONG Y200
SECTION 1B2
M161 ENGINE MECHANICAL

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other-wise noted.
TABLE OF CONTENTS
Maintenance and Repair ................................... 1B2-2 On-Vehicle Service ............................................. 1B2-2 Engine Assembly .............................................. 1B2-2 Crankcase Ventilation System ............................ 1B2-9 Generator ........................................................ 1B2-13 Engine Mount .................................................. 1B2-14 Poly V-Belt ...................................................... 1B2-16 Tensioning Device ........................................... 1B2-18 Tensioning Device Shock Absorber .................. 1B2-19 Poly V-Belt Inspection ...................................... 1B2-20 Cylinder Head Cover ........................................ 1B2-22 Cylinder Head Front Cover ............................... 1B2-24 Cylinder Head ................................................. 1B2-26 Timing Gear Case Cover .................................. 1B2-30 Crankshaft Sealing Rear Cover ........................ 1B2-33 Belt Pulley and Vibration Damper ..................... 1B2-35 Crankshaft Front Radial Seal ............................ 1B2-38 Crankshaft Rear Radial Seal ............................. 1B2-40 Crankshaft ....................................................... 1B2-41 Flywheel / Driven Plate ..................................... 1B2-47 Camshaft Adjuster ........................................... 1B2-50 Camshaft Sprocket Bolt ................................... 1B2-53 Camshaft ........................................................ 1B2-54 Camshaft Timing Position ................................ 1B2-57 Valve Spring .................................................... 1B2-59 Valve Stem Seal .............................................. 1B2-63 Chain Tensioner ............................................... 1B2-64 Timing Chain ................................................... 1B2-68 Tensioning Rail ................................................ 1B2-73 Cylinder Head Guide Rail ................................. 1B2-74 Crankcase Guide Rail ...................................... 1B2-76 Crankshaft Sprocket ........................................ 1B2-77 Piston .............................................................. 1B2-79 Connecting Rod ............................................... 1B2-82 Piston Ring ...................................................... 1B2-84 Oil Pan ............................................................ 1B2-86 Engine Oil and Oil Filter Element ...................... 1B2-88 Oil Pump ......................................................... 1B2-91 Oil Pressure Relief Valve .................................. 1B2-93 Oil Non-Return Valve ........................................ 1B2-94 Oil Dipstick Guide Tube ................................... 1B2-95 Unit Repair ........................................................ 1B2-96 Core Plugs in Crankcase .................................. 1B2-96 Cylinder Bore .................................................. 1B2-98 Crankcase Mating Surface ............................. 1B2-100 Cylinder Head Mating Surface ........................ 1B2-102 Specifications ................................................. 1B2-104 Fastener Tightening Specifications ................. 1B2-104 Special Tools and Equipment ........................ 1B2-106 Special Tools Table ........................................ 1B2-106

ENGINE ASSEMBLY
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SSANGYONG Y200

1. Disconnect the negative terminal of battery. 2. Remove the hood. 3. Remove the under cover. Installation Notice Tightening Torque 28 - 47 Nm (21 - 35 lb-ft)
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4. Disconnect the coupling of HFM sensor and remove the air cleaner cross pipe.
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5. Remove the air cleaner cover. Remove the mounting bolts and air cleaner housing and element assembly.
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6. Loosen the radiator drain cock and drain the coolant. Notice: Open the coolant reservoir cap.
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SSANGYONG Y200

7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation Notice Tightening Torque 5 N m (26 lb-ft)
Notice: Replace the seal before installation of the drain plug.
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8. Remove the cooling fan shroud. Refer to Section 1D2, Engine Cooling.
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9. Disconnect the each hose from radiator.
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10. Remove the upper mounting bolts of radiator and then remove the radiator.
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SSANGYONG Y200

11. Remove the hydraulic pipe of power steering. Notice: Completely drain the oil.
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12. Discharge the refrigerant from A/C system, and disconnect the discharge pipe and suction pipe from the compressor.
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13. Remove the fuel feed and return line. Notice: Before removing the fuel lines, release the pressure in the fuel system. Installation Notice Tightening Torque 21 - 25 N m (15 - 18 lb-ft)
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14. Disconnect the terminals from the generator.
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SSANGYONG Y200

15. Disconnect the terminals from starter motor and remove the starter motor. 16. Disconnect the engine main harness ground.
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17. Disconnect the engine ground wire.
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18. Disconnect following sensors connector. HFM sensor. Coolant temperature sensor. Knock sensor.
Camshaft and crankshaft sensors.
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19. After removing the ignition coil cover, disconnect the ignition coil connector. 20. Remove the harness cover and disconnect the 4 injection valve connectors. Disconnect the main harness.
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21. Separate the hose toward engine from canister purge solenoid valve and canister. Refer to Section 1F2, Engine Control.
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22. Remove the automatic transmission oil cooler line retaining bolts from the automatic transmission side and oil pan side. 23. Remove the automatic transmission oil cooler line retaining bolts from engine side and oil pan side.
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24. Separate the vacuum hose for brake booster. 25. Separate the other vacuum hoses.
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26. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate. Installation Notice Tightening Torque 42 N m (31 lb-ft)
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27. Remove the exhaust manifold and exhaust pipe. Installation Notice Tightening Torque 30 N m (22 lb-ft)
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28. Remove the transmission. Refer to Section 5A, Automatic Transmission.
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29. Install a chain to the bracket of engine, by using a hoist or crane. 30. Remove the engine mount nuts. Installation Notice Tightening Torque 70 N m (52 lb-ft)
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31. Carefully separate the engine assembly from the vehicle. 32. Installation should follow the removal procedure in the reverse order.
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CRANKCASE VENTILATION SYSTEM

Operation at Idling and Mid- Load
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1 HFM Sensor 2 Cylinder Head Cover 3 Oil Spearation Chamber (Full-Load or Over MidLoad) 4 Intake Air Duct (Cross Pipe) 5 Vent Line (Full-Load or Over Mid-Load) 6 Throttle Valve 7 Restrictor, Diameter 1.1mm (Mid-Load at Idling) 8 Intake Manifold 9 Vent Line (Mid-Load at Idling) 10 Air Conditioner Bracket
11 12 13 14 15 16 17
Oil Separation Chamber (Mid-Load at Idling) Crank Chamber Oil Return Pipe Oil Pan Timing Gear Case Cover Crankcase Chain Housing
A Fresh Air B Blow-By Gas D Vent Connection
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1B2-10 M161 ENGINE MECHANICAL Operation at Idling and Mid- Load
The throttle valve (6) is closed or very partially opened, and the vacuum pressure in intake manifold is high. The blow-by gas and the fresh air that is additionally supplied through the vent connection (D) in the crank-case in partial load gets supplied to the combustion chamber from the crank chamber (12) through the oil separation chamber (11), airconditioner bracket (10), vent line (9), and restrictor (7) mounted to the cylinder head. The circulated engine oil returns to the oil pan through the oil return pipe (13) at the bottom of oil separation chamber (11). The fresh air gets supplied to the crank chamber (12) through the HFM sensor (1), intake air duct (4), vent line (5), oil separation chamber (3), chain housing (17), and the timing gear case cover (15). The additional supply of the fresh air is needed to prevent from forming the residues of the engine oil.
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Operation When Full- Load at Partial Load
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1 HFM Sensor 2 Cylinder Head Cover 3 Oil Spearation Chamber (Full-Load or Over Mid-Load) 4 Intake Air Duct (Cross Pipe) 5 Vent Line (Full-Load or Over Mid-Load) 6 Throttle Valve 7 Restrictor, Diameter 1.1mm (Mid-Load at Idling) 8 Intake Manifold 9 Vent Line (Mid-Load at Idling) 10 Air Conditioner Bracket
11 12 13 14 15 16 17
Oil Separation Chamber (Mid-Load at Idling) Crank Chamber Oil Return Pipe Oil Pan Timing Gear Case Cover Crankcase Chain Housing
A Fresh Air C Blow-By Gas D Vent Connection
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1B2-12 M161 ENGINE MECHANICAL Operation When Full- Load at Partial Load
The throttle valve (6) is partially opened or fully opened. The air flows very rapidly through the vent line (5) s connection (D) and the intake air duct when full load at partial load. Consequently, most of the low-by gases are supplied to the combustion chamber through the timing gear case cover (15), chain housing (17), oil separation chamber (3), vent line (5), throttle valve (6), and intake manifold (8).
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GENERATOR
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1 Bolt (M8 X 40, 3 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 2 Bolt (M8 X 70, 2 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
3 Bolt (M8 X 85, 1 piece) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 4 Generator Bracket

1. 2. 3. 4. Disconnect the negative battery cable. Remove the drive belt. Remove the generator. Unscrew the generator carrier bolts and remove the carrier. Installation Notice Tightening Torque 70 N m (52 lb-ft)
Notice: Apply 3 Nm of torque when mounting the bolt (1) ; apply 25 Nm of torque when mounting the bolts (2), and (3) ; and then tighten the bolt (1) with 25 Nm of torque. 5. Installation should follow the removal procedure in the reverse order.
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ENGINE MOUNT
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SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-15 Removal & Installation Procedure

1. Unscrew the upper engine mount nuts and remove the engine. Installation Notice Tightening Torque 70 N m (52 lb-ft)
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2. Unscrew the lower nuts. Installation Notice Tightening Torque 38 N m (28 lb-ft)
3. Remove the hydraulic engine mounting insulator. 4. Installation should follow the removal procedure in the reverse order.
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POLY V - BELT
Preceding Work: Removal of cooling fan
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1 Poly V-Belt (2,155 mm) 2 Belt Tensioning Pulley
3 Belt Tensioner
Removal & Installation Procedure 1. Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclock-wise. 2. Remove the poly v-belt. Notice: Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary. 3. Install the belt after prying the tensioning pulley.
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SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-17 Poly V - Belt Arrangement
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1 Belt Tensioning Pulley 2 Crankshaft Belt Pulley 3 A/C Compressor Pulley
5 Generator Pulley 7 Power Steering Pump Pulley 8 Water Pump Pulley
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TENSIONING DEVICE
Preceding Work: Removal of tensioning device shock absorber
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1 Bolt (M8 x 75, 2 pieces) + Washer ............ 22.5 - 27.5 Nm (16.6 - 0.3 lb-ft) 2 Bolt (M8 x 25, 1 pieces) + Washer ............ 22.5 - 27.5 Nm (16.6 - 0.3 lb-ft)
3 Tensioning Device 4 Stud bolt 5 Tensioning Arm

1. Turn the stud bolt to counterclockwise. 2. Insert the pin (111 589 01 15 00) into the hole in tensioning arm. 3. Unscrew the bolts (1, 2) and remove the tensioning device. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
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TENSIONING DEVICE SHOCK ABSORBER
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1 2 3 4
End Cover Bolt .................... 40.5 - 9.5 Nm (29.9 - 6.5 lb-ft) Tensioning Pulley Bolt (M8 X 25) + Washer .......................... 22.5 - 7.5 Nm (16.6 - 0.3 lb-ft)
5 Tensioning Device 6 Bolt (M8 X 35) + Washer .......................... 22.5 - 7.5 Nm (16.6 - 0.3 lb-ft) 7 Shock Absorber

1. Remove the end cover (1). 2. Remove the bolt (2) and remove the tensioning pulley (3). Installation Notice Tightening Torque 40.5 - 49.5 N m (29.9 - 36.5 lb-ft)
3. Unscrew the bolts (4,6) and remove the shock absorber (7). Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
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POLY V - BELT INSPECTION

Make marks on the belt with chalk. Rotate the engine and check the belt for damage. Notice: If one of the following types of damages is found, replace the belt.
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1. Rubber lumps in the base of rib. 2. Dirt or grit ingrained.
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3. Pointed rib. 4. Belt cord visible in the base of rib.
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7. Rib detached from the base of belt.
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8. Splits across the rib. 9. Sections of rib torn out.
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10. Splits across several ribs.
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11. Splits across the back of the belt.
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SSANGYONG Y200
CYLINDER HEAD COVER
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1 Spark Plug Cover 2 Spark Plug Connector 3 Bolt (M6 X 45 : 4 pieces, M6 X 60 : 6 pieces) .................................... 9 - 11 N m (80 - 97 lb-in)
4 Cylinder Head Cover 5 Gasket.................................................... Replace
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1. Remove the intake air duct. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
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2. Remove the spark plug cover. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
Notice: Release 3 screws from the spark plug cover and remove the cover for M161 Engine coil.
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3. Remove the spark plug connector and ignition cable. 4. Unscrew the bolts (3) and remove the head cover and the gasket. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
Notice: Replace the gasket with a new one if necessary. 5. Installation should follow the removal procedure in the reverse order. 6. Check for oil leaks by operating the engine.
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SSANGYONG Y200
CYLINDER HEAD FRONT COVER

Preceding Work: Removal of cylinder head cover Removal of thermostat housing assembly Removal of engine hanger bracket
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1 Bolt (M6 X 16, 3 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) 2 Camshaft Adjuster 3 Bolt (M8 X 35, 2 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 4 Bolt (M6 X 22, 6 pieces) .................................... 9 - 11 N m (80 - 97 lb-in)
5 6 7 8 9
Front Cover (E23 : M161.973) Front Cover (E20 : M161.943) Sleeve O-Ring .................................................... Replace Thermostat Housing.
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1. Disconnect the camshaft adjuster connector and remove the camshaft adjuster (E23 engine only). Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
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2. Remove the cylinder head front cover. Installation Notice Tightening Torque (3) Tightening Torque (4) 22.5 - 27.5 N m (16.6 - 20.3 lb-ft) 9 - 11 N m (80 - 97 lb-in)
Apply the sealant at the mating surface of the cylinder head and the front cover. 3. Remove the O-Ring.
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Notice: Replace the O-ring with new one and apply the sealant. 4. Installation should follow the removal procedure in the reverse order.
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CYLINDER HEAD
Preceding Work: Removal of cylinder head cover Removal of cylinder head front cover Removal of intake manifold Removal of cylinder head lower line (intake manifold side)
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1 Cylinder Head Bolt (M12 X 100, 10 pieces) .................................... 1ststep 55 N m (41 lb-ft) 2nd step 90 rotation added 3rd step 90 rotation added 3 Bolt (M8 X 35, 4 pieces) ........................ 22.5 - 27.5 Nm (16.6 - 0.3 lb-ft)
4 5 6 7
Camshaft Bearing cap Cylinder Head Gasket.................................................... Replace Dowel Sleeve ............................................... Note
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Tools Required 617 589 00 10 00 Allen Wrench Socket 116 589 20 33 00 Sliding Hammer 116 589 01 34 00 Threaded Pin 111 589 03 15 00 Holding Pin

1. Rotate the crankshaft so that the piston of number 1 cylinder is at ATDC 20.
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2. Put the holding pin 111 589 03 15 00 into the camshaft bearing cap (number 1, 6).
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3. Put the alignment marks (arrows) on the timing chain and camshaft sprocket. 4. Remove the chain tensioner. Installation Notice Tightening Torque 72 - 88 N m (53 - 65 lb-ft)
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5. Remove the exhaust camshaft sprocket. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 60 5
Notice: The flange bolt is designed to be used only once, so always replace with new one.
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SSANGYONG Y200

6. Remove the intake camshaft sprocket (E20 engine). 7. Remove the camshaft adjuster (E23, M161.970 engine). Installation Notice (Flange Bolt) Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 60 5
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1 2 3 4 5
Flange Shaft Flange Bolt Compression Spring Adjust Piston Camshaft Sprocket
6 Seal Cover 7 Nut
8. Remove the guide rail pin using the sliding hammer 116 589 20 33 00 (02) and the threaded pin 116 589 01 34 00 (03). Notice: Apply the sealant on guide rail pin when installation.
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9. Unscrew the bolts (A). Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Bolt (A) : (M8 X 35, 4 pieces)
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SSANGYONG Y200

10. Remove the cylinder head bolts in the reverse order of the numerics (No.10 No.1) using allen wrench socket 617 589 00 10 00.
Installation Notice Tighten the bolts as numerical order with specified torque (No.1 No.10). 1st step: 55 Nm(41 lb-ft) Tightening Torque 2nd step: +90 3rd step: +90 Notice: Operate during engine cooling.
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11. Remove the No. 1 bearing cap of the exhaust camshaft. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
12. Carefully remove the cylinder head. 13. Check the cylinder head mating surface and clean the crankcase head bolt mounting hole. 14. Replace the cylinder head gasket with new one.
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15. Check the length of the cylinder head bolt. Installation Notice Length (L) When New 100 mm Max. Length 105 mm
Notice: Replace the bolt if the measured length exceed the max. length. 16. Installation should follow the removal procedure in the reverse order.
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SSANGYONG Y200
TIMING GEAR CASE COVER

Preceding Work: Removal of viscous clutch Removal of cylinder head front cover Removal of tensioning device Removal of water pump Removal of oil filter element Removal of oil pan Removal of generator bracket
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1 Bolt (M8 X 60, 3 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 2 Bolt (M8 X 75, 1 piece) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
3 4 5 6
Seal Timing Gear Case Cover O-Ring Sleeve.
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Tools Required 116 589 20 33 00 Sliding Hammer 116 589 01 34 00 Threaded Pin

1. Remove the power steering belt pulley and A/C compressor bracket. 2. Remove the oil line from power steering pump. 3. Rotate the crankshaft so that the piston of number, cylinder is at ATDC 20 .
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4. Put the alignment marks (arrows) on the timing chain and camshaft sprocket. 5. Remove the chain tensioner. Installation Notice Tightening Torque 72 - 88 N m (53 - 65 lb-ft)
6. Remove the intake and exhaust camshaft sprocket (remove the camshaft adjuster assembly in E23 engine). Installation Notice
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Tightening Torque
1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 60 5
7. Remove the guide rail pin using the sliding hammer 116 589 20 33 00 (02) and the threaded pin 116 589 01 34 00 (03). Notice: Apply the sealant on guide rail pin when installation.
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SSANGYONG Y200

8. Unscrew the bolts (A). Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
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9. Remove the belt pulley and vibration damper. Installation Notice (Center Bolt) Tightening Torque 1st step: 200 + 20 Nm (148 +15 lb-ft) 2nd step: 90 10
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10. Unscrew the bolts (1, 2) on timing gear case cover and remove the timing gear case cover. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
Notice: Be careful not to damage the cylinder head gas-ket. 11. Remove the radial shaft seal. Notice: Installation note replace the seal with new one.
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12. Clean the timing gear case cover and crankcase sealing surface. 13. Replace the O-ring with new one and apply the sealant on the sealing surface. Notice: Be careful not to stain the oil chamber of chain tensioner with the sealant. 14. Installation should follow the removal precedure in the reverse order. 15. Warm up the engine and check for oil leaks.
SSANGYONG Y200
CRANKSHAFT SEALING REAR COVER

Preceding Work: Removal of the automatic transmission drive plate or flywheel
YAD1B6S0
1 Bolt (M6 x 20, 6 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) 2 Radial Shaft Seal 3 Rear Cover
4 Sleeve 5 Bolt (M6 x 85, 2 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) 6 Washer
SSANGYONG Y200


1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice: Be careful not to damage the oil pan gasket.
YAD1B740
2. Clean the sealing surface of the crankcase and the rear sealing cover. 3. Check the radial shaft seal and replace it if necessary. 4. Apply the Loctite 573 to the rear cover sealing surface. 5. Apply the engine oil to the dust lip of the radial shaft seal. Notice: Do not use the grease.
YAD1B750
6. Install the crankshaft rear radial seal and the crankshaft sealing rear cover, using crankshaft rear seal installer 601 589 03 43 00.
YAD1B760
7. Install the crankshaft sealing rear cover mounting bolts and remove the crankshaft rear seal installer 601 589 03 43 00. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
YAD1B6T0
SSANGYONG Y200
BELT PULLEY AND VIBRATION DAMPER

Preceding Work: Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt
YAD1B6U0
1 Vibration Damper Center ............... 1st step 200+20 Nm (148 + 15 lb-ft) 2nd step 90 + 10 rotation added
2 Vibration Damper Disk 5 Vibration Damper Assembly 6 Key
SSANGYONG Y200
1B2-36 M161 ENGINE MECHANICAL Components
YAD1B660
1 2 3 4 5 6
Center Bolt (M18 x 50) Center Bolt Washer Vibration Damper and Pulley Assembly Key Crankshaft Front Seal Timing Gear Case Cover
7 8 9 10 11 12
Crankshaft Sprocket (Camshaft Driven) Crankshaft Sprocket (Oil Pump Driven) Crankshaft Oil Pan Oil Pan Gasket Oil Pan Mounting Bolt (M6 x 22)

Permissble Deviation of The Vibration Damper Radial Runout Axial Ruout 0.6 mm 0.6 mm
SSANGYONG Y200


1. Adjust the piston of number 1 cylinder to the TDC.
YAD1B6V0
2. Remove the start motor and install the engine lock 602 589 00 40 00 to the flywheel ring gear. 3. Remove the vibration damper center bolt. Installation Notice Tightening Torque 1st step: 200 + 20 Nm (148 + 15 lb-ft) 2nd step: 90 + 10
YAD1B680
4. Remove the vibration damper assembly using the puller. 5. Installation should follow the removal procedure in the reverse order. Notice: If possible, don t separate the vibration damper and the pulley.
YAD1B6W0
SSANGYONG Y200
CRANKSHAFT FRONT RADIAL SEAL

Preceding Work: Removal of belt pulley and vibration damper
YAD1B6X0
1 Center Bolt (M18 x 50) ......... 1st step 200 + 20 45 Nm (148 +15 lb-ft) 2nd step 90 + 10 2 Center Bolt Washer
3 Crankshaft Front Seal Installer 4 Crankshaft Front Seal 5 Key
SSANGYONG Y200

Tools Required 601 589 03 14 00 Crankshaft Front Seal Installer
1. Remove the radial seal with a screw driver. Notice: Use a clean cloth not to damage the radial seal mounting hole and the crankshaft. 2. Coat the radial sealing lip with engine oil. 3. Using the crankshaft front seal installer 601 589 03 14 00, assemble the radial seal. 4. Align the sleeve groove and the woodruff key and tighten the center bolt until the center bolt and the damper disk stop in the movement. Installation Notice Tightening Torque 1st step: 200 + 20 Nm (148 + 15 lb-ft) 2nd step: 90 10 5. Remove the crankshaft front seal installer 601 589 03 14 00, and install the belt pulley and the vibration damper. 6. Check for leaks while operating the engine.
YAD1B800
SSANGYONG Y200
CRANKSHAFT REAR RADIAL SEAL

Preceding Work: Removal of flywheel or drive plate
YAD1B840
1 Special Tool 2 Special Tool
3 Crankshaft Rear Seal
1. Remove the radial seal with a screw driver. Notice: Use a clean cloth not to damage the radial seal mounting hole and the crankshaft. 2. Install the special tool (2) to the crankshaft. 3. Apply the engine oil on the special tool (2). Notice: Do not use the grease.
YAD1B850
4. Install the radial seal on the inner parts assembler. 5. Press in the special tool (1) until the radial seal is stopped. 6. Check for leaks while operating the engine..
SSANGYONG Y200
CRANKSHAFT
Preceding Work: Removal of engine Removal of cylinder head Removal of timing gear case cover Removal of crankcase sealing rear cover Removal of oil pan Removal of baffle plate Removal of oil pump
YAD1B6Y0
1 Bearing Cap Bolt (M8 X 55 - 10 pieces) ................................... 1ststep 55 Nm (41 lb-ft) 2nd step 90 rotation added 2 Bearing Cap 3 Upper Main Bearing
4 5 6 8
Lower Main Bearing Upper Thrust Bearing Lower Thrust Bearing Crankshaft.
SSANGYONG Y200
Arrangement of the Thrust Bearing and the Main Bearing
YAD1B6Z0
1 2 3 4 5
Upper Main Bearing Upper Thrust Bearing Crankshaft Lower Main Bearing Lower Thrust Bearing
A Crankcase Side B Bearing Cap Side (Oil Pan Side)
(1) - (8) Weight Balance/Color Marking Point j1 - j5 Journal Main Bearing #1 - #5 Color Dot Marking The color dot marking are put on the (1), (2), (4), (6), (8), and it indicates the diameter of crankshaft journal by color as below.
SSANGYONG Y200

Color Dot Marking Blue Yellow Red White Violet Crankshaft Journal Diameter (mm) 57.960 - 57.965 57.955 - 57.960 57.950 - 57.955 57.945 - 57.950 57.940 - 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side There are seven punching marks on the mating surface to oil pan. This mark is correspondent to the bearing distinguished by color. Select the relevant bearing according to the punching mark when repaired. Purching Mark B Y
YAD1B880
Bearing Color Selected Blue Yellow Red
2. Crankshaft Bearing Cap Side Select the crankshaft main bearing according to the marking letter on the crank shaft main journal when repaired. Marking Letter B Y R W
YAD1B890
Bearing Color Selected Blue Yellow Red White Violet
Service Data
Crankshaft Standard and Repair Size Standard size 1st repair size 2nd repair size 3rd repair size 4th repair size Crankshaft Bearing Journal Diameter 57.940 - 57.965 57.705 - 57.715 57.450 - 57.465 57.205 - 57.215 56.955 - 56.965 Crankshaft Bearing Diameter 58 Crankshaft Journal Width at fit bearing 24.50 - 24.533 Connecting Rod Connecting Rod Bearing Journal Bearing Journal Diameter 47.935 - 47.965 47.700 - 47.715 47.450 - 47.465 47.200 - 4.215 46.950 - 46.965 Width 27.958 - 28.042
SSANGYONG Y200

1. Unscrew the connecting rod bearing cap bolt and remove the bearing cap. Installation Notice Tightening Torque 40 N m (30 lb-ft) + 90

YAD1B900
Make sure that the upper and lower bearing shells do not change each other. Coat the bearing shell with engine oil. Install the bearing cap according to the consecutive number.
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice Tightening Torque 55 N m (41 lb-ft)+ 90
YAD1B910
Part No. : 601 030 00 62 2.15 mm Part No. : 601 030 01 62 2.20 mm Part No. : 601 030 02 62 2.25 mm Part No. : 601 030 03 62 2.30 mm Part No. : 601 030 04 62 2.40 mm
Remove the bearing cap from front (pulley side) to rear. Make sure that the upper and lower bearing shells do not change each other and coat with engine oil. The oil grooves (arrows) in the thrust washers must face outward and insert the thrust bearing into the bearing cap. There are five kinds of thrust washers by thickness. Select the proper washer when repaired.
3. Remove the crankshaft. 4. Installation should follow the removal procedure in the reverse order. 5. After completion of the installation, check for the rotating condition of the crankshaft.
Notice: Make sure the crankshaft bearing cap properly seated in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the left side (intake manifold side). Assemble so that the projected part of the cap and crankcase face the same direction.
YAD1B920
SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-45 Inspection

1. If the length L of the crankshaft bearing cap bolt exceeds 63.8 mm, replace it.
YAD1B930
2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows).
YAD1B940
3. Measure and record the inner diameter of the crankshaft bearing. Notice: Measure at 2 points (1, 2). Measure A, B and C as shown. If average value of B and C is less than value A , then the average value of B and C is actual average value. If average value of B and C is more than value A is actual average value.
YAD1B950
4. Measure and record the diameter of the crankshaft bearing journal. Notice: Record the mean value when measured at 3 points (A,B,C). Measure the inner diameter of bearing and the diameter of journal and if it is out of the standard data, replace the bearing shell.
YAD1B960
SSANGYONG Y200
1B2-46 M161 ENGINE MECHANICAL Service Data Standard (Crankshaft Main Bearing Gap)
Item Main Bearing Journal (NO.1,5,7) Axial Measuring Position Radial Gap (mm) Static condition : 0.015 - 0.039 Dynamic condition : 0.031 - 0.051 (Consider the expansion 0.011 - 0.016) 0.010 - 0254
(Connecting Rod Bearing Gap)

Item Connection Rod Bearing Item Radial Gap (mm) 0.020 - 0.065
SSANGYONG Y200
FLYWHEEL / DRIVEN PLATE

Preceding Work: Removal of manual or automatic transmission
YAD1B810
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) .................. 1st step 45 + 5 Nm (33 + 3.7 lb-ft) 2nd step 90 + 10 2 Plate
3 Driven Plate (A/T) 4 Dowel Pin 5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)

Normal Size Stretch Side Diameter Bolt Length Tightening Torque D d L When New Min. Diameter When New M x 15 8.5 - 0.2 mm 8.0 mm 21.8 - 22.2 mm
1st step 45 + 5 Nm (33 + 37 lb-ft), 2nd step 90 + 10
SSANGYONG Y200
1B2-48 M161 ENGINE MECHANICAL Removal & Installation Procedure

1. Unscrew the flywheel mounting bolt. Installation Notice Tightening Torque 1st step: 45 + 5 Nm (33 + 3.7 lb-ft) 2nd step: 90 10
Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm. For the flywheel mounting bolt tightening, keep the socket wrench and Tommy-bar to be 90 and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for Auto transmission vehicle. 3. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-49 Sectional View
YAD1B830
1 2 3 4 5 6 7
OilPan Cover Radial Seal Bolt Crankshaft Dowel Pin Washer (Thickness : 3.5 mm)
8 9 10 11 12 13 14
Washer Bolt Front Drive Plate Rear Drive Plate Rivet Segment Ring Gear
SSANGYONG Y200
CAMSHAFT ADJUSTER
YAD1B7A0
1 Bolt (M6 X 16, 3 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) 2 Cylinder Head Front Cover 3 Bolt ........................................... 35 N m (26 lb-ft) 4 Armature 5 RollPin 6 Nut (M20 X 1.5) ....... 60 - 70 N m (44 - 52 lb-ft) 7 Seal Cover 8 Camshaft Sprocket 9 Adjust Piston 10 Conical Spring
11 Flange Bolt (M7 X 13, 3 pieces) .................... 1stStep 18 - 22 Nm (13 - 16 lb-ft) 2nd Step 60 5 Rotation Added 12 Flange Shaft 13 Compression Spring 14 Control Piston 15 Circlip 16 Oil Gallery 17 Straight Pin 18 Intake Camshaft Y49 Magnetic Actuator (2 - Pin Connector)
SSANGYONG Y200

1. Turn the crankshaft and position the no.1 cylinder piston at ATDC 20 . Notice: Turn the crankshaft in the direction of engine rotation. 2. Remove the cylinder head front cover.
YAD1B6D0
3. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
YAD1B6F0
4. Insert the holding pin 111 589 03 15 00 into the no.1 and no.6 bearing cap hole on camshaft to secure intake and exhaust camshaft. 5. Remove the chain tensioner.
YAD1B6E0
6. Unscrew the exhaust sprocket bolt and remove the exhaust camshaft sprocket. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step:60 5
YAD1B6G0
SSANGYONG Y200

7. Unscrew the bolt (3) from the armature (4) and re ove the roll pin, and remove the armature. Installation Notice Tightening Torque 35 N m (26 lb-ft)
8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice Tightening Torque
YAD1B7B0
60 - 70 N m (44 - 52 lb-ft)
Notice: Put the locking slot of nut toward armarture. 9. Take off the timing chain from intake camshaft sprocket.
10. Remove the adjuster piston (9) and conical spring (10) from intake camshaft sprocket. 11. Unscrew the bolt (11) and remove the flange shaft. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 60 5
YAD1B7C0
12. Installation should follow the removal procedure in the reverse order. 13. Check and adjust the camshaft timing.
SSANGYONG Y200
CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step:60 5
Notice: The sprocket bolts are designed to be used only once, so always replace with new one. C. M7 x 13 Collar Bolt Torx-T30 e. 6.8 mm 16. Flange Shaft 18. Control Piston 22. Intake Camshaft
YAD1B0G0
Exhaust Camshaft Sprocket Bolt

Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step:60 5
Notice: The sprocket bolts are designed to be used only once, so always replace with new one. E. M7 x 13 Collar Bolt Torx-T30 e. 6.8 mm 13a. Camshaft Sprocket 22a. Exhaust Camshaft
YAD1B0H0
SSANGYONG Y200
CAMSHAFT
Preceding Work: Removal of cylinder head cover Removal of camshaft adjust actuator and cylinder head front cover
YAD1B7D0
1 Bolt (M7 X 13, 3 pieces) ................... 1st Step 18 - 22 NSm (13 - 16 lb-ft) 2nd Step 60 5 Rotation Added 2 Exhaust Camshaft Sprocket 3 Timing Chain 4a Intake Camshaft Spocket (E20)
4b Camshaft Adjuster and Camshaft Sprocket (E23) 5 Bearing Cap Bolt (20 pieces) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 6 Camshaft Bearing Cap 7 Wrench
SSANGYONG Y200

1. Turn the crankshaft and position the no.1 cylinder piston at ATDC 20 .
YAD1B6D0
2. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain. 3. Remove the chain tensioner. Installation Notice Screw Plug Tightening Torque Tensioner Assembly 40 N m (30 lb-ft) 72 - 88 N m (53 - 65 lb-ft)
YAD1B6F0
4. Remove the exhaust camshaft sprocket. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step:60 5
Notice: The sprocket bolt is designed to be used only once, so always replace with new one. 5. Take off the timing chain from intake camshaft sprocket, and secure it not to fall down into the timing gear case.
YAD1B6G0
6. Using the wrench (7), turn the camshaft until there is no resistence in camshaft bearing area.
YAD1B7E0
SSANGYONG Y200

7. Remove the bearing cap, and remove the intake and the exhaust camshaft. Installation Notice Tightening Torque 60 - 70 N m (44 - 52 lb-ft)
Notice: Check the numbers on the bearing cap not to be mixed up.
YAD1B7F0
8. Apply the engine oil on the valve tappet and camshaft bearing. 9. Installation should follow the removal procedure in the reverse order. Notice: Base circle of cam should cantact with the valve tappet. Install the camshaft bearing caps according to the numbers on the cylinder head cast and bearing cap.
YAD1B7G0
SSANGYONG Y200
CAMSHAFT TIMING POSITION

Preceding Work: Removal of cylinder head cover Removal of cylinder head front cover
YAD1B7H0
1 2 3 4 5
Holding Pin 111 589 03 15 00 Intake Camshaft Sprocket Camshaft Bearing Cap Timing Chain Exhaust Camshaft Sprocket
6 Bolt (M7 X 13, 3 pieces) ..................... 1ststep 18 - 22 NSm (13 - 16 lb-ft) 2nd step 60 5 rotation added 7 StratePin
SSANGYONG Y200

Tools Required 111 589 03 15 00 Holding Pin
Inspection Procedure
1. Position the NO.1 cylinder piston to ATDC 20 by turning the crankshaft. Notice: When the ATDC 20 mark on vibration damper is aligned with timing gear case cover, the intake and ex-haust cam of cylinder will make the slope to the center and will face up. In this way, the insert hole in NO.1 and NO.4 camshaft bearing cap will match in line with the flange hole for camshaft sprocket. 2. Check the timing as below procedure; - Check if the holding pin 111 589 03 15 00 can be inserted into the NO.1 and NO.4 bearing cap hole. - At this condition, check if the ATDC 20 mark on vibration damper aligns with the marker on the timing gear case.
YAD1B6D0
YAD1B6E0
1. 2. 3. 4. Position the NO.1 cylinder to ATDC 20 . Remove the chain tensioner. Remove the exhaust camshaft sprocket. Adjust the timing position with inserting the holding pin 111 589 03 15 00 into the NO.1 and NO.4 camshaft bearing cap hole and flange hole while rotating the camshaft by using wrench. 5. Install the chain to the intake camshaft sprocket. 6. Install the chain to the exhaust camshaft sprocket and tighten the bolt. Installation Notice Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5
The sprocket bolt is designed to be used only once, so replace with new one. 7. Install the chain tensioner. Installation Notice Screw Plug Tightening Torque Tensioner Assembly 40 N m (30 lb-ft) 72 - 88 N m (53 - 65 lb-ft)
8. Check the camshaft timing.

SSANGYONG Y200
VALVE SPRING
Preceding Work: Removal of camshaft Removal of spark plug
YAD1B0V0
1 2 3 4 5
Valve Cotter Valve Spring Retainer Valve Spring Valve Stem Seal Lower Retainer
a b c d
Lever Pusher 111 589 18 61 00 Thrust Piece 111 589 25 63 00 Connecting Hose DW 110 - 090 Supporting Bar 111 589 01 59 00
SSANGYONG Y200

Tools Required 111 589 01 59 00 111 589 18 61 00 111 589 25 63 00 602 589 00 40 00 DW110 - 090 DW110 - 100 Supporting Bar Lever Pusher Thrust Piece Engine Lock Connecting Hose Valve Tappet Remover

1. Place the supporting bar 111 589 01 59 00 (a) at the camshaft bearing cap and tighten them with the bearing cap bolt. Installation Notice Tightening Torque 22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
YAD1B1B0
2. Turn the crankshaft to position the each cylinder piston at TDC. Tightening Torque 1st step: 18 - 22 N m (13 - 16 lb-ft) 2nd step: 90 5
Notice: Remove the valve spring only at TDC. Always rotate the crankshaft by holding the chain to prevent from timing chain damage and tangling, and for smooth rotation.
YAD1B7J0
3. Remove the valve tappet using the valve tappet remover DW110 - 100. 4. Install the connecting hose DW110 - 090 (c) to the spark plug hole.
YAD1B1D0
SSANGYONG Y200

5. Install the engine lock 602 589 00 40 00 to the ring gear to prevent the crankshaft from rotating. 6. Blow up with compressed air.
YAD1B680
7. Install the supporting bar 111 589 01 59 00 (d) and the lever pusher 111 589 18 61 00 (a). 8. Mount the thrust piece 111 589 25 63 00 (b) vertically to the valve spring retainer (2). 9. Press the valve spring (3) by using the lever pusher 111589 18 61 00 (a). 10. Remove the valve cotter (1) using the pincette. 11. Remove the upper retainer (2) and the valve spring (3).
YAD1B1E0
12. Remove the valve stem seal (4) and replace if necessary. Notice: Check the valve stem seal for damage and replace if necessary. 13. Remove the lower retainer (5). Notice: Check the retainer for damages and replace with a new one if necessary. 14. Installation should follow the removal procedure in the reverse order.
YAD1B1F0
SSANGYONG Y200
1B2-62 M161 ENGINE MECHANICAL Test (Upper and Lower Valve Tappet and Valve Cotter)
Upper Valve Spring Retainer Size (mm) (d) (D) 8.5 12.3
YAD1B1G0
Lower Valve Spring Retainer Size (mm) (a) 0.8 - 1.0
YAD1B1H0
Valve Cotter Size (mm) (B) (H) 9.0 9.2 - 9.8
YAD1B1J0
SSANGYONG Y200
VALVE STEM SEAL

Preceding Work: Removal of valve spring
YAD1B1K0
1 Drift 119 589 00 43 00 2 Valve Stem Seal
3 Protective Sleeve
1. Remove the valve stem seal (2) using the pliers. Notice: Check the valve stem seal for damage and replace if necessary. 2. Coat the valve stem seal with oil and assemble it with the protective sleeve. 3. Insert the valve stem seal by pressing it with the drift 119 589 00 43 00.
YAD1B1M0
SSANGYONG Y200
CHAIN TENSIONER
YAD1B1N0
1 2 3 4 5
Screw Plug ............................... 40 N m (30 lb-ft) Seal Filler Pin Compression Spring Snap Ring
6 Thrust Pin 7 Chain Tensioner Housing .................................. 72 - 88 Nm (53 - 65 lb-ft) 8 Seal
Removal Procedure
1. Position the number 1 cylinder to ATDC 20 . Notice: Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam s lobe (arrow) stays in the upper side. 2. Cover the generator with a clean cloth. 3. Release the tension by unscrewing the screw plug once. Notice: In case that the tension is reduced by unscrewing the screw plug, reinstall after completely removing the chain tensioner. If the chain tensioner is tightened again without completely reducing its tension, then the snap ring doesn t return to the original position and the tension gets exceeded.
YAD1B1P0
SSANGYONG Y200

4. Carefully unscrew the screw plug (1), and remove the seal (2). Notice: For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring. Remove the screw plug only when the seal and compression spring are damaged. 5. Carefully remove the filler pin (3), compression spring (4), snap ring (5), and the thrust pin (6).
YAD1B1Q0
6. Remove the chain tensioner housing (7) and the seal (8).
YAD1B1R0
1. Connect the thrust pin (6) and the snap ring (5) to the chain tensioner housing (7). Notice: When connecting the thrust pin, push in the thrust pin far enough so that it doesnt protrude at the chain tensioner housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap ring (5), and the seal (8). Installation Notice Tightening Torque 72 - 88 N m (53 - 65 lb-ft)
3. Insert the compression spring (4) with the filler pin (3) into chain tensioner housing.
YAD1B1S0
SSANGYONG Y200

4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 N m (30 lb-ft)
5. Check for leaks by operating the engine.
YAD1B1T0
SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-67 Sectional View
YAD1B1U0
1 2 3 4 5 6 7 8 9 10 11 12
Screw Plug Ball (Nonreturn Valve) Compression Spring Ball Guide Seal (Aluminum) Filler Pin Compression Spring Snap Ring Thrust Pin Ball (Nonreturn Valve) Compression Spring Thrust Piece
13 14 15 16 17 18 19 20 21
Chain Tensioner Housing Seal Timing Gear Case Cover Cylinder Head Bolt / Washer Tensioning Rail Cylinder Head Gasket Timing Chain Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole B Chain Tensioner Oil Storage Hole
SSANGYONG Y200
TIMING CHAIN
Preceding Work: Removal of cylinder head cover Removal of spark plug
YAD1B1V0
1 2 3 4
Pin New Timing Chain Timing Chain (Used) Wedge
5 Link 6 Center Plate 7 Outer Plate
SSANGYONG Y200

Tools Required 000 589 58 43 00 Chain Assembly 111 589 03 15 00 Holding Pin
1. Position the NO.1 cylinder to ATDC 20 .
YAD1B6D0
2. Insert the holding pin 111 589 03 15 00 to the intake and exhaust camshaft flange not to rotate camshaft. 3. Remove the chain tensioner.
YAD1B6E0
4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure.
YAD1B1X0
5. Cover the chain housing with a clean cloth, and grind off the timing chain pin from the intake camshaft sprocket with the grinder.
YAD1B1Y0
SSANGYONG Y200

6. Remove the outer plate (7) with the screw driver and remove the link (5).
YAD1B1Z0
7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6 mm), and the outer plate (7). 8. Rotate the crankshaft in the direction if engine revolution by pressing the new timing chain against the exhaust camshaft sprocket to prevent it to be tangled. Notice: Be sure to remove the wedge before cranking the engine. 9. Take out the used timing chain out from the chain housing. 10. Connect both separators of the new timing chain with the link (5) and the center plate (6). 11. Install the jaw (a) and the thrust piece (b) to the assembly tool as shown in the figures.
YAD1B2A0
YAD1B2B0
YAD1B2C0
SSANGYONG Y200

12. Place the outer plate (7, thickness 1.2 mm) inside the thrust piece (b).
YAD1B2D0
13. Install the chain assembly 000 589 58 43 00 above the link and tighten the spindle (c) until a block is felt. 14. Place the chain assembly 000 589 58 43 00.
YAD1B2E0
15. Replace the thrust piece (b) as shown in the figure.
YAD1B2F0
16. Install the chain assembly 000 589 58 43 00 to the link pin and tighten the spindle (c). Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAD1B2E0
SSANGYONG Y200

17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug Tightening Torque Tensioner Assembly 40 N m (30 lb-ft) 72 - 88 N m (53 - 65 lb-ft)

YAD1B2G0
SSANGYONG Y200
TENSIONING RAIL
Preceding Work: Removal of cylinder head
YAD1B7K0
1 Sliding Rail Pin 2 Sliding Rail
3 Timing Gear Case Cover

1. Remove the timing gear case cover (3). Notice: Be careful not to damage the gasket. 2. Remove the sliding rail (1) from the sliding rail pin (2). Notice: Replace the plastic guide (2) if it is damaged. For installation, exactly align the plastic guide (2) with the sliding rail (1). 3. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
CYLINDER HEAD GUIDE RAIL

Preceding Work: Removal of cylinder head front cover
YAD1B7L0
1 Bolt (M6 X 45, 2 pieces) .................................... 9 - 11 N m (80 - 97 lb-in)
2 Guide Rail
SSANGYONG Y200

Tools Required 111 589 03 15 00 Holding Pin

1. Position the number 1 cylinder to ATDC 20 guide rail. 2. Install the holding pin 111 589 03 15 00 into the no.1 and no.6 bearing cap hole. 3. Remove the chain tensioner. Installation Notice Screw Plug
YAD1B6E0
Tightening Torque Tensioner Assembly
40 N m (30 lb-ft) 72 - 88 N m (53 - 65 lb-ft)
4. Unscrew the bolt (1) and remove the guide rail. Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
YAD1B7M0
SSANGYONG Y200
CRANKCASE GUIDE RAIL

Preceding Work: Removal of timing gear case cover
YAD1B7N0
1 Guide Rail Pin 2 Guide Rail
3 Timing Gear Case Cover

1. Remove the timing gear case cover (3). Notice: Be careful not to damage the gasket when removing / installing the timing gear case cover. 2. Remove the guide rail (2) from the guide rail pin (1). Notice: Replace the plastic guide (2) if damaged. Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when installing. 3. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan Removal of tensioning rail Removal of crank case guide rail
YAD1B2L0
1 2 3 4 5
Oil Pump Chain Tensioner Oil Pump Chain Bushing Oil Pump Chain Spring Crankshaft Sprocket Key
6 Bolt (M8 x 20, 1 piece) / Washer .................................. 29 - 35 Nm (21 - 26 lb-ft) 7 Oil Pump Sprocket 8 Oil Pump 9 Oil Pump Roller Chain 10 Timing Chain
SSANGYONG Y200

Tools Required 615 589 01 33 00 Crankshaft Sprocket Puller

1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Notice: Align the assembly marks on crankshaft sprocket and timing chain. Also, align the assembly marks on camshaft sprocket and timing chain when installing. 2. Unscrew the bolt (6) and remove the oil pump sprocket (7) from the oil pump. Installation Notice Tightening Torque 29 - 35 N m (21 - 26 lb-ft)
YAD1B2N0
3. Remove the oil pump roller chain (9). 4. Remove the oil pump chain tensioner (1), oil pump chain bushing (3), and the oil pump chain spring (2). 5. Remove the crankshaft sprocket (4) using crankshaft sprocketpuller 615 589 01 33 00. Notice: Make sure not to lose the crankshaft pulley key (5) when removing. Install the crankshaft sprocket (4) after warming it up.
YAD1B850
SSANGYONG Y200
PISTON
Preceding Work: Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate
YAD1B2R0
1 Connecting Rod Bearing Cap 2 Connecting Rod 3 Connecting Rod Bolt (M9 x 52, 8 pieces) .................................. 1st step 40 N m (30 lb-ft) 2nd step 90
4 Piston 5 Snap Ring 6 Piston Pin
SSANGYONG Y200
1B2-80 M161 ENGINE MECHANICAL Removal Procedure

1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice: Make sure that the bearing cap and shell are not changed each other. 3. Removethe snapring (5)and pulloutthepiston pin (6). Notice: Remove the snap ring using a clean cloth as shown in the right picture so that the piston, piston ring, and the snap ring dont get damaged.
YAD1B2Q0
YAD1B2R0
SSANGYONG Y200

1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3. Clean the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and the piston and coat them with engine oil. 4. Install the piston ring. 5. Install the piston so that the arrow on the piston head faces to the forward of the vehicle. 6. After aligning the connecting rod and the bearing cap mark (// or a number), tighten the bolts. Installation Notice Tightening Torque 1st step : 40 Nm (30 lb-ft) 2nd step : 90
YAD1B2S0
Apply the engine oil to the bearing cap upper and lower bearing shells. 7. Check if the crankshaft rotates without any trouble by rotating it.
SSANGYONG Y200
CONNECTING ROD
Preceding Work: Removal of piston
YAD1B970
1 2 3 4
Connecting Rod Bushing Oil Gallery Balance Weight Connecting Rod Bearing Cap Bolt (M9 x 52, 8 pieces) ..................................... 1ststep 40 Nm (30 lb-ft) 2nd step 90
5 6 7 8 9
Fit Sleeve Upper Connecting Rod Bearing Lower Connecting Rod Bearing Bearing Shell Lug Marking [Indication (//) or Numbers]

Distance (L) from The Connecting Rod Bearing to Bushing Bore Center Width of The Connecting Rod (B) at Bearing Bore Width of The Connecting Rod (b) at Bushing Bore Basic Bore at The Bearing Shell (D1) Basic Bore at The Bushing (d1) Bushing Inner Diameter (d) Clearance Between The Piston Pin and The Bushing Peak-to-valley Height of Connecting Rod Bushing on Inside Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from Concentricity Permissible Difference of Each Connecting Rod in Weight 0.4 g 0.01 mm 0.045/100 mm 149 0.05 mm 21.940 - 22.000 mm 21.940 - 22.000 mm 51.600 - 51.614 mm 24.500 - 24.521 mm 22.007 - 22.013 mm 0.007 - 0.018 mm 0.005 mm 0.1/100 mm
SSANGYONG Y200

Inspection 1. Measure the basic bore of the connecting rod bearing.
Notice: If the basic bore exceeds the value of 51.614 mm, replace the bearing or check the connecting rod.
YAD1B980
2. Check connecting rod bolts. Length When New (L) Max. Length (L) Tightening Torque 51.7 - 52 mm 52.9 mm 1st step : 40 N m (30 lb-ft) 2nd step : 90
Notice: If the length exceeds max. length, replace it.
YAD1B990
3. Check the assembly mark (indication//or number:arrow) of the connecting rods and the bearing cap when installing. Notice: Make sure it doesnt exceed over 4g with other connecting rods when replacing the connecting rods. Check if the connecting rod and the bearing cap are accurately seated on the groove when replacing the bearing.
YAD1B0A0
SSANGYONG Y200
PISTON RING
Preceding Work: Removal of piston
YAD1B2T0
1 Piston Compression Ring (Top Ring) 2 Piston Compression Ring (2nd Ring) 3 Piston Oil Ring
4 5 Spacer 6 SideRail
SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-85 Replacement Procedure

1. Measure the piston ring s gap. End Gap of the Piston Ring Groove 1 0.20 - 0.40 mm Groove 2 0.20 - 0.40 mm Groove 3 0.20 - 0.45 mm Gap Between the Piston and the Groove 2 0.010 - 0.045 mm Piston Ring Groove 3 0.010 - 0.045 mm Notice: If out of specification, replace the piston ring. Groove 1 0.028 - 0.060 mm
2. Remove the piston ring with a pliers.
YAD1B2U0
3. For installation, position the piston ring to be the TOP mark on the piston ring upward and arrange the piston ring ends to be 120 part. 4. Adjust the hook spring joint in the oil ring 180 way from the ring end.
YAD1B2V0
SSANGYONG Y200
OIL PAN
YAD1B7P0
1 2 3 4
Bolt Bolt Bolt Bolt
5 Bolt 6 OilPan 7 Gasket

1. Remove the drain plug and drain the oil completely. 2. Unscrew the bolts and remove the oil pan and gasket. Notice: Arrange the bolts according to each size. 3. Clean the inside of oil pan and sealing surface, then apply the sealant. 4. Replace the gasket with new one. 5. Install the oil pan with gasket, and tighten each bolt in specified torque. 6. Check for oil leaks while running the engine.
SSANGYONG Y200
Oil Circulation
YAD1B7Q0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Oil Strainer Oil Pump Oil Pan Oil Non-Return Valve Oil Filter Oil Filter Bypass Valve Main Oil Gallery Closing Ball ( 15 mm) Crankshaft Connecting Rod Bearing Crankshaft Bearing Connecting Rod Piston Oil Spray (Piston Crown Area) Non-Return Valve (Crankcase)
16 17 18 19 20 21 22 23 24 25 26
Oil Supply (To Chain Tensioner) Camshaft Cam Bearing Valve Oil Gallery (Supply Oil to Intake Tappet) Oil Gallery (Supply Oil to Exhaust Tappet) Ball ( 8 mm) Camshaft Plug Seal Screw Plug Oil Return Gallery (Cylinder Head and Crankcase) 27 Oil Return Gallery (Crankcase) 28 End Cover ( 20 mm) 29 Oil Return Pipe
SSANGYONG Y200
ENGINE OIL AND OIL FILTER ELEMENT
YAD1B7R0
1 Oil Filter Cover 25 Nm (18 lb-ft) 2 O-Ring Replace 3 Oil Filter Element
4 Oil Drain Plug 5 Oil Filter Bypass Valve
SSANGYONG Y200

Tools Required 103 589 02 09 00 Oil Filter Remover
1. Install the oil filter remover 103 589 02 09 00 on the oil filter cover. Notice: Make the screw cover removable by tightening the bolt at the side of the oil filter remover 103 589 02 09 00. 2. Install the wrench to the upper bolt in the oil filter remover 103 589 02 09 00 and remove the oil cover by turning it. 3. Remove the oil filter element. Notice: Work with a cloth under the vehicle when removing the oil filter element to not drain the oil.
YAD1B7S0
4. Remove the drain plug and drain the engine oil. Notice: Leave the oil filler cap open to ease the engine oil discharge. 5. Tighten the engine oil drain plug after cleaning it. Installation Notice Tightening Torque 25 N m (18 lb-ft)
Replace the seal washer with new one. 6. Replace the O-ring in the oil filter cover with new one.
YAD1B7T0
Notice: Apply the engine oil to the O-ring. 7. Insert new oil filter element into the oil filter housing. 8. Temporarily tighten the oil filter cover. Install the Oil filter remover 103 589 02 09 00, and then completely tighten it. Installation Notice Tightening Torque 25 N m (18 lb-ft)
SSANGYONG Y200

9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary.
SSANGYONG Y200
OIL PUMP
Preceding Work: Removal of oil pan
YAD1B7U0
1 Bolt (M8 X 35, 3 piece) ...................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft) 2 OilPump 3 Oil Strainer Assembly 4 Bolt (M6 X 20, 2 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) (In E23 Engine, These Bolts are Combined with Baffle Plate) 5 Bolt (M6 X 12, 2 pieces) .................................... 9 - 11 N m (80 - 97 lb-in)
6 Bolt (M8 X 20, 1 pieces) .................................. 29 - 35 Nm (21 - 26 lb-ft) 7 Washer 8 Sprocket (Oil Pump Drive) 9 Chain (Oil Pump Drive) 10 Plate-Baffle 11 Bolt (M6 X 12, 6 pieces) .................................... 9 - 11 N m (80 - 97 lb-in) (E23 Engine Only : Baffle Plate Mounting Bolt)
SSANGYONG Y200

1. Unscrew the bolt (6) from the oil pump drive sprocket and separate the oil pump drive chain. Installation Notice Tightening Torque 25 - 39 N m (21 - 26 lb-ft)
2. Unscrew the bolts (4,5) and remove the oil strainer assembly (3). Installation Notice
YAD1B7V0
Tightening Torque
Bolt (4): 9 - 11 N m (80 - 97 lb-ft) Bolt (5): 9 - 11 N m (80 - 97 lb-ft)
Insert the steel gasket into the oil pump and bolt (4) mounting surface.
3. Unscrew the six bolts (11) and remove the baffle plate. Installation Notice Tightening Torque 70 N m (52 lb-ft)
4. Unscrew the three bolt (1) and remove the oil pump. Installation Notice Tightening Torque
YAD1B7W0
22.5 - 27.5 N m (16.6 - 20.3 lb-ft)
SSANGYONG Y200
OIL PRESSURE RELIEF VALVE

YAD1B7X0
1 Screw Plug ............................... 50 N m (37 lb-ft) 2 Compression Spring
3 Guide Pin 4 Piston

1. Remove the screw plug (1). Installation Notice Tightening Torque 50 N m (37 lb-ft)
2. Remove the spring (2), guide pin (3) and the piston (4). 3. Installation should follow the removal procedure in the reverse order. Notice: Don t use the seal for the screw plug.
SSANGYONG Y200
OIL NON-RETURN VALVE

Preceding Work: Removal of timing gear case cover
YAD1B7Y0
1 Oil Non-return Valve
Functions
The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oilreturning in order to prevent the oil in the chain tensioner from getting dry. As a result, the chain tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers. 2. Insert new non-return valve with hand.
YAD1B7Z0
SSANGYONG Y200
OIL DIPSTICK GUIDE TUBE
YAD1B8A0
1 Oil Dipstick Level Gauge 2 Oil Dipstick Guide Tube 3 O-Ring
4 Bolt (M6 X 16, 1 piece) .................................... 9 - 11 N m (80 - 97 lb-in) 5 Clamp

1. Pull out the oil dipstick level gauge (1). 2. Unscrew the bolt (4) and remove the oil dipstick guide tube (2). Installation Notice Tightening Torque 9 - 11 N m (80 - 97 lb-ft)
It is very hard to remove the oil dipstick guide tube without special tool. If it is not necessary, do not remove the guide tube. 3. Installation should follow the removal procedure in the reverse order. 4. Check for leaks by starting the engine.
SSANGYONG Y200
UNIT REPAIR
CORE PLUGS IN CRANKCASE
Preceding Work: Draining of the coolant
YAD1B8B0
1 Core Plug ............................................... Replace
SSANGYONG Y200

1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver.
YAD1B3Z0
3. Pull out the plug carefully using a pliers.
YAD1B4A0
4. Clean the sealing surface and apply Loctite 241.
YAD1B4B0
5. Press in new plug using a drift. Notice: Wait for about 45 minutes before filling the coolant so that the Loctite 241 hardens. 6. Warm up the engine and check the coolant for leaks.
YAD1B4C0
SSANGYONG Y200
CYLINDER BORE
YAD1B8C0
Group Code Letter and Cylinder Bore Size

Engine Group Code Letter of Cylinder A X E23 B X+5 X + 10 Piston Type to be Used A or X A, X or B X or B X+5 X + 10 Cylinder Bore Size (mm)
90.906 - 90.912 90.906 - 90.912 90.912 - 90.918 90.950 - 90.968 91.000 - 91.018
SSANGYONG Y200

Group Code Letter Cylinder Standard Size 90.9 1st Repair Size (Standard Size + 0.25) 2nd Repair Size (Standard Size + 0.5) Group Code Letter 1) A X B A X B A X B Cylinder Bore Size (mm)
89.900 - 89.906 89.906 - 89.912 89.912 - 89.918 90.150 - 90.156 89.156 - 90.162 90.162 - 90.168 90.400 - 90.406 90.406 - 90.412 90.412 - 90.418
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out-of-round When new Wear limit Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) Basic Peak-to-valley Height After Final Honing and Brushing Chamfer Angle Honing Angle 0.1 mm 0.007 mm 0.05 mm 0.05 mm 0.003 - 0.006 mm 75 50 10
Measurement of Cylinder Bore

1. Clean the cylinder wall. 2. Using a internal diameter gauge, measure the bore size in axial and transverse direction at three points (1,2,3). 1, 2, 3 Measuring Points A. Axial Direction B. Transverse Direction a. Location of the No.1 Piston Ring at TDC b. Location of the Piston BDC c. Location of the Oil Ring at BDC
YAD1B4E0
Chamfer Angle
YAD1B4F0
SSANGYONG Y200
CRANKCASE MATING SURFACE
YAD1B4G0

Height of The Crankcase H (When new) Minimum Height After Milling Flatness Permissible Deviation of Parallelismof The Upper to Lower Mating Surface Peak-to-valley Height Crankcase Upper Mating Surface Crankcase Lower Mating Surface Axial Direction Transverse Direction Crankcase Upper Mating Surface Crankcase Lower Mating Surface 289.35 - 289.45 mm 289.05 mm 0.03 mm 0.04 mm 0.1 mm 0.05 mm 0.012 - 0.009 mm 0.025 - 0.020 mm
SSANGYONG Y200
Chamfering Procedure
1. Chamfer angle : 75
YAD1B4F0
2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).
YAD1B4H0
SSANGYONG Y200
CYLINDER HEAD MATING SURFACE

Preceding Work: Removal of valves
YAD1B4J0

Overall Height of Cylinder Head Minimum Height After Machining Flatness Distance T (Between Camshaft Bearing and Valve Stem) Repair Size Axial Direction Transverse Direction Standard Size Intake Exhaust Intake Exhaust 135.9 - 136.0 mm 135.5 mm 0.08 mm 0.0 mm 24.21 - 24.75 mm 22.21 - 22.75 mm 23.96 - 24.51 mm 21.96 - 22.51 mm
Notice: Do not exceed 0.4 mm for the milling of the mating surface of crankcase and cylinder head.
SSANGYONG Y200

Measurement of Mating Surfac 1. Measure the height (H) of the cylinder head (refer to Service data standard). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4. Re-measure the height (H) of the cylinder head. 5. Seal the intake and exhaust valves. 6. Measure the dimension (T) between the camshaft bearing and the valve system (refer to Service data standard). 7. Mill the cylinder head valve seat (refer to Service data standard).
Universal Tool
Sceledum, Type RTY Surface Grinding Machine Roaro Schio / Italy
SSANGYONG Y200
SPECIFICATIONS
Application Fuel Feed and Return Line Exhaust Manifold and Pipe Engine Mounting Nuts Generator Carrier Bolts Tensioning Pulley Bolt Steering Pump Bolts A/C Braket Bolts Intake Air Duct Mounting Nuts Spark Plug Cover Bolts Cylinder Head Cover Bolts Magnetic Assembly Bolt Cylinder Head Front Cover Bolts Cylinder Head Bolts M8 M6 Nm 21 - 25 30 70 25 40.5 - 49.5 22.5 - 27.5 22.5 - 27.5 9 - 11 9 - 11 9 - 11 9 - 11 22.5 - 27.5 9 - 11 55 +90 +90 Timing Gear Case Cover Bolts Crankshaft Sealing Rear Cover Mounting Bolts Vibration Damper Center Bolts Flywheel Mounting Bolt Amarture Bolt in Flywheel Camshaft Adjuster Flange Bolts Intake Flange Shaft Bolts Exhaust Camshaft Sprocket Bolts Intake Flange Shaft Bolts Exhaust Camshaft Sprocket Bolts Camshaft Bearing Cap Bolts Chain Tensioner Screw Plug Chain Tension Assembly Oil Pump Sprocket Bolt Tensioning Device Bolts Water Pump Pulley Upper Intake Manifold Bolt Lower Intake Mainfold Bolt Flange Bolt to Exhaust Mainfold 22.5 - 27.5 9 - 11 200 + 20 +90 + 10 40 +90 45 + 5 +90 + 10 35 18 - 22 60 5 18 - 22 60 5 18 - 22 60 5 22.5 - 27.5 40 72 - 88 29 - 35 26 - 32 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 30 Lb-Ft 15 - 18 22 52 18 29.9 - 36.5 16.6 - 20.3 16.6 - 20.3 16.6 - 20.3 41 +90 +90 16.6 - 20.3 148 + 15 +90 + 10 30 +90 33 + 3.7 +90 + 10 26 13 - 16 60 5 13 - 16 60 5 13 - 16 60 5 16.6 - 20.3 30 53 - 65 21 - 26 19 - 24 16.6 - 20.3 16.6 - 20.3 16.6 - 20.3 22 Lb-In 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97 80 - 97 -
SSANGYONG Y200

Application Exhaust Mainfold Nut to Stud Bolt Oil Drain Plug Oil Filter Cover Oil Filter Bolt Oil Pump Drive Sprocket Bolt Oil Pump Mounting Bolt Oil Strainer Bracket Bolt Oil Pressure Relief Valve Screw Plug Oil Dipstick Guide Tube Bolt Oil Gallery Screw Plug Shock Absorber Bolts Crankshaft Bearing Cap Bolts Torque Converter Mounting Bracket Bolts Nm 26 - 34 25 25 22.5 - 27.5 29 - 35 22.5 - 27.5 9 - 11 50 9 - 11 15 22.5 - 27.5 55/+90 42 Lb-Ft 19 - 25 18 18 16.6 - 20.3 21 - 26 16.6 - 20.3 37 11 16.6 - 20.3 41/+90 31 Lb-In 80 - 97 80 - 97 -
SSANGYONG Y200

SPECIAL TOOLS TABLE
000 589 58 43 00 Chain Assembly
103 589 02 09 00 Oil Filter Remover
YAD1B1W0
YAD1B2Y0
111 589 25 63 00 Thrust Piece
YAD1B0W0
YAD1B0Y0
111 589 18 61 00 Lever Pusher
YAD1B0X0
YAD1B580
116 589 01 34 00 Threaded Pin
119 589 00 43 00 Drift
YAD1B570
YAD1B1L0
SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-107 Special Tools Table (Contd)
601 589 03 14 00 Crankshaft Front Seal Installer
602 589 00 40 00 Engine Lock
YAD1B790
YAD1B720
617 589 00 10 00 Allen Wrench Socket
YAD1B4K0
YAD1B560
615 589 01 33 00 Crankshaft Sprocket Puller
DW110 - 090 Connecting Hose
YAD1B2M0
YAD1B0Z0
601 589 03 43 00 Crankshaft Rear Seal Installer
DW110 - 100 Valve Tappet Remover
YAD1B730
YAD1B1A0
SSANGYONG Y200
1B2-108 M161 ENGINE MECHANICAL Special Tools Table (Contd)
111 589 03 15 00 Holding Pin
YAD1B4R0
SSANGYONG Y200
SECTION 1B3
DIESEL ENGINE MECHANICAL

TABLE OF CONTENTS
Description and Operation ...............................1B3-2 Valve Device .................................................... 1B3-2 Component Locator .......................................... 1B3-4 Cylinder Head ................................................... 1B3-4 Cylinder Block .................................................. 1B3-6 Engine Component ........................................... 1B3-8 Repair Instructions .......................................... 1B3-10 On-Vehicle Service ........................................... 1B3-10 Engine Assembly ..............................................1B3-10 Poly V-Belt and Tensioning Device .................... 1B3-19 Poly V-Belt ...................................................... 1B3-19 Tensioning Device .......................................... 1B3-23 Crankcase and Cylinder Head ........................... 1B3-26 Cylinder Head ................................................. 1B3-26 Prechamber .................................................... 1B3-46 Oil Pan ............................................................ 1B3-48 Timing Case Cover ......................................... 1B3-49 Crankshaft Assembly ........................................ 1B3-56 Vibration Damper and Hub ............................. 1B3-56 Flywheel and Crankshaft End Cover ............... 1B3-62 Crankshaft Ball Bearing .................................. 1B3-66 Crankshaft ...................................................... 1B3-67 Crankshaft Sprocket ....................................... 1B3-76 Piston .............................................................1B3-81 Flywheel Ring Gear ......................................... 1B3-87 Timing Device and Valve ................................... 1B3-90 Valve Tappets ................................................ 1B3-90 Valve Spring (Cylinder Head Removed) ......... 1B3-92 Valve Spring (Cylinder Head Installed) ...........1B3-95 Valve Stem Seals ............................................ 1B3-98 Valve Guides ................................................ 1B3-102 Valve Seat Rings .......................................... 1B3-105 Camshaft ...................................................... 1B3-112 Timing Chain ................................................ 1B3-118 Chain Tensioner ............................................ 1B3-122 Lubrication System .......................................... 1B3-124 Oil Filter ........................................................ 1B3-124 Oil Spray Nozzle ........................................... 1B3-126 Oil Pump ....................................................... 1B3-127 Unit Repair ..................................................... 1B3-129 Milling of Prechamber Sealing Surface ......... 1B3-129 TDC(TDC Sensor Bracket) Setting ................ 1B3-133 Machining of Flywheel .................................. 1B3-135 Hydraulic Valve Clearance Compensation Element Check .......................................... 1B3-136 Valve Springs Check .................................... 1B3-138 Check and Machining of Valves ................... 1B3-139 Machining of Valve Seat ............................... 1B3-144 Camshaft Timing Test................................... 1B3-149 Cylinder Head Pressure Leakage Test ......... 1B3-151 Facing Cylinder Head Mating Surface .......... 1B3-152 Replacement of Crankcase Core Plug .......... 1B3-154 Facing Crankcase Contacting Surface .......... 1B3-156 Cylinder Bore Measurement ......................... 1B3-157 Specifications ................................................ 1B3-158 Fastener Tightening Specifications ............... 1B3-158 Special Tools and Equipment ...................... 1B3-160 Special Tools Table ...................................... 1B3-160

VALVE DEVICE
Operation
The diesel engines have valves with bucket tappets and automatic valve clearance adjustment. This eliminates the need to re-set the valve clearance. The compact design of the valve timing gear from the cam through the bucket tappet to the valve contributes to weight savings, to low drag power and also to increased rigidity. Oil is supplide to the bucket tappets through oil bores in the cylinder head.
Function
YAD1BA30
1 2 3 4
Cam Tappet Guide Sleeve Thrust Piece
5 6 a b
Pressure Spring Ball Valve Supply Chamber Working Chamber
YAD1BA10
1 Cam 2 Camshaft 3 Tappet
4 Oil 5 Valve
The maintenance-free hydraulic valve clearance adjusting elements automatically compensates the valve clearance resulting from thermal expansion and wear. This produces a quiet-running valve train.
The hydraulic valve clearance adjusting elements are installed in the bucket tappets and operate the valves directly through the thrust pins and guide sleeves. When the engine is running and a load is applied on the element by cam tip, the element cam go down fully. The oil displaced from the working chamber flows via the annular gap (clearance between guide sleeve and thrust pin) to the supply chamber. As soon as the cam lobe rotates upwards from the tappet (2), the load on the guide sleeve (3) is relieved. The spring (5) pushes the thrust pin (4) up until the tappet is resting against the cam (1). The vacuum produced in the working chamber (b) as a result of the upward movement of the guide sleeve opens the ball valve (6) and oil flows out of the supply chamber (a) into the working chamber (b). The ball valve closes when the cam presses against the tappet and thus applies pressure on the thrust pin. The oil in the working chamber acts as a hydraulic rigid connection when the engine is running and the relevant valve is opened. The oil required for this purpose is supplied to the elements along a longitudinal passage in the cylinder head. From here, the oil flows through a bore to the relevant adjustment element. The oil to the supply chamber flows via the groove provided in the base of the tappet.
YAD1BA20
SSANGYONG Y200
BLANK
SSANGYONG Y200
COMPONENT LOCATOR
CYLINDER HEAD
YAD1BA40
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 Blow By Gas Return Hose Blow By Gas Return Pipe Oil Filler Cap Bolt Cylinder Head Cover Cylinder Head Cover Gasket Camshaft Cap Bolt Cylinder Head Bolt Camshaft Bearing Cap Pre Chamber Assembly 11 12 13 14 15 16 17 18 19 20 Cylinder Head Plug Plug Connector Engine Coolant Temperature Sensor Thermo Valve Cylinder Head Gasket Valve Assembly Camshaft Camshaft Adjust Key
SSANGYONG Y200
CYLINDER BLOCK
YAD1BA50
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 11 12 Piston & Piston Ring Assembly Connection Rod Assembly Oil Dipstick Gauge Oil Dipstick Gauge Bracket Cylinder Liner Plug Screw & Seal Ring Crankshaft Bearing Cap Cylinder Block Plug Crankshaft Journal Bearing Crankshaft Pulley 13 14 15 16 17 18 19 20 21 22 23 24 Vibration Damper Hub Crankshaft Sprocket Key Crankshaft Crankshaft Journal Bearing Crankshaft Thrust Bearing Crankshaft Sealing Cover Bolt Flywheel Plate Oil Pump Assembly
SSANGYONG Y200
ENGINE COMPONENT
YAD1BA60
SSANGYONG Y200

1 2 3 4 5 Fuel Filter Assembly Oil Filter Assembly Injection Pump Assembly Power Steering Pump Assembly Starter Assembly 6 7 8 9 A/C Compressor Assembly Generator Assembly Turbo Charger Assembly EGR Valve Assembly
SSANGYONG Y200
REPAIR INSTRUCTIONS ON-VEHICLE SERVICE ENGINE ASSEMBLY
YAD1BA70
1. Engine Assembly
SSANGYONG Y200

Removal Procedure
1. Disconnect the negative battery cable.
YAD1BA80
2. Remove the hood.
YAD1BA90
3. Remove the skid plate. Installation Notice Tightening Torque 28 - 47 N m (21 - 35 lb-ft)
YAD1B020
4. Remove the radiator drain cock and drain the coolant. Notice: Open the coolant reservoir tank cap.
1
YAD1BAA0
SSANGYONG Y200

5. Remove the drain plug and seal from the cylinder block and drain the coolant completely. Installation Notice Tightening Torque 30 N m (22 lb-ft)
After draining, replace the seal and reinstall the drain plug.
YAD1BAB0
6. Disconnect the lower coolant hose from the radiator.
YAD1BAC0
7. Disconnect the upper coolant hose from the radiator.
YAD1BAD0
8. Remove the radiator grille mounting screws and radiator grille. 9. Remove the front end upper member mounting blots and front end upper. Installation Notice Tightening Torque 30 - 40 N m (22 - 30 lb-ft)
YAD1BAE0
SSANGYONG Y200

10. Remove the hoses (air intake to intercooler, intercooler to intake duct).
;; ;; ;; ;; ;; ;;
SSANGYONG Y200
YAD1BAF0
11. Loosen the cooling fan shroud bolts and remove the cooling fan shroud. Installation Notice Tightening Torque 3 - 7 Nm (27 - 62 lb-in)
YAD1BAG0
12. Remove the air cleaner to turbo charger hose(2) with blow by hose(1).
YAD1BAH0
13. Disconnect the exhaust gas recirculation (EGR) valve hose and necessary hoses and pipes.
YAD1BAJ0

14. Remove the turbo charge to exhaust pipe bolts and separate the exhaust pipe flange from the turbo charger. Installation Notice Tightening Torque 30 N m (22 lb-ft)
YAD1BAK0
15. Disconnect the accelerator cable from the control linkage. Notice: After installation of accelerator cable, check the engine idling and operation condition.
YAD1BAL0
16. Disconnect the brake booster hose from vacuum pump.
YAD1BAM0
17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump.
YAD1BAN0
SSANGYONG Y200

18. Remove the A/C compressor IN/OUT pipes. Notice: Evacuate the refrigerant before removal.
YAD1BAP0
19. Remove the power steering pump lines. Notice: Completely drain the fluid.
YAD1BAQ0
20. Remove the fuel lines from the fuel filter and cover the filter with plug.
YAD1BAR0
21. Disconnect the coolant hose from the water inlet.
YAD1BAS0
SSANGYONG Y200

22. Disconnect the injection timing relay connector from injection pump.
YAD1BAT0
23. Disconnect the starter motor wires and necessary connectors.
YAD1BAU0
24. Disconnect the preheating time relay cable and glow plug cable.
YAD1BAV0
25. Disconnect the ground cable. 26. Disconnect the generator wires.
YAD1BAW0
SSANGYONG Y200

27. Disconnect the engine coolant temperature sensor connector.
YAD1BAX0
28. Remove the automatic transmission oil cooler lines. Installation Notice Tightening Torque 25 - 35 N m (18 - 26 lb-ft)
Use the new washer before installation of oil cooler lines.
YAD1BAY0
29. Remove the transmission mounting bolts and separate the transmission from the engine. Installation Notice Tightening Torque 54 - 68 N m (40 - 50 lb-ft)
YAD1BAZ0
30. Remove the engine mounting bracket bolts. Installation Notice Tightening Torque 50 - 75 N m (37 - 55 lb-ft)
YAD1BB00
SSANGYONG Y200

31. Remove the engine assembly from the vehicle by using a hoistor crane. 32. Installation should follow the removal procedure in the reverse order.
YAD1BB10
SSANGYONG Y200
POLY V-BELT AND TENSIONING DEVICE

POLY V-BELT
YAD1BB20
1 Nut ........................................... 21 N m (15 lb-ft) 2 Tensioning Lever 3 Bolt
4 Spring 5 Tensioning Lever 6 Poly V-Belt
SSANGYONG Y200

1. Remove the tensioning lever nut (1). Installation Notice Tightening Torque 21 N m (15 lb-ft)
2. Push the tensioning lever in direction of arrow with a rod ( 12, 180 mm) and pull out the bolt to the rear.
YAD1BB30
3. Push back the tensioning lever (arrow direction) to release the spring tension and remove the belt.
YAD1BB40
4. Install the poly V-belt beginning at the tensioning pulley (7).
YAD1BB50
7 8 9 10 11 12 13
Tensioning Pulley Crankshaft Generator Water Pump Guide Pulley Power Steering Pump A/C Compressor
Length of Belt Length (L) With Air Conditioner Without Air Conditioner 2,100 mm 2,040 mm
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-21 Poly V-Belt Inspection

Inspection Procedure Mark poly V-belt at a clearly visible point with chalk. Rotate the engine and check the belt. Notice: If one of the following types of damage is found, replace the belt.
YAD1BB60
1. Rubber lumps in the base of rips. 2. Dirt or grit ingrained.
YAD1B380
3. Pointed rips. 4. Belt cord visible in the base of rips.
YAD1B390
YAD1B400
SSANGYONG Y200

7. Belt detached from the base of rip.
YAD1B410
8. Splits across the rips. 9. Sections of rip torn out.
YAD1B420
10. Splits across several rips.
YAD1B430
11. Splits across the back.
YAD1B440
SSANGYONG Y200
TENSIONING DEVICE
Preceding Work: Removal of cooling fan
YAD1BLJ0
1 2 3 4 5 6 7 8 9
Bolt ........................................... 21 N m (15 lb-ft) Damper Nut ........................................... 21 N m (15 lb-ft) Tensioning Lever Guide Rail Pin Bolt Poly V-Belt Belt Pulley Bolt ........................................... 10 N m (89 lb-in)
10 11 12 13 14 15 16 17 18
Tensioning Pulley Socket Bolt .............................. 29 N m (21 lb-ft) Closing Cover Washer Tensioning Lever Fit Bolt.................................... 100 N m (74 lb-ft) Closing Cover Spring Bolt ........................................... 20 N m (15 lb-ft)
SSANGYONG Y200

1. Remove the tensioning lever nut. Installation Notice Tightening Torque 21 N m (15 lb-ft)
2. Push the tensioning lever in direction of arrow with a rod ( 12, 180 mm) and push out the bolt to the rear.
YAD1BB30
3. Push back the tensioning lever to release the spring tension and remove the belt.
YAD1BB40
4. Remove the bolt (9) and then remove the belt pulley (8). Installation Notice Tightening Torque 10 N m (89 lb-in)
YAD1BB70
5. Remove the bolt (1, 18) and take off the damper (2). Installation Notice bolt (1) : 21 N m (15 lb-ft) bolt (18): 20 N m (15 lb-ft)
Tightening Torque
Pay attention to installation position of the damper.
YAD1BB80
SSANGYONG Y200

6. Pull off the tensioning lever (4) from guide rail pin. 7. Remove the spring (17). Notice: Insert spring (17) with color coding (blue/ violet) facing up.
YAD1BB90
8. Pry off the closing cover (12) and remove the socket bolt (11) and then remove the tensioning pulley (10). Installation Notice Tightening Torque 29 N m (21 lb-ft)
YAD1BBA0
9. Pry off the closing cover (16) and remove the fit bolt (15). Installation Notice Tightening Torque 100 N m (74 lb-ft)
Apply loctite on thread of fit bolt. 10. Remove the tensioning lever (14) and washer (13). 11. Clean thread in the timing case cover and fit bolt.
YAD1BBB0
SSANGYONG Y200
CRANKCASE AND CYLINDER HEAD

CYLINDER HEAD
YAD1BBC0
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 Bolt .................................. 25 N m (18 lb-ft)+90 Washer Camshaft Drive Sproket ......................... Relace Camshaft Bolt .......................................... 10 N m (89 lb-in) Threaded Ring ...................... 130 N m (96 lb-ft) Prechamber Bolt .......................................... 25 N m (18 lb-ft) Camshaft Bearing Cap 10 11 12 13 14 15 16 17 Cylinder Head Bolt ............................ See Table Plug Engine Coolant Temperature Thermo Valve Sensor Cylinder Block Gasket................................................... Replace Cylinder Head Sliding Rail
SSANGYONG Y200

Cylinder Head Bolt Tightening Torque
Cylinder Head Bolts (12-sided socket head) (Engine cold) M8 Cylinder Head Bolts 1st Step 2nd Step 3rd Step 10 Nm (89 lb-in) 35 Nm (26 lb-ft) 180 25 Nm (18 lb-ft)
Tightening Sequence for Cylinder Head Bolts
YAD1BBD0
Notice: The cylinder head may only be removed when the engine has cooled down. The cylinder head is removed together with the exhaust manifold. As the cylinder head bolts undergo a permanent tightening. They require to be replaced if they exceed the maximum lengthes indicated in the table. Thread Dia. Length(L) When New M10 M10 M10
YAD1BBE0
Max. Length(L) 82 mm 104 mm 117 mm
80 mm 102 mm 115 mm
The twelve-sided socket head bolts are tightened with each stages of torque and torque angle. It is not necessary to retighten the cylinder head bolts at the 1000~1500 km inspection or after 1000~1500 km of repairs.
SSANGYONG Y200

Tools Required 116 589 02 34 00 Threaded Pin 116 589 03 07 00 T Type Socket Wrench 116 589 20 33 00 Sliding Hammer 602 589 00 40 00 Engine Lock 603 589 00 40 00 Counter Holder
Removal Procedure
1. Completely drain the coolant from the radiator and cylinder block. 2. Remove the cooling fan shroud. 3. Hold the fan with counter holder 603 589 00 40 00 and remove the bolt and then remove the cooling fan.
YAD1BBF0
4. Remove the bracket oil dipstick tube.
YAD1BBG0
5. Remove the tensioning lever nut. 6. Remove the nut on the tensioning lever and insert the rod( 18, 180 mm). By pushing the rod to the arrow direction, pull back the bolt.
YAD1BB30
SSANGYONG Y200

7. Push the tensioning lever to the opposite direction to release the spring tension and remove the poly V-belt.
YAD1BB40
8. Unscrew the EGR pipe mounting bolts onto the exhaust manifold. 9. Remove the duct bracket from the cylinder head.
YAD1BBH0
10. Unscrew the intake duct mounting bolts onto the intake manifold.
YAD1BBJ0
11. Separate the connecting rod from the control lever.
YAD1BBK0
SSANGYONG Y200

12. Pull out the accelerator control linkage.
YAD1BBL0
13. Remove the fuel injection line (1) from the fuel injection nozzle (12).
YAD1BBM0
14. Remove the fuel injection line from the fuel injection pump.
YAD1BBN0
15. Remove the bracket mounting bolts and then remove the fuel injection line (1).
YAD1BBP0
SSANGYONG Y200

16. Disconnect the blow by hose from the cylinder head cover.
YAD1BBQ0
17. Disconnect the glow plug cables.
YAD1BBT0
18. Remove the intake manifold (10) and gasket.
YAD1BBR0
19. Remove the cylinder head cover and gasket.
YAD1BBS0
SSANGYONG Y200

20. Remove the cable channel.
YAD1BBU0
21. Disconnect the cables from the glow plug sensor and engine coolant temperature sensor.
YAD1BBV0
22. Remove the heater pipe bracket from the oil filter. 23. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe.
YAD1BBW0
24. Disconnect the fuel lines from the fuel filter.
YAD1BBX0
SSANGYONG Y200

25. Disconnect the fuel lines from the injection pump.
YAD1BBY0
26. Remove the fuel filter.
YAD1BBZ0
27. Remove the fuel injection nozzle and nozzle washer.
YAD1BC00
28. Rotate the crankshaft and set the no.1 cylinder at TDC. Notice: Do not rotate the crankshaft to the opposite direction of engine revolution.
YAD1BC10
SSANGYONG Y200

29. Place alignment marks on the camshaft gear and timing chain.
YAD1BC20
30. Ensure that the camshaft and the bearing cap marking are aligned.
YAD1BC30
31. Remove the starter motor and install the engine lock 602 589 00 40 00 onto the flywheel ring gear.
YAD1BC40
32. Remove the exhaust manifold and exhaust pipe.
YAD1BC50
SSANGYONG Y200

33. Remove the chain tensioner and seal.
YAD1BC60
34. Remove the bolt and separate the drive sprocket. Notice: During removal, be careful not to drop the sprocket and chain into the timing case. Carefully pull off the chain and then pull out the sprocket.
YAD1BC70
35. Remove the camshaft bearing cap bolts according to the numerical sequence. Notice: Remove the No.1 bolts first and then remove the No. 2 bolts. Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged.
YAD1BC80
36. Remove the bearing caps and then pull out the camshaft(20) upward. Notice: Be careful not to miss the locking washer. 37. Remove the locking washer. Notice: Check the locking washer and replace if necessary.
YAD1BC90
SSANGYONG Y200

38. Using the sliding hammer 116 589 20 33 00 (36) and the threaded pin 116 589 02 34 00 (37), pull out the sliding rail pins (25, 26) and remove the sliding rail (24).
YAD1BCA0
39. Remove the vacuum line from the vacuum pump. 40. Disconnect the vacuum pipe from thermo valve.
YAD1BCB0
41. Remove the socket bolts (13) of the chain box using the T type socket wrench 116 589 03 07 00.
YAD1BCC0
42. Remove the cylinder head bolts in numerical sequence. 43. Remove the cylinder head and gasket.
YAD1BCD0
SSANGYONG Y200

1. Replace the cylinder head gasket.
YAD1BCE0
2. Install the cylinder head onto the crankcase. Notice: Align the cylinder head holes with the guide pins.
YAD1BCF0
3. Measure the length(L) of cylinder head bolts. Notice: If the max. length is exceeded, replace the bolts. Thread Dia. Length (L) when New M10 M10 M10 80 mm 102 mm 115 mm Max. Limit(L) 82 mm 104 mm 117 mm
YAD1BBE0
4. Coat the head contact surface of bolts and thread with oil and insert them as shown. - Cylinder head bolts arrangement Bore 1 .............................................. M10 80 2 .............................................. M10 3 .............................................. M10 4 .............................................. M 8 5 .............................................. M 8 102 115 50 80
YAD1BCG0
SSANGYONG Y200

5. Tighten the cylinder head bolts to specified torque and torque angle. 1st Step 2nd Step Tightening Torque Torque Angle Wait for Torque Angle 10 Nm (89 lb-in) 35 Nm (26 lb-ft) 90 10 minutes 90
YAD1BCH0
YAD1BBD0
6. Install the socket bolts in the chain box using the T type socket wrench 116 589 03 07 00. Installation Notice Tightening Torque 25 Nm (18 lb-ft)
YAD1BCK0
7. Connect the vacuum pipe to the thermo valve. 8. Connect the vacuum lines to the vacuum pump.
YAD1BCL0
SSANGYONG Y200

9. Install the fuel filter and connect the pipe. Installation Notice Tightening Torque 25 Nm (18 lb-ft)
Be careful not to be confused the connections and hoses.
YAD1BBX0
10. Connect the fuel line to the injection pump. Installation Notice Tightening Torque 13 Nm (10 lb-ft)
YAD1BBY0
11. Install the sliding rail (24) and insert the sliding rail pins (25, 26) using the sliding hammer 116 589 20 33 00 (36) and threaded pin 116 589 02 34 00 (37). Notice: Apply sealing compound on the each collar of the sliding rail pins.
YAD1BCA0
12. Insert the locking washer. 13. Inspect the valve tappet and check that the tappet moves smoothly.
YAD1BCM0
SSANGYONG Y200

14. Coat the camshaft with oil and install the camshaft on the cylinder head to be TDC mark(arrow) upward. 15. Measure the axial end play of the camshaft. Installation Notice End Play 0.06 ~ 0.21 mm
If out of standard, adjust it with the proper thickness of locking washer.
YAD1BCN0
16. Install the bearing caps on the camshaft according to the number on the caps.
YAD1BCP0
17. Tighten the bearing cap bolts according to the numerical sequence. Installation Notice Tightening Torque 25 Nm (18 lb-ft)
Tighten the No. 1 bolts (light arrow) first and then tighten the No. 2 bolts (dark arrow) stage by stage.
YAD1BCQ0
18. Position the camshaft on marking and install the camshaft sprocket. Notice: Align the alignment marks on the chain and sprocket.
YAD1BC30
SSANGYONG Y200
YAD1BCR0
19. Check the TDC position of the crankshaft.
YAD1BC10
20. Install the camshaft sprocket bolt. Installation Notice Tightening Torque 1st Step 25 Nm (18 lb-ft) 2nd Step 90
YAD1BC70
Notice: Measure the max. length L and replace the bolt if it exceeds 53.6 mm.
YAD1BCS0
SSANGYONG Y200

21. Install the exhaust manifold and gasket. Installation Notice Tightening Torque 25 Nm (18 lb-ft)
YAD1BCT0
22. Replace the seal and then install the chain tensioner. Installation Notice Tightening Torque 80 Nm (59 lb-ft)
YAD1BC60
23. Remove the engine lock 602 589 00 40 00.
YAD1BC40
24. Insert the nozzle washer into the hole to face round part downward. 25. Install the fuel injection nozzle. Installation Notice Tightening Torque 40 Nm (30 lb-ft)
YAD1BCU0
SSANGYONG Y200

26. Connect the fuel hose. 27. Install the cable channel and connect the cables to glow plugs.
YAD1BBU0
28. Replace the gasket and install the cylinder head cover. Installation Notice Tightening Torque 29. Install the blow-by hose. 10 Nm (89 lb-in)
YAD1BCV0
30. Connect the wires to the engine coolant temperature sensor and the glow plug sensor.
YAD1BBV0
31. Replace the intake manifold gasket. 32. Install the intake manifold. Installation Notice Tightening Torque 25 Nm (18 lb-ft)
YAD1BCW0
SSANGYONG Y200

33. Replace the O-ring of heater feed pipe and install it to the cylinder head. Notice: For installation, clean the hole. 34. Install the bracket of heater feed pipe to the oil filter.
YAD1BCX0
35. Install the fuel pipe and the accelerator control linkage.
YAD1BCY0
36. Connect the fuel lines to the injection nozzles and to the injection pump. Installation Notice Tightening Torque 18 Nm (13 lb-ft)
YAD1BBN0
37. Install the poly V-belt. Notice: Be careful not to contaminate the belt.
YAD1BCZ0
SSANGYONG Y200

38. By inserting a rod into the tensioning lever upper hole and pulling the rod, install the bolt and then tighten the nut. Installation Notice Tightening Torque 21 Nm (15 lb-ft)
YAD1BB30
39. Install the oil dipstick tube bracket. Installation Notice Tightening Torque 10 Nm (89 lb-in)
YAD1BBG0
40. Hold the cooling fan with the counter holder 603 589 00 40 00 and tighten the bolt.
YAD1BBF0
SSANGYONG Y200
PRECHAMBER
Preceding work: Removal of glow plug Removal of fuel injection nozzle Tools Required 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer
Removal Procedure
1. Using the serration wrench 603 589 00 09 00 (4), remove the threaded ring (1).
YAD1BD00
2. Install the sliding hammer 667 589 03 63 00 (5) into the prechamber.
YAD1BD10
3. Remove the perchamber (2). Notice: After removing the prechamber, cover over the bores with clean rag.
YAD1BD20
4. Inspect the prechamber. Notice: If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced, the sealing surfaces in the cylinder head must be remachined.
YAD1BD30
SSANGYONG Y200
Notice: In case the prechambers are reused, inspect the prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used. 1. Clean the sealing surface of the prechamber. 2. Insert the prechamber into the cylinder head at the same time aligning the cam on the collar of the prechambers with the slots in the cylinder head. Installation Notice
YAD1BD40
Thickness of Spacer Ring
0.3, 0.6, 1.0 mm
If the spacer rings are fitted to the prechambers, the spacer rings should be replaced with rings of the same thickness. 3. Coat the threaded ring with oil and assemble the ring by using the serration wrench 603 589 00 09 00. Installation Notice Tightening Torque 130 Nm (96 lb-ft)
SSANGYONG Y200
OIL PAN
YAD1BD50
1 2 3 4
Gasket.................................................... Replace Oil Pan Bolt ........................................... 10 Nm (89 lb-in) Washer ................................................... Replace
5 Drain Plug ................................ 25 Nm (18 lb-ft) 6 Bolt ........................................... 10 Nm (89 lb-in) 7 Bolt ........................................... 25 Nm (18 lb-ft)
Notice: Replace the washer seal with new one.
SSANGYONG Y200
TIMING CASE COVER

Preceding Work : Removal of the cooling fan Removal of the V-belt tensioning device Removal of the vibration damper and hub Removal of the generator
YAD1BD60
Bolt ........................................... 10 Nm (89 lb-in) Cylinder Head Cover Gasket.................................................... Replace Socket Bolt .............................. 25 Nm (18 lb-ft) Fuel Filter Square Nut Oil Pan Socket Bolt .............................. 10 Nm (89 lb-in) Bolt .................................. M6 : 10 Nm (89 lb-in) ......................................... M8 : 23 Nm (17 lb-ft) 10 Power Steering Pump 11 Bolt 12 Belt Pulley
1 2 3 4 5 6 7 8 9
13 14 15 16 17 18 19 20 21 22 23 24 25
Bolt ........................................... 32 Nm (24 lb-ft) Timing Case Cover Bolt ........................................... 23 Nm (17 lb-ft) Generator Bracket Bolt ........................................... 45 Nm (33 lb-ft) Bolt ........................................... 25 Nm (18 lb-ft) Bolt ........................................... 10 Nm (89 lb-in) Closing Cover Socket Bolt .............................. 23 Nm (17 lb-ft) Guide Pulley Bolt ............................................. 9 Nm (80 lb-in) Guide Pulley Bracket Nut ............................................ 23Nm (17 lb-ft)
SSANGYONG Y200

Tools Required 116 589 03 07 00 T Type Socket Wrench
Removal Procedure
1. Remove the fan clutch and cooling fan belt pulley. 2. Drain the engine oil completely. 3. Remove the crankshaft pulley. 4. Loosen the bolt (1) and then remove the cylinder head cover (2) and gasket. 5. Remove the vacuum pump.
YAD1BCV0
6. Detach the closing cover (20). Remove the bolts (21) and then remove the guide pulley (22).
YAD1BD70
7. Remove the guide pulley bracket (24).
YAD1BD80
8. Disconnect the pipes of power steering pump and remove the belt pulley. Notice: Be careful not to lose the key. 9. Remove the nut and pull out the bolt and then remove the power steering pump.
YAD1BD90
SSANGYONG Y200

10. Remove the generator bracket (16).
YAD1BDA0
11. Remove the fuel filter.
YAD1BDB0
12. Remove the camshaft. 13. Remove the socket bolts (4) in the chain box using the socket wrench 115 589 03 07 00.
YAD1BDC0
14. Remove the injection pump. Refer to Section 1F3 Diesel Engine Control.
YAD1BDD0
SSANGYONG Y200

15. Remove the oil pan bolts (8, 9) in the area of the timing case cover (14). 16. Slightly loosen the remaining oil pan bolts.
YAD1BDE0
17. Remove the timing case cover (19) bolts and then remove the timing case cover (14). Notice: Be careful not to damage the cylinder head gasket or oil pan gasket.
YAD1BDF0
1. Thoroughly clean the sealing surface and apply sealant.
YAD1BDG0
2. Install the timing case cover. Installation Notice Tightening Torque Bolts arrangement 1. M6 x 60 2. M6 x 70 3. M6 x 40 10 Nm (89 lb-in)
YAD1BDH0
SSANGYONG Y200

3. Tighten the socket bolts in the chain box. Installation Notice Tightening Torque 4. Tighten the oil pan bolts. Installation Notice Socket Bolt Tightening Torque M6 Bolt M8 Bolt
YAD1BDC0
25 Nm (18 lb-ft)
10 Nm (89 lb-in) 10 Nm (89 lb-in) 25 Nm (18 lb-ft)
5. Install the flange, vibration damper and crankshaft belt pulley. Notice: Replace front radial seal if necessary.
YAD1BDJ0
6. Install the generator bracket. Installation Notice Tightening Torque Front Side 25 Nm (18 lb-ft) 25 Nm (18 lb-ft)
YAD1BDK0
7. Install the generator. Installation Notice Tightening Torque Upper Lower 25 Nm (18 lb-ft) 45 Nm (33 lb-ft)
YAD1BDL0
SSANGYONG Y200

8. Install the cylinder head cover. Installation Notice Tightening Torque 10 Nm (89 lb-in)
9. Tighten the injection pump mounting bolts. Installation Notice Tightening Torque 23 Nm (17 lb-ft)
YAD1BDM0
10. Install the fuel filter. Installation Notice Tightening Torque 11. Install the vacuum pump. Installation Notice Tightening Torque 10 Nm (89 lb-in) 25 Nm (18 lb-ft)
YAD1BDN0
12. Install the power steering pump. Installation Notice Tightening Torque 23 Nm (17 lb-ft)
13. Install the power steering pump pulley. Installation Notice Tightening Torque 32 Nm (24 lb-ft)
YAD1BDP0
14. Install the guide pulley bracket. Installation Notice Tightening Torque 9 Nm (80 lb-in)
YAD1BD80
SSANGYONG Y200

15. Install the guide pulley (22) and fit the closing cover (20). Installation Notice Tightening Torque 23 Nm (17 lb-ft)
YAD1BD70
16. Replace the gasket (3) and install the cylinder head cover (2). Installation Notice Tightening Torque 10 Nm (89 lb-in)
17. Install the cooling fan belt pulley and fan clutch. 18. Install the belt tensioning device and then install the belt. 19. Install the cooling fan. 20. Fill the engine oil and check oil leaks by running the engine.
YAD1BCV0
SSANGYONG Y200
CRANKSHAFT ASSEMBLY
VIBRATION DAMPER AND HUB
Preceding Work: Removal of the cooling fan Removal of poly V-belt
YAD1BDQ0
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 11 12 Bolt ........................................... 10 Nm (89 lb-in) Cooling Fan Belt Pulley Socket Bolt .............................. 23 Nm (17 lb-ft) Crankshaft Belt Pulley Vibration Damper Bolt .............................. 200 Nm (148 lb-ft)+ 90 Washer Straight Pin Hub Oil Pan Radial Seal Key 13 14 15 16 17 18 19 20 21 22 23 24 Radial Seal Timing Gear Case Cover Key Crankshaft Sprocket Crankshaft Socket Bolt .............................. 23 Nm (17 lb-ft) Washer Bolt ................................ 20 Nm (148 lb-ft)+ 90 Hub Straight Pin Crankshaft Velt Pulley Vibration Damper
SSANGYONG Y200

Tools Required 103 589 00 33 00 601 589 03 14 00 Puller Sleeve
602 589 00 40 00 Engine Lock
Removal Procedure
1. Remove the starter motor and install the engine lock 602 589 00 40 00 into the flywheel ring gear. 2. Remove the poly V-belt. 3. Remove the cooling fan. Notice : Keep the fan in vertical position.
YAD1BC40
4. Remove the cooling fan belt pulley (2). 5. Place alignment marks (arrow) on the vibration damper (5) and crankshaft belt pulley (4).
YAD1BDR0
6. Remove the timing sensor bracket. Notice: Remove if necessary.
YAD1BDS0
7. Remove the socket bolts (3) and then remove the belt pulley (4) and vibration damper (5).
YAD1BDT0
SSANGYONG Y200

8. Remove the washer and bolt.
YAD1BDU0
9. Remove the hub by using a puller 103 589 00 33 00.
YAD1BDV0
10. Pull out the radial seal (1) and be careful not to damage the sealing surface of timing case cover.
YAD1BDW0
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-61 Installation Procedure

1. Install the hub. Notice: Exactly align the woodruff key and the groove of hub (arrow).
YAD1BDX0
2. Install the washer and tighten the bolt. Installation Notice Tightening Torque 200 Nm (148 lb-ft)+ 90
YAD1BDY0
3. Install the vibration damper. Notice: Exactly align and insert onto the straight pin.
YAD1BDZ0
4. Install the crankshaft belt pulley. Installation Notice Tightening Torque Align the alignment marks. 23 Nm (17 lb-ft)
YAD1BE00
SSANGYONG Y200

5. Install the timing sensor bracket. Refer to TDC Setting in this section.
YAD1BE10
6. Install the cooling fan pulley. Installation Notice Tightening Torque 10 Nm (89 lb-in)
7. Install the cooling fan. 8. Install the fan belt. 9. Remove the engine lock 602 589 00 40 00.
YAD1BE20
10. Throughly clean the mounting bore of the radial seal. 11. Coat a little oil on the sealing lip of new radial (1) and contact surface. Notice: Dont use grease. 12. Install the radisl seal (1) by using a sleeve 601 589 03 14 00 (4). Notice: Align the groove of sleeve and woodruff key (arrow).
YAD1BE30
;;;; ;;;; ;;;;
Notice : The sealing lip of the repair radial seal is offset to the inside by 2 mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange.
;;;; ;;;; ;;;;

YAD1BE40
A Standard Radial Seal B Repair Radial Seal
SSANGYONG Y200
FLYWHEEL AND CRANKSHAFT END COVER

Preceding Work: Removal of the transmission Removal of the clutch
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1 2 3 4 5 6
Crankshaft Flange End Clver .............................. Clean Loctite 573 Bolt ........................ 10 Nm (89 lb-in) Loctite 573 Radial Seal ............................................ Replace Dowel Sleeve Bolt ........................ 10 Nm (89 lb-in) Loctite 573
7 Straight Pin 8 Flywheel (Manual Transmission) 9 12-Sided Stretch Bolt ............................ Check, 45 Nm (33 lb-ft)+ 90 10 Drive Plate (Automatic Transmission) 11 Flywheel (Automatic Transmission)
SSANGYONG Y200

Tools Required 601 589 03 43 00 Oil Seal Assembler 602 589 00 40 00 Engine Lock
Removal Procedure
1. Install the engine lock 602 589 00 40 00. 2. Remove the 12-sided stretch bolts. Notice: Remove the flywheel and drive plate, if equipped with automatic transmission.
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Notice: If the length Lof bolts exceeds 22.5 mm, replace the bolts.
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3. Remove the bolts (3. 6) from end cover, by pulling out the lug (arrow), remove the cover. Notice: Be careful not to damage the oil pan gasket.
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4. Remove the radial seal (4) with care not to damage the sealing surface.
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SSANGYONG Y200

1. Throughly clean the sealing surface of end cover and apply Loctite 573. 2. Clean the groove of radial seal. 3. Apply Loctite 573 on the bolts and install the end cover. Installation Notice Tightening Torque 10 N m (89 lb-in)
Be careful not to damage the oil pan gasket.

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4. Install the inner oil seal assembler 601 589 03 43 00 to the crankshaft flange.
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5. Coat a little oil on the sealing lip of new radial seal and contacting surface. Notice: Don t use grease. 6. Insert the new radial seal (4) on to the oil seal assembler 601 589 03 43 00 (7).
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Notice: The sealing lip of the repair radial seal is offset to the inside by 3 mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange.
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A Standard Radial Seal B Repair Radial Seal
SSANGYONG Y200

7. Install the outer oil seal assembler 601 589 03 43 00 on the seal and by tightening the bolts, press the radial seal into the end cover as far as the stop. Notice: The seal must be positioned exactly at right angles in the end cover to ensure that it provide a proper seal.
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8. Install the flywheel. Installation Notice Tightening Torque 45 N m (33 lb-ft)+ 90
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SSANGYONG Y200
CRANKSHAFT BALL BEARING
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1 Spacer 2 Cover ...................................................... Replace
3 Ball Bearing 4 Bolt.................................. 45 N m (33 lb-ft)+ 90
Notice: Manual transmission only. Tools Required 000 589 25 33 00 Internal Extractor 000 589 33 33 00 Counter Support

1. Remove the manual transmission. 2. Using a internal extractor 000 589 25 33 00 and counter support 000 589 33 33 00, pull out the locking ring and ball bearing together. 3. Apply Loctite 241 on the new ball bearing and then insert the ball bearing to be stopped at the spacer ring by using a proper mandrel.
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SSANGYONG Y200
CRANKSHAFT
Preceding Work: Removal of the end cover Removal of the piston Removal of the crankshaft sprocket
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3 4 5 6
Crankshaft Main Bearing Shells (Upper) Trust Bearings (Upper) Crankshaft Crankshaft Main Bearing Shells (Lower)
7 8 9 10
Thrust Bearings (Lower) Crankshaft Bearing Cap Crankshaft Bearing Cap (Fit Bearing) 12-sided Stretch Bolts .... 55 N m (41 lb-ft)+ 90
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-69 Thrust Washer and Bearing Arrangement
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3 4 5 6 7
Crankshaft Main Bearing Shells (Upper) Thrust Bearings (Upper) Crankshaft Crankshaft Main Bearing Shells (Lower) Thrust Bearings (Lower)
A Radial Bearings B Radial and Axial Bearings (Thrust Bearing)
Notice: The gaps between the bearing shell and bore and between the bearing shell and journal are different each other. Refer to service data.
SSANGYONG Y200
1B3-70 DIESEL ENGINE MECHANICAL Crankshaft Standard and Repair Sizes

Crankshaft bearing journal diameter 50.950 - 57.965 57.500 - 57.715 57.450 - 57.465 57.200 - 57.215 56.950 - 56.965 Thrust bearing journal width 24.500 - 24.533 24.600 - 24.633 Repair size 1 Repair size 2 Repair size 3 Repair size 4 24.700 - 24.733 24.900 - 24.933 25.000 - 25.033 Thrust bearing journal diameter 47.950 - 47.965 47.700 - 47.715 47.450 - 47.650 47.200 - 47.215 46.950 - 46.965
Standard size
Bearing Clearances
Crankshaft bearing Radial clearances Axial clearances New Limit New Limit 0.027 - 0.051 mm Max. 0.070 mm 0.100 - 0.254 mm Max. 0.300 mm Thrust bearing 0.026 - 0.068 mm Max. 0.080 mm -
Matching Fit Bearing Journal Width to Thrust Bearings

Fit bearing journal width 24.500 - 24.533 mm 24.600 - 24.633 mm 24.700 - 24.733 mm 24.900 - 24.933 mm 25.000 - 25.033 mm Thrust bearings thickness 2.15 mm 2.20 mm 2.25 mm 2.35 mm 2.40 mm
Notice: Measure crankshaft axial clearance and adjust with proper thrust Bearing. The same thickness of washer must be installed on both sides of the fit bearing.
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-71 Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Marking of basic bearing bore in lower parting surface 1 punch mark or blue 2 punch marks or yellow 3 punch marks or red Color code of relevant crankshaft bearing shell Blue or white-blue Yellow or white-yellow Red or white-red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft

Marking of bearing journals on crank webs Blue or white-blue Yellow or white-blue Red or white-blue Color code of relevant crankshaft bearing shell Blue or white-blue Yellow or white-yellow Red or white-red
SSANGYONG Y200

Tools required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension

1. Remove the bearing cab bolt. 2. Remove the bearing caps (8). Notice: The crankshaft bearing caps are marked with stamped numbers. Remove the bearing cap from the vibration damper side.
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3. Remove the crankshaft bearing caps (9) and lower thrust bearings (7). 4. Remove the lower bearing shell (6) from the bearing cap (9).
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5. Remove the crankshaft (5).
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6. Remove the upper thrust bearings (4). 7. Remove the upper bearing shells (3) from crankcase.
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SSANGYONG Y200

8. Thoroughly clean the oil gallery. 9. Select a proper new bearing shells with reference to table. 10. Coat the new bearing shells with oil and insert into the crankcase and into the crankshaft bearing caps. Notice: Do not mix up upper and lower crankshaft bearing shells. 11. Install the bearing caps according to marking and tighten the 12-sided stretch bolts. Installation Notice
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Tightening Torque
55 N m (41 lb-ft)+ 90
No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E) using the dial gauge 001 589 53 21 00 and extension 366 589 00 21 05.
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13. Measure at 3 points (A, B and C) and if the average value of B and C is less than A s value, the average value of B and C is the mean value and if more than As value, As value is the mean value.
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SSANGYONG Y200

14. Measure crankshaft bearing journal diameter (F). Notice: When measured in A and B, the runout should not exceed 0.010 mm.
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15. Measure radial clearance of crankshaft bearing (G). Clearance G 0.027 - 0.051 mm
Notice: If G is out of standard, replace the bearing shells and adjust the radial clearance of crankshaft bearing. Example) Measured value E = 57.700 mm Measured value F = 57.659 mm Clearance G
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= 0.041 mm
16. Remove the crankshaft bearing cap. 17. Measure width of thrust bearing journal (H) and adjust with proper thrust bearings (see table). Notice: The same thickness of thrust washers should be installed on both sides of the thrust bearing.
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18. Coat the upper thrust bearing (4) with oil and insert into the crankcase so that the oil grooves are facing the crank webs (arrow).
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SSANGYONG Y200

19. Coat the lower thrust bearing (7) with oil and insert into the crankshaft bearing cap so that the oil grooves are facing the crank webs (arrow). Notice: The retaining lugs should be positioned in the grooves (arrow).
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Notice: If the max. length of bolts (L) exceed 63.8 mm, replace them.
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20. Coat the new crankshaft with engine oil and place it on the crankcase. 21. Install the crankshaft bearing caps according to marking and tighten the bolts. Installation Notice Tightening Torque Install from No. 1 cap. 55 N m (41 lb-ft)+ 90
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22. Rotate the crankshaft with hand and check whether it rotates smoothly. 23. Measure crankshaft bearing axial clearance using dial gauge 001 589 53 21 00 and dial gauge holder 363 589 02 21 00. Clearance 0.100 - 0.245 mm
Notice : If the clearance is out of standard, adjust the axial clearance of crankshaft bearing by replacing the thrust washers. Notice: The same thickness of thrust washers should be installed on both sides of the thrust bearing.
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SSANGYONG Y200

24. Insert the new connecting rod bearing shells into the connecting rod and connecting rod bearing cap and tighten the 12-sided stretch bolts (11). Installation Notice Tightening Torque 35 N m (26 lb-ft)+ 90
25. Measure inner diameter of connecting rod bearing.
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26. Measure connecting rod bearing journal diameter (K). Notice: Refer to measurement of the crankshaft bearing journal diameter. 27. Measure the radial clearance (L) of the connecting rod bearing. Example) Measured value J = 47.700 mm Measured value K = 47.653 mm Clearance L
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= 0.047 mm 0.026 - 0.068 mm
Radial Clearance L
Notice : If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing the connecting rod bearing shells. 28. Remove the connecting rod bearing cap. 29. Install the piston. 30. Rotate the crankshaft by hand and check whether it rotates smoothly. 31. If the bearings are damaged, - replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and replace the hose if necessary. Notice: After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensor bracket setting. 32. Fill oil and run the engine and then check the oil pressure and oil level. Notice: Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500 km.
SSANGYONG Y200
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan Removal of timing case cover
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1 12-Sided Stretch Bolt (M11) ............................ Check, 25 N m (18 lb-ft)+ 90 2 Washer 3 Camshaft Sprocket 4 Timing Chain 5 Bearing Pin 6 Bearing Pin 7 Oil Pump 8 Oil Pump Sprocket 9 Oil Pump Chain
10 11 12 13 14 16 17 18 19
Washer Bolt ........................................... 25 N m (18 lb-ft) Crankshaft Sprocket Crankshaft Key Guide Rail Spring Bushing Tensioning Lever
SSANGYONG Y200

Special Tools 102 589 05 33 00 Puller 116 589 07 15 00 Drift
Removal Procedure
1. Pull out the tensioning lever (19) together with the spring (17) and guide rail (16) far enough until the tensioning lever has passed the oil pump chain (9) and is resting against the crankshaft (13).
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2. Pull out tensioning lever (19), spring (17) and bushing (18) from the bearing pin (6).
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3. Pull out the guide rail (16).
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4. Remove the bolt(11) and then remove the washer (10), oil pump chain (9) and sprocket (8).
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SSANGYONG Y200

5. Place alignment marks (arrow) on the timing chain (4) and crankshaft sprocket (12). 6. Remove the woodruff key (15).
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7. Place alignment marks (arrow) on the timing chain (4) and camshaft sprocket (3). 8. Remove the chain tensioner. 9. Remove the bolt (1) and then remove the washer (2) and camshaft sprocket (3).
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10. Remove the crankshaft sprocket (12) by using a puller 102 589 05 33 00 (20).
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SSANGYONG Y200
1B3-80 DIESEL ENGINE MECHANICAL Installation Procedure

1. Put the same alignment mark on the new crankshaft sprocket as in the old sprocket. Notice: Check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for wear and replace if necessary.
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2. Install the new crankshaft sprocket (12) by using a drift 116 589 07 15 00 (21). Notice: Align the groove of sprocket and woodruff key (arrow) exactly.
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3. Fit the timing chain (4) on the crankshaft sprocket (12). Notice: Align the alignment marks (arrow) on the chain and sprocket.
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4. Install the camshaft sprocket (3). Installation Notice Tightening Torque 25 N m (18 lb-ft)+ 90
Pay attention on the alignment marks and dowel pin (arrow).
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SSANGYONG Y200

Notice: If the max. length L of the stretch bolt exceeds 53.6 mm, replace it.
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5. Fit the oil pump chain (9) on the crankshaft sprocket (12) and insert the oil pump sprocket (8) into the oil pump chain and then install it on the oil pump. Installation Notice Tightening Torque 25 N m (18 lb-ft)
The curved side of the oil pump sprocket should face the oil pump. 6. Insert the woodruff key (15).
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7. Install the guide rail (16). Attach the spring (17) to guide rail and to tensioning lever together onto the bearing pins (5, 6). Notice: Ensure that the spring is correctly located in the guide rail (arrow).
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SSANGYONG Y200
PISTON
Preceding Work: Removal of the cylinder head Removal of the oil pump
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1 2 3 4 5 6
Oil Ring 2nd Ring Top Ring Snap Ring .............................................. Replace Piston Pin Piston
7 8 9 10 11 12
Connecting Rod Bushing .......................... Check Connecting Rod Connecting Rod Upper Bearing Shell Connecting Rod Lower Bearing Shell Connecting Rod Bearing Cap Connecting Rod Bolt ...... 35 Nm (26 lb-ft)+ 90
Notice: There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there would be a unbalancing of engine.
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-83 Service Data

Piston clearance Piston crown protrusion in TDC position Connecting rod bushing diameter Max. 0.12 mm 0.735 - 0.965 mm 26.012 - 26.018 mm
Connecting Rod Bolt Dimensions

Thread Stretch shaft (C) diameter (new) Minimum stretch shaft diameter (C) Length (L) (new) M9 x 1 7.4 mm 7.1 mm 52 mm
SSANGYONG Y200

Tools Required 000 589 04 14 00 Tensoning Strap 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder
Removal Procedure
1. Remove combustion residues from the cylinder bores. 2. Remove the connecting rod bolts (12) and then remove the connecting rod bearing caps (11).
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3. Remove the connecting rod bearing shells (9, 10). Notice : Be careful not mix the bearing caps and shells each other.
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4. Remove the piston (6) and connecting rod (8).
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5. Remove the snap ring (4) and pull out the piston pin (5). 6. Separate the piston and connecting rod.
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SSANGYONG Y200

1. Fit the piston onto the connecting rod so that the arrow (15) and the locking slot (16) are facing in direction of the vehicle.
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2. Coat the piston pin (15) with engine oil and insert it by hand. Notice: Do not heat up the piston.
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3. Install the new snap ring (4) into the grooves (arrow). 4. Check the piston rings (1, 2, 3) and replace them if necessary.
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5. Install and arrange the piston rings to be evenly 120 from each ends gap.
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SSANGYONG Y200

6. Coat the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and piston with oil. 7. Compress the piston rings with a tensioning strap 000 589 04 14 00.
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8. Insert the piston assembly into the cylinder with a wooden stick (18). Notice: The arrow on the piston crown must point toward the front of vehicle.
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9. Insert the connecting rod bearing shells (9, 10). Notice: Be careful of the difference in upper and lower bearing shells and not to be changed. 10. Position the connecting rod bearings caps. Notice: Position so that the retaining lugs are on the same side of the connecting rod bearing (arrow).
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11. Measure stretch shaft diameter (C) of the connecting rod bolts. Limit C 7.1 mm
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SSANGYONG Y200

12. Coat the bolts (12) with oil and then tighten the bolts. Installation Notice Tightening Torque 35 N m (26 lb-ft)+ 90
13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft.
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14. Measure clearance between the piston crown and cylinder. Standard Max. 0.12 mm
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15. Position the piston at TDC and measure the distance between the piston crown and the crankcase surface using dial gauge 001 589 00 53 21 and dial gauge holder 363 589 02 21 00. Standard Max. 0.965 mm
Notice: Measure at points marked.
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SSANGYONG Y200
FLYWHEEL RING GEAR

Preceding Work: Removal of flywheel
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1 Ring Gear 2 Flywheel
a Centering Collar Diameter
SSANGYONG Y200

Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder
1. Drill a hole into the ring gear (1) (arrow) and snap with a chisel. 2. Thoroughly clean the collar surfaces of ring gear.
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3. Measure diameter (a) of centering collar. Diameter a 275 + 0.5 mm
Notice: If out of standard, replace the flywheel.
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4. Heat up the new ring gear up to 220C (428 F) by using a heating device. Notice: Use temperature measuring chalk.
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5. Install the new ring gear (1) onto the flywheel (2) by using a drift.
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SSANGYONG Y200

6. Measure axial runout of ring gear (1) on a surface plate using dial gauge 001 589 53 21 00 and dial gauge holder 363 589 02 21 00. Limit Max. 0.4 mm
Notice: For correct measurement, put the flywheel on the flat measuring board.
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SSANGYONG Y200
TIMING DEVICE AND VALVE

VALVE TAPPETS
Preceding Work: Removal of camshaft
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1 Valve Tappet 2 Cylinder Head 3 Oil Gallery
4 Seal ........................................................ Replace 5 Screw Plug
SSANGYONG Y200

Tools Required 102 589 03 40 00 Magnetic Bar
1. Pull out the valve tappet (1) using magnetic bar 102 589 03 40 00.
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2. Remove the plug (5) and blow compressed air into the oil gallery (3). At this time, check that the outlet bores (arrow) at the seat of the valve tappet are clear. 3. Replace the seal (4) and tighten the plug (5). 4. Insert the new valve tappet. Notice: Coat the valve tappet with oil.
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SSANGYONG Y200
VALVE SPRINGS (CYLINDER HEAD REMOVED)

Proceding Work: Remove of cylinder head
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1 2 3 4
Valve Tappet Valve Cotters Spring Retainer Valve Spring .......... Check, replace if necessary
5 Cylinder Head 6 Stud Bolt ................................ 12 N m (106 lb-in) 7 Nut ............................. Replace, 25 N m(18 lb-ft)
SSANGYONG Y200

Tools Required
102 589 03 40 00 116 589 06 63 00 601 589 01 59 00 601 589 02 59 00 667 589 00 31 00 Magnetic Bar Magnetic Finger Assembling Board Supporting Bridge Press Lever

1. Remove the nuts (8) uniformly and then remove the washer (7), exhaust manifold (9) and gasket.
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Installation Notice Check the stud bolt (6) for damage and replace if necessary. Tightening Torque 12 N m (106 lb-in)
Replace the gasket and tighten the nuts (8). Tightening Torque 25 N m (18 lb-ft)
2. Install the assembling board 601 589 01 59 00 (11) to the cylinder head with 4 cylinder head blots (10).
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3. Pull out the valve tappet (1) with magnetic bar 102 589 03 40 00 (12). Notice: Place the valve tappets upside down (open end upward).
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4. Install the supporting bridge 601 589 02 59 00 (13) on the cylinder head (5).
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SSANGYONG Y200

5. Using the press lever 667 589 00 31 00 (14), press the spring retainer downward and remove the valve cotters (2) with magnetic finger 116 589 06 63 00 (15). Notice: Be careful not to damage guide bore of the valve tappet.
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6. Remove the spring retainer (3) and spring (4). Notice: Install the valve spring with the color coding (arrow) facing down. 7. Check the valve spring and replace if necessary. 8. Installation should follow the removal procedure in the reverse order.
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SSANGYONG Y200
VALVE SPRINGS (CYLINDER HEAD INSTALLED)

Preceding Work: Removal of camshaft
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1 Valve Tappet 2 Valve Cotters 3 Spring Retainer
4 Valve Spring ......... Check, replace if necessary 5 Timing Chain 6 Cylinder Head
Notice: Remove the valve springs only when the piston is at TDC.
SSANGYONG Y200

Tools Required 102 589 03 40 00 116 589 06 63 00 603 589 01 40 00 667 589 00 31 00 667 589 02 63 00 Magnetic Bar Magnetic Finger Holding Wheel Press Lever Supproting Bar

1. Remove the valve tappet (1) with magentic bar 102 589 03 40 00.
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Notice: Place the valve tappets upside down (open end upward). 2. Install the holding wheel 603 589 01 40 00 (7) into the timing chain of camshaft sprocket piston. 3. Position the piston of relevant cylinder at TDC.
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4. Install the supporting bar 667 589 02 63 00 (8).
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5. Using the press lever 667 589 00 31 00 (9), press the spring retainer (3) downward and remove the valve cotters (2) with magnetic finger 116 589 06 63 00 (10). Notice: Be careful not to damage guide bore of the valve tappet.
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SSANGYONG Y200

6. Remove the spring retainer (3) and spring (4). 7. Check the valve spring and replace if necessary. 8. Insert valve spring (4) with the color coding (arrow) facing down and insert valve spring Retainer (3).
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9. By press the spring retainer (3) with press lever 667 589 00 31 00 (9), install the valve cotters with magnetic finger 116 589 06 63 00 (10).
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10. Remove the supporting bar 667 589 02 63 00. 11. Remove the holding wheel 603 589 01 40 00 (7) from the timing chain (5).
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13. Coat the valve tappet with oil and install it with magnetic bar 102 589 03 40 00.
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SSANGYONG Y200
VALVE STEM SEALS

Preceding Work: Removal of camshaft.
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1 Valve Tappet 2 Valve Cotters 3 Spring Retainer
4 Valve Spring .......... Check, replace if necessary 5 Valve Stem Seal 6 Valve
Notice: Remove the valve stem seals when the pistion is positioned at TDC.
SSANGYONG Y200

Tools Required 102 589 03 40 00 Magnetic Bar 104 589 00 37 00 Pliers 116 589 06 63 00 Magnetic Finger 601 589 02 43 00 Drift 603 589 01 40 00 Holding Wheel 667 589 00 31 00 667 589 02 63 00 Press Lever Supporting Bar
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Intake valve stem seal Chamfer Inner diameter d Color Wire ring Offset 7.3mm Brown Black
Exhaust valve stem seal All round 8.2 mm Green Yellow
SSANGYONG Y200
1. Remove the valve tappet (1) with magnetic bar 102 589 03 40 00. Notice: Place the valve tappets upside down (open end upward).
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2. Install the holding wheel 603 589 01 40 00 (7) into the timing chain (11). 3. Position the piston of relevant cylinder at TDC.
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4. Install the supporting bar 667 589 02 63 00 (8).
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5. Using press lever 667 589 00 31 00 (9), press the spring retainer (3) downward and remove the valve collets with magnetic finger 116 589 06 63 00 (10).
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SSANGYONG Y200

6. Remove the spring retainer (3) and valve spring (4).
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7. Remove the valve stem seal with pliers 104 589 00 37 00 (5).
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8. Insert the cap (12) onto the valve (6) and install the new valve stem seal (5) with drift 601 589 02 43 00 and then remover the cap.
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9. By pressing the spring seat with press lever 667 589 00 31 00 (9), install the valve cotters (2) with magnetic finger 116 589 06 63 00 (10). Notice: Be careful not to damage guide bore of the valve tappet.
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SSANGYONG Y200
VALVE GUIDES
Preceding Work: Removal of cylinder head Removal of valve spring Removal of valve
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1 Cylinder Head 2 Valve Guide
3 Valve Seat Ring a Basic Bore Diameter
Service Data
Item Intake Exaust Repair size 1 Repair size 2 Repair size 1 Repair size 2 Outer Diameter D 14.251 14.440 - 14.451 14.240 - 14.251 14.440 - 14.451 Color Code Red White Red White Basic Bore Diameter a 14.200 - 14.211 14.400 - 14.411 14.200 - 14.211 14.400 - 14.411 Overlap Valve Guide Inner Length D - a Diameter A L 0.029 - 0.051 0.029 - 0.051 8.000 - 8.030 9.000 - 9.050 39.5 37.7
SSANGYONG Y200

Notice: Measure center (arrow) of the valve guide and if the inner diameter A exceeds standard value, replace the guide.
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Tools Required 000 589 10 53 00 Reamer (for Exhaust) 000 589 10 68 00 Cylinder Brush 000 589 21 53 00 Reamer (for Intake) 102 589 00 23 00 103 589 02 15 00 103 589 03 15 00 115 589 34 63 00 117 589 03 23 00 346 589 00 63 00 601 589 05 15 00 601 589 06 15 00 GO / NO GO Gauge (for Intake) Drift (for Exhaust) Drift (for Intake) Mounting Device GO / NO GO Gauge (for Exhaust) Super Cooling Box Drift (for Intake) Drift (for Exhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves

Valve Seat Intake Exhaust Intake Exhaust 115 589 00 53 00 (14.2 mm) 115 589 01 53 00 (14.4 mm) Broaching Tool No. Guide Sleeve Tool No. 102 589 00 63 00 102 589 08 63 00 601 589 15 63 00 Guide Sleeve Side B B A B
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-105 Checking

1. Thoroughly clean the valve guide bore using a cylinder brush 000 589 10 68 00.
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2. Insert the GO/NO GO gauge (Intake: 102 589 00 23 00, Exhaust: 117 589 03 23 00) into the valve guide bore. If the NO GO side is inserted fully, replace the valve guide (Intake 8 mm, Exhaust 9mm).
YAD1BGT0
1. Drive out the valve guide (2) by using a drift (Intake: 103 589 03 15 00, Exhaust: 103 589 02 15 00) (5). Notice: The valve guide must be driven out upward of the cylinder head. 2. Thoroughly clean the basic bore by using a cylinder brush 000 589 10 68 00. 3. Check the basic bore in cylinder head for scoring marks and ream to next repair size if necessary.
YAD1BGU0
4. Reaming basic bore in cylinder head (repair size). - Thoroughly remove carbon deposits in cylinder head. Notice: Particularly remove the insides of the valve seat rings. - Remove the elevation (arrow) of intake valve seat rings.
YAD1BGV0
SSANGYONG Y200

- Select correct broaching tool and guide sleeve (refer to the table). Notice: Before broaching work, the broaching tool must be cleared of swarf with a stiff plastic brush. - Lubricate the basic bore, guide sleeve and broaching tool with petroleum. - Push broaching tool (6) in broaching direction (arrow) into the guide sleeve (7) far enough so that the first cut of the broaching tool is positioned in the basic bore when guide sleeve is fitted onto the valve seat ring (3). - Center the guide sleeve (7) in the valve seat ring (3) by turning. - Knock through the broaching tool (6) with a plastic hammer (approx. 25 g) and aluminum drift.
YAD1BGW0
YAD1BGX0
5. Heat the cylinder head (1) in a wear tank to approx. 80 C (176 F) with mounting device 115 589 34 63 00.
YAD1BGY0
6. Cool down the new valve guide (2) into the super cooling box 346 589 00 63 00 with liquid nitrogen. Notice: Do not touch the cooled valve guide by hand.
YAD1BGZ0
SSANGYONG Y200

7. Drive in new valve guide with drift (Intake: 601 589 05 15 00, Exhaust: 601 589 06 15 00) (8) until the wire ring makes contact. Notice: The valve guide must be driven in from the cylinder head cover.
YAD1BH00
8. Check the valve guide bore with GO / NO GO gauge (Intake: 102 589 00 23 00, Exhaust: 117 589 03 23 00) (9). The GO side (marked 0 ) should just still drop. If the GO side cannot be inserted, the bore of valve guide should be reamed. Notice: Perform the check only on cooled down cylinder head.
YAD1BH10
9. If necessary, ream the valve guide bore evenly with a reamer (Intake: 000 589 21 53 00, Exhaust: 000 589 10 53 00) (10). Notice: Never turn the reamer against the direction of rotation.
YAD1BH20
SSANGYONG Y200
VALVE SEAT RINGS

Preceding Work: Removal of valve Checking of valve guide, replace if necessary Removal of prechamber
YAD1BH30
1 2 A B
Cylinder Head Valve Seat Ring Height (Cylinder Head Upper / Lower Surface) Height (Cylinder Head Cover Surface / Seat of Valve Seat Ring)
D D1 D2 H
Valve Seat Ring Outer Diameter Valve Seat Ring Inner Diameter Basic Bore Diameter Height of Valve Seat Ring
Service Data
Item D2 D D1 H Overlap U=D-D2 B A Intake 40.000 - 40.016 mm 40.084 - 40.100 mm 33.400 - 33.600 mm 6.955 - 7.045 mm 0.068 - 0.100 mm 133.4 mm 142.5 mm Exhaust 37.000 - 37.016 mm 37.084 - 37.100 mm 30.400 - 30.600 mm 6.955 - 7.045 mm 0.068 - 0.100 mm 133.4 mm 142.5 mm
SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-109 Commercial Tools

Cylinder Head Clamping Device Hunger D-8000 Mnchen 70 Type Ventilknecht K2000 Order No. 221 00 100 Valve Seat Turning Tool Hunger D-8000 Mnchen 70 Type VDS 1A Order No. 236 03 308 Ring Seat Turning Tool Hunger D-8000 Mnchen 70 Type RDS 1 Order No. 219 00 100 Pneumatic Removal / Installation Device (Drift : 8 mm, 9 mm, 14 mm) Tensioning Head Hunger D-8000 Mnchen 70 Type PVM 1 Hunger D-8000 Mnchen 70 Order No. 250 15 250 Cutting Tool for Recessing Grooves Hunger D-8000 Mnchen 70 Order No. 217 93 601 Test Set for Valves Hunger D-8000 Mnchen 70 Order No. 216 69 210 Internal Dial Gauge (Range : 25 - 60 mm) Mahr D-7300 Esslingen Order No. 844 External Micrometer (Range : 25 - 60 mm) Mahr D-7300 Esslingen Order No. 40 S Electrically Heated Water Tank Otto Drr D-7123 Sachsenherm - Ochsenbach
SSANGYONG Y200

Tools Required 115 589 34 63 00 Mounting Device 345 589 00 63 00 Super Cooling Box
Removal Procedure
1. Measure dimension A . Limit 142.5 mm
2. Clamp the cylinder head with clamping device.
YAD1BH40
3. Cut groove into the valve seat ring so that dimension C is approx. 2 mm and dimension E is approx. 6 mm.
YAD1BH50
4. Remove the cylinder head from the clamping device and place it onto wooden blocks. 5. Remove the valve guide (3) by using a drift (Intake: 8 mm, Exhaust: 9 mm).
YAD1BH60
6. Insert the tensioning head (4) and extracted wedges(arrow) by turning the bolt (5). Notice: Carefully tighten the bolt (5) otherwise the valve seat ring in the cylinder head will be excessively tensioned. 7. Lock the bolt (5) with nut (6).
YAD1BH70
SSANGYONG Y200

8. Turn over the cylinder head. 9. Remove the tensioning head (4) and valve seat ring (2) with drift (14 mm) and removal tool. 10. Clean the basic bore of valve seat ring.
YAD1BH80
11. Measure the basic bore diameter (D2) and outer diameter (D) of the new valve seat ring (standard size). 12. Calculate the overlap value U (D - D2). Overlap Valve U 0.068 - 0.100 mm
Example) Measured value D = 37.100 mm Measured value D2 = 37.010 mm Overlap value U = 0.090 mm
YAD1BH90
If overlap value U is out of standard, machine the basic bore for the valve seat ring. 13. Clamp the cylinder head with clamping device. 14. Machining basic bore for valve seat ring (repair size). Notice: Maintain minimum value of B . - Machine the basic bore.
Limit
Max. D2 Intake Exhaust 40.516 mm 37.516 mm 133.4 mm
Min. B
YAD1BHA0
- Measure machined basic bore and outer diameter D of valve seat ring (repair size). - Measure the overlap U Overlap U (D - D2) 0.068 - 0.100 mm
Example) Measured value D = 37.600 mm Measured value D2 = 37.480 mm Overlap U = 0.120 mm
YAD1BHB0
The basic diameter D2 must be machined by 0.020 mm in order to get the required overlap value.
SSANGYONG Y200

15. Hang the cylinder head (1) to the lifting device and heat in a water tank to approx. 80C(176 F) with mounting device 115 589 34 63 00.
YAD1BGY0
16. Cool down new valve seat ring (2) into the cooling box 345 589 00 63 00 with liquid nitrogen. Notice: Do not touch the cooled valve seat rings with hand.
YAD1BHC0
17. Drive in new valve seat ring (2) with a proper wooden drift.
YAD1BHD0
18. Install the valve guide (3) with a proper drift (Intake: 8 mm, Exhaust: 9 mm) and assembling tool. Notice: The valve guide must be driven in from the cylinder head cover. 19. Machine the valve seats.
YAD1BHE0
SSANGYONG Y200
CAMSHAFT
Preceding Work: Removal of cylinder head cover
YAD1BHH0
1 2 3 4 5 6 7 8
Bolt ........................................... 25 N m (18 lb-ft) Washer Camshaft Bearing Cap Camshaft Dowel Pin Locking Washer Timing Chain Cylinder Head
9 10 11 12
Oil Pan Camshaft Sprocket Washer 12-Sided Bolt (M11) ................................. Check, 25 Nm (18 lb-ft)+ 90 13 Gasket ................................................... Replace 14 Chain Tensioner ....................... 80 N m (59 lb-ft)
SSANGYONG Y200

Removal Procedure
1. Rotate the crankshaft and position the piston of No.1 cylinder at TDC. Notice: Do not rotate the crankshaft in the opposite direction of engine rotation.
YAD1BC10
In this position, the markings of the camshaft/ camshaft bearing cap (arrow) must be aligned.
YAD1BC30
2. Place alignment marks on the camshaft sprocket and timing chain.
YAD1BC20
3. Remove the starter motor and install the engine lock 602 589 00 40 00.
YAD1BC40
SSANGYONG Y200

4. Remove the bolt and then remove the camshaft sprocket. Notice: During removal, be careful not to drop the sprocket with chain. Remove the chain carefully and then pull out the sprocket.
YAD1BC70
5. Remove the chain tensioner.
YAD1BC60
6. Remove the camshaft bearing cap bolts according to the removal order. Notice: Remove the camshaft bearing cap bolts of 1 first and then remove the bolts of 2 one revolution in stages until the counter-pressure is released. In order to avoid damaging the camshaft, it is essential to adhere to the removal order for the camshaft bearing caps.
YAD1BC80
7. Remove the camshaft bearing cap. 8. Pull off the camshaft. Notice: Be careful not to miss front locking washer.
YAD1BC90
SSANGYONG Y200

9. Pull out the locking washer. Notice: Check the condition of locking washer and replace if necessary.
YAD1BCM0
1. Insert the locking washer. 2. Check the valve tappet and ensure that tappet moves smoothly. 3. Coat the camshaft with oil and install the camshaft onto the cylinder head so that the TDC marking (arrow) is positioned upward vertically.
YAD1BCN0
4. Install the camshaft bearing caps according to markings(1, 2, 3 etc.).
YAD1BCP0
5. Tighten the camshaft bearing cap bolts acccording to installation order. Installation Notice Tightening Torque 25 N m (18 lb-ft)+ 90
Tighten the No. 1 bolts (light arrow) by one revolution in stages first and then tighten the No. 2 bolts (dark arrow).
YAD1BCQ0
SSANGYONG Y200

6. Install the camshaft sprocket to be aligned the markings of the camshaft / camshaft bearing cap (arrow). Notice: Align the alignment marks on the timing chain and sprocket.
YAD1BC30
7. Tighten the camshaft sprocket bolt. Installation Notice Tightening Torque 25 N m (18 lb-ft)+ 90
YAD1BC70
Notice: If max. length L of the 12-sided bolt exceeds 53.6mm, replace it.
YAD1BCS0
8. Install the chain tensioner. Installation Notice Tightening Torque 80 N m (59 lb-ft)
Replace the seal. Before installation, by pumping in the oil approx. 10 times, fill the oil.
YAD1BHJ0
SSANGYONG Y200

9. Remove the engine lock 602 589 00 40 00.
YAD1BC40
10. Check the TDC marking of OT on the crankshaft.
YAD1BC10
SSANGYONG Y200
TIMING CHAIN
Preceding Work: Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover
YAD1BHK0
1 Chain Link 2 Timing Chain
3 Camshaft Sprocket 4 Outer Plate
SSANGYONG Y200

Tools Required 000 589 58 43 00 Chain Assembling Device
1. Cover over the chain box with cleaning rag and grind off both chain pins (arrow) at a chain link (1) of the timing chain.
YAD1BHL0
2. Remove the outer plate (4) and chain link (1). Notice: Ensure that the ends of the timing chain do not drop into the chain box.
YAD1BHM0
3. Loosen the chain tension with approx. 4 turns. 4. Connect the new timing chain (arrow) with chain link (1) to the old timing chain (2).
YAD1BHN0
5. By rotating the crankshaft in the of engine rotation, pull out the old timing chain with installing the new timing chain. 6. Remove the old timing chain and hold the ends of the new timing chain to camshaft sprocket (3) with wire (arrow).
YAD1BHP0
SSANGYONG Y200

7. Insert the new chain link (1) to connect the chain.
YAD1BHQ0
8. Insert the new outer plate (4) into the chain assembling device 000 589 58 43 00 tool (8) and then the outer plate will be held by a magnet.
YAD1BHR0
9. Place the chain assembling device 000 589 58 43 00 (8) onto the chain link and press the outer plate on as far as the stop.
YAD1BHS0
10. Switch over the die (9) of the chain assembling device 000 589 58 43 00 (8).
YAD1BHT0
SSANGYONG Y200

11. Place the fitting tool (8) onto the chain link and rivet the chain pins one by one. Tightening Torque 35 - 40 N m (20 - 30 lb-ft)
YAD1BHS0
12. Check the riveting of chain pins and re-rivet if necessary. 13. Remove the wire.
YAD1BHL0
14. Position the no.1 cylinder at TDC.
YAD1BC10
Notice: In this position, the marking on camshaft / camshaft bearing cap (arrow) must also be aligned. If the markings are not aligned, the timing chain must be re-set and the injection pump timing has to be set.
YAD1BC30
SSANGYONG Y200
CHAIN TENSIONER
YAD1BHU0
1 Chain Tensioner ....................... 80 N m (59 lb-ft)
2 Seal ........................................................ Replace
SSANGYONG Y200

Notice: Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill. Faulty chain tensioners should be replaced completely.
YAD1BHV0
3 4 5 6 7 8 9 10
Screw Plug Aluminum Gasket Ball Ball Guide Compression Spring Compression Spring Housing Thrust Pin
11 12 13 14 15
Valve Disc O-Ring Snap Ring Compression Spring Filler
a Feed Bore from Cylinder Head b To Oil Pan
SSANGYONG Y200
LUBRICATION SYSTEM
OIL FILTER
YAD1BHW0
1 2 3 4
Housing Cap ............................ 25 N m (18 lb-ft) O-Ring .................................................... Replace Oil Filter ............... Element replace if necessary Oil Filter Housing
5 Bolt ........................................... 25 N m (18 lb-ft) 6 Oil Pressure Switch 7 Gasket
SSANGYONG Y200

1. Disconnect the oil cooler inlet and outlet hoses.
YAD1BHX0
2. Remove the oil pressure switch line. 3. Remove the oil filter housing bolts and oil filter housing. Installation Notice Tightening Torque 25 N m (18 lb-ft)
4. Clean the sealing surface. 5. Installation should follow the removal procedure in the reverse order.
YAD1BHY0
SSANGYONG Y200
OIL SPRAY NOZZLE
YAD1BHZ0
1 Fitting Sleeve 2 Oil Spray Nozzle
3 Combination Bolt ................... 10 N m (89 lb-in) a Oil Duct

1. Remove oil pan or crankshaft. 2. Loose the bolt and then remove the nozzle. Installation Notice Tightening Torque 10 N m (89 lb-in)
YAD1BJ00
SSANGYONG Y200
OIL PUMP
YAD1BJ10
1 2 3 4
Oil Pump Bolt ........................................... 25 N m (18 lb-ft) Sprocket Poston
5 6 7 8
Pressure Spring Guide Pin Screw Plug ............................... 50 N m (37 lb-ft) Bolt ........................................... 25 N m (18 lb-ft)

1. Removae the bolt from the oil pump drive sprocket and separate the gear and the oil pump drive chain. Installation Notice Tightening Torque 25 N m (18 lb-ft)
YAD1BJ20
SSANGYONG Y200

2. Remove the oil pump mounting bolts and oil pump. Installation Notice Tightening Torque 25 N m (18 lb-ft)
YAD1BJ30
3. Unscrew the screw plug and remove the relief valve. Installation Notice Tightening Torque 50 N m (37 lb-ft)
SSANGYONG Y200
UNIT REPAIR
MILLING OF PRECHAMBER SEALING SURFACE
YAD1BJ40
1 Drift 2 Sleeve 3 Milling Cutter
4 Counter Sink (Special Tool - 601 589 00 66 00) 5 Cylinder Head
Notice: The prechamber sealing surface may only be remachined once with the cylinder head fitted. It is essential to adhere to the specified projection C of the prechamber of 7.6 - 8.1mm. This ensures that the required clearance exists between prechamber and piston crown with the piston in TDC. For this reason, spacer rings should be inserted on remachined sealing surfaces. Thickness of spacers 0.3, 0.6, 1.0 mm
If a spacer ring is already fitted, or a marking is made on the cylinder head, the cylinder head must be removed and size C measured if further remachining is necessary on a prechamber sealing surface.
SSANGYONG Y200

Tools Required 601 589 00 66 00 Counter Sink 607 589 00 23 00 Height Gauge
Milling of the Prechamber Sealing Surface

1. Remove the injection nozzle. 2. Remove the prechamber. 3. Cover the prechamber bore to avoid any chips dropping into the combustion chamber. 4. Remove the protective sleeve from the counter sink 601 589 00 60 00 and rotate the counter sink 601 589 00 60 00 into the prechamber bore to be machined as far as the stop. 5. Maintain size X from the top edge of mandrel to the top edge of the sleeve with the height gauge 667 589 00 23 00.
YAD1BJ50
YAD1BJ60
6. Measure the X by using a vernier caliper.
YAD1BJ70
7. Mount the turning tool onto the counter sink 601 589 00 60 00 and rotate to the right approx. 5 revolutions by applying slight pressure.
YAD1BJ80
SSANGYONG Y200

8. Remeasure size X and compare it with the first measurement and determine the thickness of spacer ring. Ex Size before machining Size after machining 25.7 mm 25.5 mm
The spacer ring should be selected so that it is at least 0.1 mm and not more than 0.3 mm thicker than the measured on the sealing surface. In this example, the necessary thickness of spacer ring should be within 0.3 ~ 0.5 mm and the thickness of spacer ring to be installed is 0.3 mm. 9. Remove the counter sink 601 589 00 60 00 and clean the chips. Notice: If the sealing surface is not completely flat, remachine the sealing surface. 10. Remove rag from the prechamber bore and crank the engine with starter motor to threw out any chips which may have got into the combustion chamber. 11. Insert the proper spacer ring into the prechamber sealing surface.
12. Punch a mark on the cylinder head above the prechamber sealing surface which has been machined.
YAD1BJ90
1 3. Install the prechambers.

Notice: If the cylinder head is removed, the projection C is measured in place of size X and the appropriate size of spacer ring selected. Normal Projection (C) 7.6 - 8.1 mm
YAD1BJA0
SSANGYONG Y200
SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTS
Description and Operation ................................... 2C-2 Front Suspension ................................................. 2C-2 Specifications ...................................................... 2C-4 Component Locator ............................................. 2C-5 Front Suspension Assembly ................................. 2C-5 Cross-Sectional View ........................................... 2C-6 Suspension Assembly ......................................... 2C-6 Shock Absorber ................................................... 2C-7 Diagnostic Information and Procedures ................ 2C-8 Repair Instructions ................................................ 2C-9 On-vehicle Service ............................................... 2C-9 Stabilizer ........................................................... 2C-11 Shock Absorber Assembly ................................ 2C-12 Upper/Lower Arm Assembly .............................. 2C-14 Unit Repair .......................................................... 2C-16 Front Coil Spring ................................................ 2C-16 Hub and Bearing ............................................... 2C-18 Special Tool and Equipment.............................. 2C-20 Special Tools Table ........................................... 2C-20
2C-2 FRONT SUSPENSION

FRONT SUSPENSION
Shock Absorber
This vehicle is applied to the strut type and the telescopic double tube type. The shock absorber is connected to the piston rod in the strut. Positioned between the car body and the tire, acts with coil springs to insure a smooth ride ; dampens vibrations and improves driving stability and controllability by pressing the tires against the road surface.
YAD2C010
1. Front suspension type : Double Wishbone 2. Component Knuckle, upper arm assembly, lower arm assembly, coil spring, shock absorber assembly, stabilizer. The front suspension is a combination strut and spring design, with the control arms that pivot from the engine frame. The frame has isolation mounts on the body and a conventional rubber bushing is used on the lower control arm pivot. The front lower control arm bushing is mounted horizontally. The upper end of the strut is isolated by a rubber mount which contains a bearing to allow for wheel turning. The lower end of the steering knuckle pivots on a ball joint riveted to the control arm. The ball joint is fastened to the steering knuckle with a castellated nut and cotter pin.
YAD2C020
The telescopic shock absorber is consist of the tube with the piston and the rod, and the other cylinder tube. The piston section has the orifice and valve and the cylinder is filled fully with oil. This double tube type enables to control the vibration properly because oil resistance forces are generated on compression and expansion of shock absorber. Thus, this double type is better than the mono tube type regarding the driving safety.
Stabilizer
If the spring with lower spring constant is applied on the vehicle in order to increase the ride comfort, the vehicles slope increases on turning due to the centrifugal force. Because its trend increases for the independent suspension system, the stabilizer bar should be applied to the system in order to make a balance the vehicle. The stabilizer bar is the type of the torsion bar and the both end of the stabilizer bar are connected to the control bar, the center of the stabilizer bar is mounted to the body frame.
Coil Spring
The coil spring is made by winding solid steel rod to form the coil shape. Its energy absorption rate per weight is higher than that of the leaf spring and it allows to absorb little vibration properly resulted in keeping the ride comfort. Therefore, its difficult to make a effect on vibration damping because there is not any friction between coils.
YAD2C030
SSANGYONG Y200
FRONT SUSPENSION 2C-3

Upper/Lower Arm Assembly
YAD2C040
The lower arm assembly mounts the shock absorber with bushings in order to support the load delivered from the spring , the shock absorber and the bumper. The upper arm also supports the load delivering to the knuckle. This assembly enables to absorb the various shock and to ensure the driving safety.
SSANGYONG Y200
SPECIFICATIONS
Application Suspension System Spring Type Shock Absorber Stabilizer Wheel Alignment Toe-In Camber Caster Specification Double Wishbone Coil spring Telescopic Double Tube Type(GAS) Torsion Bar Type 2 2 mm 0 30 (Both side difference must be below 30) 2 45 30 (Both side difference must be below 30)
SSANGYONG Y200
COMPONENT LOCATOR
FRONT SUSPENSION ASSEMBLY
YAD2E050
1 2 3 4
Stabilizer Bar Cam bolt Lower arm Yoke
5 6 7 8
Stabilizer Bar Link Knuckle Upper arm Shock Absorber Assembly (Including coil spring)
SSANGYONG Y200
CROSS-SECTIONAL VIEW
SUSPENSION ASSEMBLY
YAD2C060
SSANGYONG Y200
SHOCK ABSORBER
YAD2C070
1 2 3 4 5 6 7 8 9
Lower Spring Sheet Yoke Bracket Rebound Stopper Cylinder Piston Shock-Absorber assembly Spring Yoke Boot
10 11 12 13 14 15 16 17 18
Bump Stopper Spring Sheet Rubber Upper Spring Sheet Rubber Rubber Spacer Washer Nut Bolt
SSANGYONG Y200
DIAGNOSTIC INFORMATION AND PROCEDURES

Symptom Vehicle Rolling Abnormal Noises Possible Cause Broken Stabilizer Bar Faulty Shock Absorber Loosening Mountings Damaged or Worn Wheel Bearing Damaged Shock Absorber Damaged Tire Poor Riding Over Inflated Tire Faulty Shock Absorber Loosened Wheel Nut Bent or Broken Coil Spring Damaged Tire Worn Bushing Vehicle Pulls to Right or Left Deformed Arm Assembly Worn Bushing Bent or Broken Coil Spring Hard Steering Incorrect Front Wheel Alignment Excessive Resistance of Lower Arm Ball Joint Insufficient Tire Pressure Faulty Power Steering Steering Instability Incorrect Front Wheel Alignment Worn or Loosened Lower Arm Bushing Vehicle Bottoming Worn or Broken Coil Spring Replace Adjust Repair or Replace Repair Re-Tighten or Replace Replace Replace Re-Tighten Replace Replace Replace Pressure Adjust Replace Tighten as specified torque Replace Replace Replace Replace Replace Replace Repair Replace Action
SSANGYONG Y200
YAD2C080
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Nut Nut Washer Rubber Bushing Upper Spring Sheet Rubber Spring Sheet Rubber Boot Boot Spring Shock Absorber Lower Spring Sheet Yoke 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Nut Bolt Bolt Bolt Bushing Nut Upper Arm Nut Bushing Washer Bolt Lower Arm Bushing Bushing
SSANGYONG Y200
STABILIZER
Removal Procedure
1. Remove the skid plate at front bottom side.
YAD2C090
2. Remove the upper mounting nut and the lower mounting nut from the front stabilizer bar link. Remove the front stabilizer bar link.
YAD2C100
3. Remove the mounting cap bolt from the front stabilizer bar and remove the front stabilizer bar.
YAD2C110
1. Install the front stabilizer bar to the frame and tighten manually the stabilizer bar mounting cap bolt. It allows the bar link to install to its original position. Installation Notice Tightening Torque 60 - 80 N m (44 - 59 lb-ft)
YAD2C120
SSANGYONG Y200

2. Install the bra link between the stabilizer bar and the lower arm and tighten the mounting nut as the specified torque. Installation Notice Tightening Torque (1) 110 - 120 N m (2) 110 - 130 N m
YAD2C130
3. Install the front stabilizer bar and the skid plate. Installation Notice Tightening Torque 35 N m (26 lb-ft)
YAD2C140
SHOCK ABSORBER ASSEMBLY

Removal Procedure
1. Remove three upper nuts from the shock absorber assembly.
YAD2C150
2. Remove the yoke mounting pin nut at the lower arm and the yoke mounting pin.
YAD2C160
SSANGYONG Y200

3. Remove the shock absorber and coil spring assembly. Separate the lower yoke mounting bolt and the yoke. 4. Remove the shock absorber yoke.
YAD2C170
5. Separate the shock absorber assembly with pushing down the lower arm.
YAD2C180
1. Install the coil spring(shock absorber) assembly and the yoke to the body. And then install the lower shock absorber into the yoke hole and insert the upper shock absorber to bolt hole by tightening the nut manually. Installation Notice Tightening Torque 40 - 60 N m (30 - 44 lb-ft)
YAD2C190
2. Tighten bolts of the shock absorber assembly and yoke. Be careful to tightening direction of the bolt as shown.(See the arrow). Installation Notice Tightening Torque 60 - 70 N m (44 - 52 lb-ft)
YAD2C200
SSANGYONG Y200

3. Fix the shock absorber yoke at the lower arm bolt hole and insert to tighten the yoke mounting pin to the hole. Installation Notice Tightening Torque 150 - 180 N m
YAD2C210
UPPER/LOWER ARM ASSEMBLY

Removal Procedure
Notice: Perform the pre-work before the removal procedure. Remove the shock absorber. Remove the steering knuckle by referring the steering section. 1. Remove the mounting nut (slotted nut) and the split pin (cotter pin) from the upper/lower arm ball joint.
YAD2C220
Notice: Separate the ball joint from the steering knuckle using the special tool as shown.
YAD2C230
2. Remove mounting bolts and nuts of the upper arm/ frame bracket (both front and rear) and separate the upper arm.
YAD2C240
SSANGYONG Y200

3. Remove mounting bolts and nuts of the lower arm (both front and rear) and separate the lower arm.
YAD2C250
1. Install the lower arm to the frame bracket and tighten the mounting bolt and nut as the specified torque. Notice : Tighten the bolt on the direction from rear side to front side of the vehicle. Fix the bolt center with the bracket indication. Installation Notice Tightening Torque
YAD2C260
160 - 170 N m
2. Install the upper arm to the frame bracket. Installation Notice Tightening Torque 110 - 130 N m
YAD2C270
3. Install the knuckle assembly to the shaft and insert the ball joint of the upper/lower arm. And then tighten the slotted nut and split pin. Installation Notice Slotted nut Tightening Torque Upper side (1) Lower side (2) 110 - 120 N m 110 - 130 N m
YAD2C280
SSANGYONG Y200
UNIT REPAIR
FRONT COIL SPRING
Removal Procedure
1. Remove the front coil spring assembly. 2. Fix the special tool to the coil spring assembly as shown and compress the coil spring. Notice: Install the special tool to the coil spring tightly not to separate it during work and be careful to spring end portion should look forward to the person during compressing the coil spring. 3. Remove the shock absorber mounting nut and remove the lock nut of the special tool in order to separate the shock absorber.
YAD2C290
YAD2C300
4. Remove the coil spring components in specified disassemble order. Notice: Be careful to cause the spring elasticity to any personal injury when it is separated the special tool from the coil spring.
YAD2C310
SSANGYONG Y200
1. Compress the coil spring as the specified torque and install the related components. And then tighten the lock nut. Installation Notice Length at compression Tightening torque of lock nut 334 N m 25 - 40 N m (18 - 30 lb-ft)
Notice: Be careful to the installation direction for installing the coil spring.
YAD2C320
Note: When it s difficult to tighten the nut as specified torque, fix the length from upper lock nut to bolt end to 23 ~ 24 mm.
2. Check the coil spring installation. Check the installation direction of the coil spring. Verify that the coil spring is installed onto the spring sheet correctly.
YAD2C330
SSANGYONG Y200

Notice: One of the upper bracket bolts should coincide with the lower yoke insert projection as shown.
YAD2C340
HUB AND BEARING

Disassembly/Assembly (Part time)
1. Remove the front hub and bearing assembly. 2. Remove the outer bearing (1) and inner seal. Notice: Always use a new part as replacing inner seal. 3. Remove the inner bearing (2).
YAD2C350
4. Remove the inner bearing race.
YAD2C360
5. Remove the outer bearing race.
YAD2C370
SSANGYONG Y200

Notice: Install the outer bearing race using the front outer bearing race installer and handle.
YAD2C380
Install the inner bearing race using the front inner bearing race installer and handle
6. Installation should follow the removal procedure in the reverse order
YAD2C390
SSANGYONG Y200

SPECIAL TOOLS TABLE
DW340 - 050 Sliding Hammer
661 589 13 33 00 Ball joint remover
YAD2C400
YAD2C440
DW 340 - 060 Front hub cap remover/ installer
DW 340 - 021 - 01 Handle
YAD2C410
YAD2C450
DW340 - 070 Front hub flange remover
DW 340 - 021 - 02 Front inner bearing race installer
YAD2C420
YAD2C460
661 589 01 07 00 Front hub adjust nut remover/installer
DW 340 - 021 - 03 Front outer bearing race installer
YAD2C430
YAD2C470
SSANGYONG Y200
SECTION 2D
REAR SUSPENSION
TABLE OF CONTENTS
Description and Operation ................................... 2D-2 Rear Suspension ................................................. 2D-2 Specifications ...................................................... 2D-3 Component Locator ............................................. 2D-4 Rear Suspension Assembly ................................. 2D-4 Shock Absorber ................................................... 2D-5 Diagnostic Information and Procedures .............. 2D-6 Rear Suspension ................................................. 2D-6 Wheel Bearing End Play ...................................... 2D-7 Wheel Bearing Free load ...................................... 2D-7 Repair Instructions ................................................ 2D-8 On-Vehicle Service ............................................... 2D-8 Rear Suspension Assembly ................................. 2D-9 Special Tools and Equipment ............................ 2D-16 Special Tools Table ............................................ 2D-16
2D-2 REAR SUSPENSION

REAR SUSPENSION
The rear suspension system is to keep the ride comfort or safety and this vehicle is applied to 5 link suspension system. This system consists of both coil spring, upper/lower arm, the lateral rod, stabilizer, connecting rod and bumper.
1. Stabilizer:
It enables to keep the balance on turning and to minimize the vehicles slope when both right and left wheels move differently.
2. Lateral Rod:
It allows to control the load at the lateral direction.
3. Upper/Lower Arm:
It allows to control the load at the front/rear direction side.
4. Shock Absorber:
It allows to absorb the vibration at the vertical direction in order to make ride comfort feel better and reduce the spring fatigue.
5. Coil Spring:
YAD2D010
It is installed between the rear axle and body frame. This unit enables to release any shock or any vibration from tires in order to prevent its force from delivering to the body.
SSANGYONG Y200
REAR SUSPENSION 2D-3
SPECIFICATIONS
Suspension Type Spring Type Stabilizer Type Shock Absorber Type Max. Length Min. Length Engine Type Coil O.D. Coil I.D(A) Free-load Height(B) Compression Height(C) O.D(D)
YAD2D020
5 Links (Two Upper Arm, Two Lower Arm, One Lateral Rod) Coil Spring Torsion Bar Type Telescopic Double Tube Type 495 mm 308 mm GSL 3.2, DSL(A/T) 13.1 mm 114 mm 405.7 mm 260.0 mm 127.1 mm 2.45 5% DSL(M/T) 13.0 mm 114 mm 386.8 mm 250.0 mm 127.0 mm 2.45 5%
Constant
SSANGYONG Y200
COMPONENT LOCATOR
REAR SUSPANSION ASSEMBLY
YAD2D030
1 2 3 4 5
Coil Spring Seat(upper) Coil Spring Lateral Rod Shock Absorber Upper arm(link)
6 7 8 9
Lower Arm (link) Stabilizer Link Stabilizer Pump Stopper
SSANGYONG Y200
SHOCK ABSORBER
YAD2D040
SSANGYONG Y200

REAR SUSPENSION
Symptom Vehicle Rolling. Abnormal Noises Possible Cause Broken Stabilizer Bar Faulty Shock Absorber Loosening Mountings Damaged or Worn Wheel Bearing Damaged Shock Absorber Damaged Tire Poor Riding Over Inflated Tire Faulty Shock Absorber Loosened Wheel Nut Bent or Broken Coil Spring Damaged Tire Worn Bushing Vehicle Pulls to Right or Left Deformed Arm Assembly Worn Bushing Bent or Broken Coil Spring Hard Steering Excessive Resistance of Lower Arm Ball Joint Insufficient Tire Pressure Faulty Power Steering Steering Instability Vehicle Bottoming Worn or Loosened Lower Arm Bushing Worn or Broken Coil Spring Replace Replace Adjust Re-Tighten or Replace Replace Replace Re-Tighten Replace Replace Replace Pressure Adjust Replace Tighten as specified torque Replace Replace Replace Replace Replace Replace Replace Action
SSANGYONG Y200
WHEEL BEARING END PLAY

1. Release the parking brake. 2. Raise rear tires. 3. Inspect the wheel bearing end play by shaking the tire up & down. Rear wheel bearing end play 0 mm
YAD2D050
4. If the wheel bearing end play is excessive, retighten the castle nut. 5. If the wheel bearing end play continues to be excessive, replace the wheel bearing.
WHEEL BEARING FREE LOAD

1. Release the parking brake. 2. Raise rear tires and rotate the tire repeatedly. 3. Remove the tire. 4. Hang the measuring tool to the hub bolt and measure the free load at the drum starts to rotate. 5. Check the free load of the rear wheel bearing within the specified value. Specified free load
YAD2D060
1.4 ~ 4.3 kg.cm
6. Retighten the castle nut as specified torque when the measured value is not within the specified value. 7. Replace the wheel bearing as needed.
SSANGYONG Y200
YAD2D070
1 2 3 4 5
Rear Suspension Assembly Rubber Upper Arm Lower Arm Stabilizer Link
6 7 8 9
Stabilizer Coil Spring Shock Absorber Lateral Rod
SSANGYONG Y200
REAR SUSPENSION ASSEMBLY

Removal Procedure
1. Support the rear axle housing bottom safely using the jack and fix the front wheel as shown.
YAD2D080
2. Remove the mounting nut of the lower link connected the stabilizer bar and separate the stabilizer bar.
YAD2D090
3. Remove the mounting cap bolt retaining both end of the stabilizer bar and remove the stabilizer bar, the mounting cap and the bushing.
YAD2D100
4. Remove the upper mounting nut of the link with the stabilizer bar removed and remove the link.
YAD2D110
SSANGYONG Y200

5. Remove the lateral rod mounting nut by retaining the frame.
YAD2D120
6. Remove the lateral rod mounting nut by retaining the axle and remove the lateral rod assembly.
YAD2D130
7. Remove the lower nut of the shock absorber.
YAD2D140
8. Remove the upper nut and remove the shock absorber
YAD2D150
SSANGYONG Y200

9. Remove the bolt and nut retaining the frame.
YAD2D160
10. Remove the upper bolt and nut retaining the axle and remove the upper arm.
YAD2D170
11. Remove the lower arm mounting the frame.
YAD2D180
12. Remove the lower arm mounting bolt & nut retaining the axle and then remove the lower arm.
YAD2D180
SSANGYONG Y200

13. Loosen the brake & hose and remove the spring by pushing to incline the rear axle.
YAD2D190
14. Remove the mounting nut of the shock absorber bottom and the upper arm. And then remove the spring.
YAD2D200
1. Installation should follow the removal procedure in the reverse order. 2. Be careful to the installation direction of the coil spring to install the spring correctly. Notice: 1. Be careful that the diameter of the upper coil spring is longer than that of the lower s. 2. Verify that the coil spring should be installed onto the spring seat of the axle and body(frame) correctly.
YAD2D210
SSANGYONG Y200

3. Insert the upper side of the shock absorber to the frame and tighten nuts manually. And then install the lower sides to the axle and tighten nuts as specified torque. Installation Notice Tightening Torque : 30 - 45 Nm (22 - 33 lb-ft) Upper side (1) Tightening Length : 6 - 9 mm Lower side (2)
YAD2D220
Tightening Torque : 50 - 65 Nm (37 - 48 lb-ft)
4. Install the upper arm to the frame bracket and the axle. And then tighten bolts as specified torque. Installation Notice Tightening Torque(frame(1)) Tightening Torque(axle(2)) 165 N m 165 N m
YAD2D230
5. Install the lower arm to the frame bracket and the axle. And then tighten bolts as specified torque. Installation Notice Tightening Torque(frame(1)) Tightening Torque(axle(2)) 165 N m 165 N m
YAD2D240
6. Install the lateral rod to both the frame and axle side. Installation Notice Tightening Torque(frame(1)) Tightening Torque(axle(2)) 165 N m 165 N m
YAD2D250
SSANGYONG Y200

7. Install the connecting rod to the frame bracket. Notice: Follow the tightening length for installing the nut. Installation Notice Tightening Torque Tightening Length(A) 38 N m (28 lb-ft) 7 - 12 mm
YAD2D260
8. Install the stabilizer bar to the axle bracket with the mounting cap and connect the bar with the connecting rod. And then tighten the mounting cap bolt and nut as specified torque. Installation Notice Tightening Torque 30 - 45 N m (22 - 33 lb-ft)
YAD2D270
9. The rubbers installation should follow the connecting order of the link rubber(packing). Notice: Always replace a new part when there is any wear or damage in the lever.
10. Check the shock absorber for any damage, oil leakage or abnormal noise.
YAD2D280
SSANGYONG Y200

Notice: For scrapping the gas shock absorber, drill the hole in the A section with the shock absorber full expansion and discharge the gas.
YAD2D290
SSANGYONG Y200

SPECIAL TOOLS TABLE
661 589 12 33 00 Rear spring compressor
Torque Wrench
YAD2D300
YAD2D310
SSANGYONG Y200
SECTION 2E
TIRES AND WHEELS

TABLE OF CONTENTS
Description and Operation ................................... 2E-2 General ............................................................... 2E-2 Tires Abnormal Action ........................................ 2E-3 Wheel Alignment ................................................. 2E-4 Specifications ...................................................... 2E-5 Diagnostic Information and Procedures .............. 2E-6 General Inspection ............................................... 2E-7 Inspection the Appearance .................................. 2E-7 General Inspection .............................................. 2E-9 Component Locator ........................................... 2E-12 Tire and Wheel Assembly .................................. 2E-12 Repair Instructions .............................................. 2E-13 ON-Vehicle Service ............................................... 2E-13 General Tire ....................................................... 2E-13 Spare Tire .......................................................... 2E-14 Maintenance and Replacement ........................ 2E-15 Separation ......................................................... 2E-15 Maintenance ...................................................... 2E-16 Installation ......................................................... 2E-17
2E-2 TIRES AND WHEELS

GENERAL
Tire And Wheel Balancing
There are two types of the tire and wheel balancing: static and dynamic. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called wheel tramp. This condition may eventually cause uneven tire wear. Dynamic balance is the equal distribution of weight on each side of the centerline so that when the assembly spins there is no tendency for it to move from side to side. Assemblies that are dynamically unbalanced may cause wheel shimmy. 2. Breaker A cord belt between tread and carcass prevents damages of inner code due to outer shock and vibration. 3. Carcass This major part made by pilling code papers of strong synthetic fiber forms a structure of tire. Since it maintains tire pressure and endures applied load and shock to tire, it should have a high anti-fatigue characteristic. 4. Side Wall It is provided to improve the comfortable driving by protecting carcass and cushion movement. 5. Bead A steel wire winding the ending part of carcass code, coated with rubber film and wrapped with nylon cord papers. It fixes tire to a rim.
General Balance Precautions

Remove all deposits of foreign material from the inside of the wheel. Caution: Remove stones from the tread in order to avoid operator injury during spin balancing. Inspect the tire for any damage. Balance the tire according to the equipment manufacturers recommendations.
Structure of Tubeless Tube
YAD2E010
The tire structure is different slightly according to the types of the tire but a various type of the tire has the common structure as following; 1. Tread A part (that contacts) road surfaces directly is fixed on the outsude of carcass and breaker. It is a strong rubber coat made of high anti-abrasion rubber. Its running performance depends on is surface profile.
YAD2E020
SSANGYONG Y200
TIRES AND WHEELS 2E-3 Convention for Radial Tire

P 225 / 75 R - 15 102 T
The Relation Between Load and Tire
Max Speed : 190 km/h Load Index : 850 kg Rim Diameter : 15 inch. Radial Tire Aspect Ratio = (Section Height Section Width) x 100 : 75 % Section Width : 225 mm Passenger Car
YAD2E040
TIRES ABNORMAL ACTION

Standing Wave
Load Index Symbol 94 95 96 97 98 99 100 101 102 103 104 105 Limit Speed (km/h) 670 690 710 730 750 775 800
YAD2E050
Max Speed Symbol Symbol F M N P Q R S T U H V Z Limit Speed (km/h) 80 130 140 150 160 170 180 190 200 210 240 Above 240
825 850 875 900 925 During running the rotating tire repeats deformation and restoring movement generated in tread. But when the wheel rotating speed reaches high, the next deformation applied to tire before restoring last deformation so the trembling wave appears in the tread portion. The lower the tire pressure the severe the trembling wave appears during the high speed.
The Relation Between Inflation Pressure and Tire
Hydroplaning
YAD2E030
YAD2E060
SSANGYONG Y200

The condition of driving a vehicle fast on the road surface covered with water can cause tires to fail to rotate with a good contact on the surface, so results in remaining them a float. This is so-called hydroplaning. It causes brake failure, lower tractive force and losing the steering performance so it is very vulnerable condition.
Camber
WHEEL ALIGNMENT
The first responsibility of engineering is to design safe steering and suspension systems. Each component must be strong enough to with stand and absorb extreme punishment. Both the steering system and the front and the rear suspension must function geometrically with the body mass. The steering and suspension systems require that the front wheels self-return and that the tire rolling effort and the road friction be held to a negligible force in order to allow the customer to direct the vehicle with the least effort and the most comfort. A complete wheel alignment check should include measurements of the rear toe and camber.
YAD2E080
Toe-in
Camber is the tilting of the top of the tire from the vertical when viewed from the front of the vehicle. When the tires tilt outward, the camber is positive. When the tires tilt inward, the camber is negative. The camber angle is measured in degrees from the vertical. Camber influnces both directional control and tire wear. If the vehicle has too much positive camber, the outside shoulder of the tire will wear. If the vehicle has too much negative camber, the inside shoulder of the tire will wear. Camber is measured in degrees and is not adjustable.
Caster
YAD2E070
Toe-in is the turning in of the tires, while toe-out is the turning out of the tires from the geometric centerline or thrust line. The toe ensures parallel rolling of the wheels. The toe serves to offset the small deflections of the wheel support system which occur when the vehicle is rolling forward. The specified toe angle is the setting which achievesdegrees 0 of toe when the vehicle is moving. Incorrect toe-in or toe-out will cause tire wear and reduced fuel economy. As the individual steering and suspension components wear from vehicle mileage, additional toe will be needed to compensate for the wear. Always correct the toe dimension last.
YAD2E090
Caster is the tilting of the uppermost point of the steering axis either forward or backward from the vertical when viewed from the side of the vehicle. A backward tilt is positive and a forward tilt negative. Caster influences directional control of the steering but does not affect tire wear. Weak springs or overloading a vehicle will affect caster. One wheel with more positive caster will pull toward the center of the car. This condition will cause the car to move or lean toward the side with the least amount of positive caster. Caster is measures in degrees and is not adjustable.
SSANGYONG Y200
TIRES AND WHEELS 2E-5
SPECIFICATIONS
Wheel Size Wheel Nut Tightening Torque Tire Type Inflation Pressure (psi) Aluminum Type Steel Type Aluminum Wheel Steel Wheel Radial Tire P225/75R15 P235/70R16 P255/65R16 Wheel Alignment Toe-in Camber Caster 2 2 mm 0 30 (Below 30' the difference between right and left) 2 45 30 (Below 30' the difference between right and left) 7JJ x 16 6.5JJ x 16 8 - 12 kgf.m 11 - 13 kgf.m Radial Tire 30 psi 30 psi 30 psi
SSANGYONG Y200

Condition Irregular tires wear Cause Improper tire inflation pressure Poor wheel balance Improper tire rotation Poor toe-in Poor adjusting the pre-load of the wheel bearing Poor braking performance Driving noise, Vibration Low tire inflation pressure Poor balance of wheels, tires Severe vibration due to wheels, tires Irregular tires wear Rapid wear Excessive tire inflation pressure High speed driving with low tire pressure Excessive vehicle weight Action Adjust Adjust Rotation tires on the maintenance schedule Adjust Adjust Adjust Adjust Adjust Adjust or replacement Check and adjust Adjust Adjust Proper weight
SSANGYONG Y200
GENERAL INSPECTION
INSPECTION THE APPEARANCE
Condition Rapid wear at shoulders Cause Under inflation or lack of rotation Action Adjust inflation pressure
YAD2E100
YAD2E110
Rapid wear at center
Over inflation or rotation
YAD2E120
YAD2E130
Tread damage
Low the inflation pressure
YAD2E140
YAD2E150
Uneven wear
Incorrect camber Incorrect toe-in
Adjust camber
YAD2E160
YAD2E110
SSANGYONG Y200
2E-8 TIRES AND WHEELS Inspection The Appearance (Contd)

Condition Feathered edge Incorrect toe-in Cause Action Adjust toe-in
YAD2E170
YAD2E180
Bold spot
Unbalanced wheel
Adjust wheel balance
YAD2E190
YAD2E200
Sharply wear at the tread outside
Unbalanced wheel Wheel bearing play
Adjust Check play Check pre-load
Ball joint play

YAD2E210
Check Check
Faulty shock absorber
SSANGYONG Y200
GENERAL INSPECTION
Inspection Tread
Inspect the tread condition on the tire surface and various damages resulting from the foreign material, crack, stone or nail etc. If there is any damage in the tire, repair or replace it.
Tire Wear
Measure the depth of the tire tread. If the depth of the tread is below the specified value, replace the tire. Limit of the Tread Wear 1.6 mm (0.06 in.)
You can see the mark in the groove, this is the indicator of the tread wear limit. The limit of the tread wear for all season tires are 1.6 mm as same as the general tires and the platform mark indicates as .
YAD2E220
Inspection the Inflation of Tires

1. Inflation pressure Front/Rear 2.1 kg/cm2 (30 psi)
YAD2E230
2. Inspect the pressure of the tire surface and check the inflation pressure. Notice: Lower than recommended pressure can cause tire squeal on turns, hard steering, tire cord breakage and tire rim bruises, etc. Higher than recommended pressure can cause hard ride, tire bruising or damage and rapid tread wear at the center of the tire.
YAD2E240
SSANGYONG Y200
Inspection Wheel Runout
Measure wheel runout with an accurate dial indicator. Measurement may be taken with the wheels either on or off the vehicle, using an accurate mounting surface such as a wheel balancer. Measurements may be taken with or without the tire mounted on the wheel. 1. Measure the dial runout and lateral runout on both the inboard and outboard rim flanges. Specification Steel Wheel
YAD2E250
Radial runout : 0.8 mm (0.03 inch) Lateral runout : 1.0 mm (0.04 inch)
Alloy Wheels Radial runout : 0.8 mm (0.03 inch) Lateral runout : 1.0 mm (0.04 inch)
2. Measure free radial runout on the tire tread. Specification Steel and Alloy Wheels Free radial runout : 1.5 mm (0.06 inch) Free lateral runout : 1.5 mm (0.06 inch) Notice: If any measurement exceeds the above specifications, replace the applicable tires or wheels.
Wheel Balance
Balance is the easiest procedure to perform and should be done first if the vibration occurs at high speeds or if the tires or the wheels are replaced. When proceeding the wheel balancing procedure refer to the following; 1. Do not the wheel weight over two at the inboard and the outboard flanges. 2. The total weight ofthe wheel weight should not exceed the 100 g (3.5 ounces) 3. Balancing the assemblies with the factory aluminum wheels requires the use of the special nylon-coated, clip-on wheel weights. Balance Weight 10 g 0.4 oz 20 g 0.7 oz 30 g 40 g 50 g 60 g
YAD2E260
1.10 oz 1.40 oz 1.80 oz 2.10 oz
YAD2E270
SSANGYONG Y200

Rotation Tires
Front and rear tires perform different jobs and can wear differently depending on the tires of road driven, driving condition, etc. The front tires will wear faster than the rear ones. To avoid uneven wear of tires and to prolong tire life, inspect and rotate the tires every 5,000 km (3,100 miles). After rotating the tires, adjust the tire inflation pressures and be sure to check wheel nuts tightness.
YAD2E280
Caution at replacement tires Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control.
SSANGYONG Y200
COMPONENT LOCATOR
TIRE AND WHEEL ASSEMBLY
YAD2E290
1 2 3 4
Wheel Nut Wheel Balance Weight Tire
5 6 7 8
Wheel Cap Wheel Cap Wheel Cap Wheel Cap
SSANGYONG Y200

GENERAL TIRE
1. Remove the wheel cap.
YAD2E300
2. Loosen the wheel nuts and then raise and suitably support the vehicle. 3. Remove the wheel nuts.
YAD2E310
YAD2E320
SSANGYONG Y200
General Instruction

3 5 2 4 1 6
Clean the contact surface between the wheel and the hub. Do not apply oil or grease to the nuts and bolts (cause the wheel to work loose). Raise the tires 3 cm off the ground using the jacket. Tighten the wheel nuts diagonally as shown. Tightening Torque Steel Wheel: 80 - 120 N m Alloy Wheel: 120 - 130 N m
YAD2E330
SPARE TIRE
Removal Procedure
1. Prepare the spare tire handle and the wheel nut wrench. 2 Install the handle through the hole at the rear side of the vehicle. 3 Install the wheel nut wrench at the end of the handle. 4 Turn the wheel nut wrench counterclockwise until the spare tire takes down the ground.
YAD2E340
5 Pull out the lift plate as shown. 6 Install the lift plate in the center of the wheel for installation. 7 Turn the handle clockwise until listen the sound click . 8 Remove the handle and the wheel nut wrench. Notice: Keep the spare tire available always. When reinstall the spare tire, install the tire tightly.
YAD2E350
If the spare tire may move after installation, reinstall the tire or contact to the approved service shop for repair. For installing the spare tire on the vehicle, follow the installation direction. If you may install the tire in reverse direction, it is not possible to install it correctly.
SSANGYONG Y200
MAINTENANCE AND REPLACEMENT

SEPARATION
1. Fix the tire into the equipment and pull out the valve core from the tire. Discharge the air inside the tire completely. Notice: The assembly and disassembly of the tire is dangerous working job. So, only the skillful worker must work this job following the approved procedures.
YAD2E360
2. Tighten the locker in the center of the equipment to assemble the rim to the equipment. 3. Remove the balance weight on the rim.
YAD2E370
4. Separate the tires bead from the rim flange using the approved lubricant. Notice: Do not use silicone, synthetic detergent and gasoline, etc.
YAD2E380
SSANGYONG Y200

5. Apply the lubricant between the rim and the bead.
YAD2E390
6. Insert the removal lever between the tires bead and the rim and separate the rim from the tire. Notice: Do not use the tool that may cause any damage such as pipe, damaged bar.
YAD2E400
7. Pull out the opposite bead upward using the lever and then separate the bead from the rim.
YAD2E410
MAINTENANCE
1. Check any damage the rim and replace as needed. Notice: Do not repair the rim as welding or soldering. Replace the new valve as replaces new tire.
SSANGYONG Y200
INSTALLATION
1. Clean the rust, damaged rubber and dust, etc on the rim s surface with the brush.
YAD2E420
2. Install the rim to the equipment with the valve upward. 3. Tighten the locker in the center of the equipment to assemble the rim to the equipment.
YAD2E430
4. Apply the lubricant at the both bead portions and both rim s flange of the tire.
YAD2E440
5. Check any foreign material or liquid for the tire inside and then install to push down the tire.
YAD2E450
SSANGYONG Y200

6. Set the tire pressure to the specifications. Notice: Do not remove the tire from the equipment before setting the tire pressure. Specification of the tire pressure 2.1 kg cm2 (30 psi)
YAD2E460
SSANGYONG Y200
SECTION 3A
FRONT AXLE
TABLE OF CONTENTS
General Description and Operation ............... 3A-2 Front Axle Housing Assembly ......................... 3A-2 Axle Shaft Assembly ........................................ 3A-3 Specifications ................................................... 3A-4 Diagnosis Information and Procedures .......... 3A-5 Component Locator ......................................... 3A-6 Front Axle Shaft ................................................ 3A-6 Front Axle Housing ........................................... 3A-7 Vacuum Line ................................................... 3A-10 Maintenance and Repair ................................. 3A-11 On-Vehicle Service ............................................ 3A-11 Front Axle Shaft .............................................. 3A-11 Vacuum Line ................................................... 3A-18 Axle Housing .................................................. 3A-19 Unit Repair ....................................................... 3A-20 Axle Housing Assembly ................................. 3A-20 Differential Joint Assembly ............................ 3A-26 Wheel Joint Assembly ................................... 3A-28 Special Tools And Equipment ....................... 3A-30 Special Tools Table ........................................ 3A-30
3A-2 FRONT AXLE
GENERAL DESCRIPTION AND OPERATION

FRONT AXLE HOUSING ASSEMBLY
YAD3A020
1 2 3 4 5 6
Axle Tube Assembly Snap Ring Ball Bearing Oil Seal Protector Retainer
7 8 9 10 11
Inner Shaft (LH) Inner Shaft (RH) Bolt Front Axle Bracket (LH) Front Axle Bracket (RH)
The front axle is installed between the left and right wheel. It have the function which transfers the power of engine to the wheels. Especially, it transfers the high power to the front wheels when driving 4-wheel. The axle shaft connected with CV joint in left/right of axle and differential carrier in center is installed. The length of left/right axle shaft is different and the structure is independent. Both ends part of shaft is fixed with the spline.
SSANGYONG Y200
FRONT AXLE 3A-3
AXLE SHAFT ASSEMBLY
YAD3A030
1 2 3 4 5 6
Drive Shaft Housing (Inboard) Boot (Outboard) Boot (Inboard) Shaft Boot Band
7 8 9 10 11
Boot Band Boot Band Boot Band Seal Ball Joint
SSANGYONG Y200
3A-4 FRONT AXLE
SPECIFICATIONS
Drive Shaft Type Axle Housing Type Differential Reduction Ratio Gaso. (E32 or E23) Type Gear Type Gasoline + M/T Diesel + M/T Gasoline + M/T Diesel + M/T Oil Capacity Specification CV Joint Build up Conventional Hypoid Gear 3.73 4.27 4.56 4.89 1.4 L SAE 80W / 90 or API Gl-5
SSANGYONG Y200
FRONT AXLE 3A-5
DIAGNOSIS INFORMATION AND PROCEDURES

Phenomena Noise (During Straight Driving) Lack of Oil Low Viscosity of Oil Inferior Oil Excessive Backlash of Ring Gears Worn or Damaged Tooth of Ring and Pinion Gear Worn or Damaged Tooth of Drive Pinion Gear Wear of Side Bearing and Side Gear Spline Bending of Axle Housing Distortion of Differential Case Wear of Pinion Shaft Incorrect Drive Pinion Preload. Incorrect Contact of Ring Gear and Pinion Oil Leakage Excessive Oil Fault Seal of Carrier Contact Surface Axle Housing Crack Worn or Damaged Oil Seal Noise (During Turning) Worn or Damaged Tooth of Pinion or Side Gear Wear of Pinion Shaft Excessive Backlash of Pinion Gear and Side Gear Excessive End-Play of Rear Axle Shaft Incorrect Contact of Side Gear and Differential Case Axle Housing Crack Distortion or Poor Installation of Drive pinion Oil Seal Damaged of Torn Drive Pinion Oil Seal Loosened Bearing Collar Worn or Damaged Universal Joint Worn or damaged Axle Shaft Bearing Heating Lack of Oil Insufficient Backlash of Gears Excessive Preload of Bearing Checks Replenish Replace Replace Adjust Replace Replace Replace Replace Replace Replace Adjust Reassembly Adjust Correct Replace Replace Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replenish Adjust Adjust Action
SSANGYONG Y200
3A-6 FRONT AXLE
COMPONENT LOCATOR
FRONT AXLE SHAFT
YAD3A040
1 2 3 4 5 6 7 8
Front Axle Inner Shaft Mounting (Axle Housing) Front Axle Drive Shaft Washer Bolt Steering Knuckle Dust Seal Outboard Joint Assembly Boot Clamp
9 10 11 12 13 14 15
Outboard Boot Boot Clamp Shaft Boot Clamp Inboard Boot Boot Clamp Inboard Joint Assembly
SSANGYONG Y200
FRONT AXLE 3A-7
FRONT AXLE HOUSING
YAD3A330
1 2 3 4 5 6 7 8 9
Axle Mounting Bracket Breather Hose Bolt Nut Cross Member Bolt Bushing Spacer Spacer
10 11 12 13 14 15 16 17
Nut Front Axle Housing Nut Bolt Washer Inner Shaft (Left) Inner Shaft (Right) Washer Plain
SSANGYONG Y200
3A-8 FRONT AXLE
YAD3A380
SSANGYONG Y200
FRONT AXLE 3A-9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Front Axle Housing Mounting Bracket Inner Shaft (Left) Bolt Oil Seal ................................................................ ........ Replace, Apply Grease to the Sealing Rib Snap Ring Bearing Snap Ring Oil Drain Plug Front Axle Housing Breather Nipple Inner Shaft (Right) Pinion Lock Nut Washer Companion Flange Oil Seal ................................................................ ......... Replace, Apply grease to the sealing Rib Bearing Shim Bearing Baffle Shim 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Bearing Oil Slinger Driver Pinion Oil Filler Plug Bolt Axle Housing Cover........... Apply Liquid Gasket Ring Gear Bearing Shim Shaft Lock Pin Differential Case Bolt Bolt Washer Bearing Cap Thrust Washer Side Gear Differential shaft Differential Pinion Thrust Washer
SSANGYONG Y200
3A-10 FRONT AXLE
VACUUM LINE
YAD3A300
1 2 3 4 5 6 7 8 9
Vacuum Auto-locking Hub Assembly Bolt .................................. 50-60 Nm(37-44 lb-ft) Washer Auto-locking Hub Cap Retaining Ring Shim Locking Hub Hose and Tube Assembly T-Connector
10 11 12 13 14 15 16 17
Hose Molded Check Valve Corrugated Tube Auto-locking Hub Solenoid Valve Bolt Hose (L:2000/Yellow) Hose (L:3200/Red) Hose (L:1500/White) (DSL) Hose (L:800/Blue) (GSL)
SSANGYONG Y200
FRONT AXLE 3A-11

FRONT AXLE SHAFT
Removal
1. Remove the tire.
YAD3A050
2. with ABS (Only part time vehicle) Remove the wheel speed sensor from the steering knuckle and pull off the cable.
YAD3A060
3. Remove the split pin from steering linkage linkknuckle mounting and pull off the slot nut and detach the link from knuckle arm. Notice: Replace the split pin with new one when it is installed again.
YAD3A070
SSANGYONG Y200
3A-12 FRONT AXLE

4. Remove the two knuckle-brake caliper assembly mounting blots and pull off the caliper assembly. Notice: Be careful not to damage the brake oil hose.
YAD3A080
5. Vehicle with pant time transfer case only Remove the hub mounting bolt & washer and pull off the hub cover.
YAD3A090
Remove the retainer ring & outer shin in the drive shaft and pull off the lock.
Notice: For assembly, adjust the clearance between the snap ring & hub not to exceed 0.2mm. (Shim thickness : 0.2, 0.3, 0.5, 1.0mm) Notice: For assembly, be careful not to damage O-ring of the locking hub.
YAD3A100
Detach the vacuum hose of locking hub from steering knuckle.
YAD3A110
SSANGYONG Y200
FRONT AXLE 3A-13
Remove the hub & brake disc assembly.
YAD3A120
6. With full time transfer case only
Remove the hub nut & washer.
Notice: For assembly, after you coincide the groove of drive shaft tip with the hub tip and cork, apply the paint and grease to the corking part.
YAD3A130
Remove the front disc assembly from the axle shaft.
YAD3A140
Remove three wheel bearing bolts (M12) and pull off hub assembly by using the special tool.
Notice: For reassembly, replace the wheel bearing bolt with new one which applied the lock tight (blue color).
YAD3A150
SSANGYONG Y200
3A-14 FRONT AXLE

7. Remove two dust shield mounting bolts (M6) and pull off the dust shield.
YAD3A160
8. Remove the split pin and nut from the steering knuckle arm and upper arm ball joint connection. Notice: For assembly, replace the split pin with new one. 9. Remove the split pin and nut from the steering knuckle arm and lower arm ball joint connection. Notice: For assembly, replace the split pin with new one.
YAD3A170
10. Carefully remove the steering knuckle assembly.
YAD3A180
11. Remove the drive shaft using the special tool.
YAD3A190
SSANGYONG Y200
FRONT AXLE 3A-15
Installation
Clean all the parts. Check O-ring, snap ring for the wear and damage. If damaged, replace them with new ones. 1. Insert the axle shaft to the axle housing. Be sure to insert the axle shaft to the housing. Notice: When you insert the axle shaft, be careful not to damage the boots. 2. Install the steering knuckle to the axle shaft exactly.
YAD3A200
3. Install the steering knuckle to the upper/lower arm and fix the split pin. Installation Notice Tightening Torque Lower arm Upper arm 140 - 160 Nm 140 - 160 Nm
YAD3A170
4. Install the dust shield to the knuckle.
YAD3A210
5. With full time transfer case only
Install the hub assembly to the axle shaft and tighten the hexagon bolts applied the lock tight (Blue color).
Installation Notice Tightening Torque 100 - 130 Nm
YAD3A220
SSANGYONG Y200
3A-16 FRONT AXLE
Install the front disc and tighten the hub nut & washer. When you install then, align the hub nut-washer to the shaft end and tighten the hub nut as the specified torque. After bending the groove part of shaft, apply the painting and grease to the groove part.
YAD3A230
6. With part time transfer case
Install the brake disc assembly and tighten the fixing bolts.

YAD3A240
Install the disc brake caliper assembly to the brake disc. Align the hub body to the flange mounting hole and insert it into the shaft.
Notice: When you insert the hub body, check the o-ring for the damage.
Insert the shin in order that the clearance between snap ring and hub cover does not exceed Max 0.2mm on condition that you pull the shaft completely in outside direction. Fix the hub body using the snap ring. Shim thickness Max. clearance 0.2, 0.3, 0.5, 1.0 mm 0.2 mm
YAD3A250
Install the hub cover to the body and tighten it as the specified torque.
Installation Notice Tightening torque 50 - 60 Nm (37 - 44 lb-ft)
YAD3A260
SSANGYONG Y200
FRONT AXLE 3A-17

7. Tighten the front disc brake caliper assembly mounting bolts on condition that the front disc is mounted. Installation Notice Tightening Torque 85 - 105 Nm
YAD3A270
8. Insert the steering linkage ends to the steering knuckle and tighten the slot nut. Notice: When you install, replace the split pin with new one. Installation Notice Tightening torque 35 - 45 Nm (26 - 33 lb-ft)
YAD3A280
9. Install the wheel speed sensor and connect the vacuum line (with ABS only). Installation Notice ABS wheel speed sensor mounting bolt 6 - 8 Nm (53 - 71 lb-in)
YAD3A290
10. Install the tire and test the braking force.
SSANGYONG Y200
3A-18 FRONT AXLE
VACUUM LINE
Removal/Installation
1. Be careful not to change the direction of valve when connecting the check valve(11) with each hose.
YAD3A310
2. Adjust the clearance between the retainer ring (5) and locking hub (7) to the normal value by using the appropriate shim (6).
Normal
MAX. 0.2 mm
Notice: Shim thickness 0.1, 0.2, 0.3, 0.5, 1.0 mm 3. Tighten the auto locking hub cap bolt to the specified torque and order. Installation Notice
YAD3A320
Tightening Torque
50 - 60 Nm (37 - 44 lb-ft)
SSANGYONG Y200
FRONT AXLE 3A-19
AXLE HOUSING
Removal/Installation
1. Remove the propeller shaft from the front axle input shaft. Installation Notice Tightening Torque 81 - 89 Nm (60 - 66 lb-ft)
2. Remove the steering gear linkage.

YAD3A340
3. Remove the breather hose. 4. Remove the cross member and axle housing mounting nut (1). Installation Notice Tightening torque 95 - 142 Nm
5. Remove the frame and cross member mounting nut (2) and pull off the cross member. Installation Notice Tightening Torque
YAD3A350
62 - 93 Nm (45 - 69 lb-ft)
6. Support the axle housing on a suitable jack, remove the axle housing mounting bracket nuts.
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Installation Notice Tightening Torque 62 - 93 Nm (45 - 69 lb-ft)
YAD3A360
7. Lowering the jack carefully, remove the axle housing assembly. 8. Installation should follow the removal procedure in the reverse order.
YAD3A370
SSANGYONG Y200
3A-20 FRONT AXLE
;;;;;;; ;;;;;;; ;;;;;;;

YAD3A400
UNIT REPAIR
AXLE HOUSING ASSEMBLY
Disassembly
1. Remove the drain plug and drain the oil and than reinstall the drain plug. Installation Notice Tightening Torque 28 - 40 Nm (21 - 30 lb-ft)
2. Remove the axle housing mounting bracket bolt and pull off the bracket and inner shaft assembly.
YAD3A410
3. Remove the bearing fixing snap ring of inner shaft and pull off the bearing. Remove the inner shaft and housing bracket
YAD3A420
4. Remove the axle housing cover. Notice: Clean the gasket dregs of the cover and housing contact surface.
YAD3A430
SSANGYONG Y200
FRONT AXLE 3A-21

5. Remove the bearing cap mounting bolt and pull off the bearing cap. Pull out the differential carrier assembly. Notice: Do alignment marks on the bearing dap not to change the caps before removal. When pulling out, be careful not to damage the axle housing.
YAD3A440
6. Disassemble the parts of differential carrier assembly.
YAD3A450
7. Remove the drive pinion lock nut. Disassemble the parts of drive pinion.
YAD3A460
SSANGYONG Y200
3A-22 FRONT AXLE
Inspection of Ring Gear Tooth Contact Pattern

1. Normal Contact Apply gear-marking compound (Prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern.
YAD3A470
2. Abnormal Contact Tooth contact pattern

1. Heel contact
Possible cause Excessive backlash Noise can be occurred
Remedy
Adjust backlash (Drecrease backlash) Select proper shin to move the drive pinion toward the ring gear (toward toe)
YAD3A480
YAD3A490
2. Toe contact
Insufficient backlash Tooth can be damaged or broken under heavy load
Adjust backlash (Increase backlash) Select proper shim to move the drive pinion against the ring gear (toward heel)
YAD3A500
YAD3A510
3. Face contact
Excessive backlash Drive pinion shaft is apart from the ring gear Noise can be occurred
Adjust backlash (Increase pinion shim) Move the drive pinion toward the ring gear (toward center of ring gear)
YAD3A520
YAD3A530
4. Flank contact
Insufficient backlash Gear contacts on the low flank Gear can be damaged or worn Noise can be occurred
YAD3A540
Adjust backlash (Decrease pinion shim) Move the ring gear toward the drive pinion (toward ring gear center line)
YAD3A550
SSANGYONG Y200
FRONT AXLE 3A-23 Assembly

1. Clean all parts and check the followings. Check the ring gear, drive pinion for wear and damage. If damaged, replace it as a set. Check the bearing for sticks, wear, noise and turning resistance. Check the side gear, pinion, pinion shaft and thrust washer for wear and damage. Check the differential carrier for crack and wear (bearing contact surface). Check the gear case for crack.
YAD3A560
2. Assemble the drive pinion assembly to the axle housing and then tighten the pinion lock nut. Installation Notice Tightening torque 240 - 310 Nm
YAD3A570
3. Assemble the differential carrier assembly. Align the ring gear to the mark of differential carrier, tighten the fixing bolts. Installation Notice Tightening Torque 75 - 90 Nm (55 - 66 lb-ft)
YAD3A580
4. Measure the backlash of side gear and pinion gear. Specified value 0 - 0.5 mm
YAD3A590
SSANGYONG Y200
3A-24 FRONT AXLE

5. Install the differential carrier assembly into the axle housing. Set up the bearing cap and then tighten the cap bolts. Installation Notice Tightening Torque 48 - 69 Nm (35 - 51 lb-ft)
Notice: Be careful not to change the caps. Be sure to keep the original position of the caps.
YAD3A600
6. Measure the backlash of drive pinion and ring gear. Specified value 0.13 - 0.20 mm
YAD3A610
7. Install the axle housing cover. Tighten the fixing bolts. Installation Notice Tightening Torque 39 - 46 Nm (29 - 34 lb-ft)
YAD3A620
8. Assemble the parts of the front axle inner shaft and housing mounting bracket. Notice: Apply the grease to the oil seal rib.
YAD3A630
SSANGYONG Y200
FRONT AXLE 3A-25

9. Align the axle shaft and differential carrier spline and insert the axle shaft. Assemble the axle housing mowiting bracket to the axle housing. Installation Notice Tightening Torque 80 - 100 Nm (59 - 74 lb-ft)
YAD3A640
SSANGYONG Y200
3A-26 FRONT AXLE
DIFFERENTIAL JOINT ASSEMBLY

1. Remove the drive axle. 2. Detach the joint boot clamp. 1 Detach the boot clamp (large) After pressing the clamp prominence using the special tool, detach the clamp. 2 Detach the boot clamp (small) After unfolding the clamp holding part using the driver / hammer, detach the clamp.
YAD3A650
3. Detach the joint housing from the boot. 1 Boot 2 Joint housing
YAD3A660
4. Get rid of the grease in the joing assembly. 5. Remove the triport joint. 1 Pull out the circlip. 2 Pull out the triport joint.
YAD3A670
6. Remove the drive axle shaft boot.
YAD3A680
SSANGYONG Y200
FRONT AXLE 3A-27

Inspection
1. Check the shaft spline for the wear and damage. 2. Check the leakage by the boot crack, tears. 3. Check the bending of shaft. Notice: if the defect happens in one shaft, because the other is damaged, exchange the both.
YAD3A690
Assembly
1. Assembly should follow the dismantlement in the reverse order. 2. Apply the specified grease to the joint housing. Injection quantity 90 - 100 g
Notice: If not use the specified grease, the joint and boot may be damaged. Notice: For assembly, replace the boot clamp with the new one.
YAD3A700
3. Check the followings after completing the assembly. Check whether the joint move to up/down, left/ right, forward freely. Check whether the grease leak in the clamp part after checking the operation.
SSANGYONG Y200
3A-28 FRONT AXLE
WHEEL JOINT ASSEMBLY

Disassembly
1. Remove the drive axle. 2. Detach the joint boot clamp. 1 Detach the boot clamp (large) 2 Detach the boot clamp (Small) After unfolding the clamp holding part by using the driver/hammer, detach the clamp.
YAD3A710
3. Get rid of the grease in the joint assembly. 4. Remove the joint assembly. 1 Spread out the circlip. 2 Pull out the joint assembly to the wheel side with the circlip spread out.
YAD3A720
5. Remove the drive axle shaft.
YAD3A730
Assembly
1. Assembly should follow the disassembly procedure in the reverse order. 2. Install the joint assembly. Put the joint assembly in drive axle shaft to spread out the circlip opening slightly. 1 Insert (-) driver into the circlip opening to spread out the circlip. 2 Put the joint assembly in circlip home with the circlip spread out.
YAD3A740
SSANGYONG Y200
FRONT AXLE 3A-29

3. Apply the specified grease to the joint housing. Injection quantity 80 - 90 g
Notice: If not use the specified grease, the joint and boot may be damaged. Notice: For assembly, replace the boot clamp with the new one.
YAD3A750
4. Check the followings after completing the assembly. Check whether the joint move to up/down, left/ right, forward freely. Check whether the grease leak in the clamp part after checking the operation. Notice: Because the wheel joint cannot be repaired in single part, if there is defect, replace it whit the new assembly.
YAD3A760
SSANGYONG Y200
3A-30 FRONT AXLE

SPECIAL TOOLS TABLE
661 589 13 33 00 Ball Joint Remover
Snap Ring Plier
YAD3A770
YAD3A780
Part Time Snap Ring Remover / Installer
YAD3A790
SSANGYONG Y200
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
General Description and Operation ..................... 3C-2 Specifications ...................................................... 3C-2 Diagnostic Information and Procedures .............. 3C-3 Component Locator ............................................ 3C-4 Cross Sectional View ........................................... 3C-4 Propeller Shaft Assembly ..................................... 3C-5 Maintenance and Repair ..................................... 3C-6 On-Vehicle Service ................................................. 3C-6 Propeller Shaft Assembly ..................................... 3C-6 Unit Repair ............................................................ 3C-9 Propeller Shaft ..................................................... 3C-9
3C-2 PROPELLER SHAFT

The propeller shaft transfers the power through the transmission and transfer case to the front/rear axle differential carrier (final reduction fear). It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending. Both ends of propeller shaft is connected with the spider and the center of propeller shaft is connected with the spline because the height/length of transmission and axle is not constant. The rubber bushing which wraps the center bearing is installed in rear propeller shaft. So the vibration and balance is maintained constantly.
YAD3C010
SPECIFICATIONS
Structure Joint Type Number of Spider Front Shaft Rear Shaft Outer Diameter of Spider (mm) Tube Run-out (After Installation) Front Shaft Dimension (LXI.DXO.D) Rear Shaft Dimension (LXI.DXO.D) Unbalance Quantity (at 4,500 RPM) Diesel + M/TA/T + 4408 T/C Gasoline + M/TA/T + 4421 T/C Diesel + M/TA/T + 4408 T/C Gasoline + M/TA/T + 4421 T/C Full Time T/C Part Time T/C Yoke & Spider Typed Universal Joint Spider (Needle Roller Bearing) 2 2 3 16.668 Within 0.4 mm 607.1 59.5 63.5 591.1 59.5 63.5 (585.2+569.5) 59.5 63.5 (566.1+569.5) 59.5 63.5 within 30 gcm
SSANGYONG Y200
PROPELLER SHAFT 3C-3

Phenomena Vibration Checks Incorrect Assembly of Sliding Joint Bending of Propeller Shaft Poor Symmetry (Left/Right) of Universal Joint Snap Ring Loosened Yoke connection bolt Noise Worn or Damaged Universal Joint Bearing Separation of Universal Joint Snap Ring Loosened Yoke connection part Warn sliding Joint Spline pant Insufficient Grease Action Adjust Replace Adjust Tightening Replace Adjust/Replace Tightening Replace Replenish
SSANGYONG Y200
COMPONENT LOCATOR
CROSS SECTIONAL VIEW
Rear Propeller Shaft
YAD3C020
1 2 3 4 5 6 7
Flange Yoke Journal Bearing Cap Cross Shaft Journal Slip Yoke Assembly Grease Nipple Dust Cap Oil Seal
8 9 10 11 12 13
Split Washer Slip Tube Shaft Tube Tube Yoke Flange Yoke Center Bearing
SSANGYONG Y200
PROPELLER SHAFT ASSEMBLY
YAD3C030
1 2 3 4 5
Front Axle Bolt Front Propeller Shaft Bolt Transfer Case
6 7 8 9
Bolt Rear Propeller Shaft Bolt Rear Axle
SSANGYONG Y200

PROPELLER SHAFT ASSEMBLY
Removal
1. Do alignment marks before removing the propeller shaft.
YAD3C040
2. Remove the flange yoke fixing bolt/nut that connects the front propeller shaft axle side with transfer case. Pull out the front propeller shaft assembly.
YAD3C050
3. Remove the flange yoke bolt/nut of transfer case side in rear propeller shaft.
YAD3C060
SSANGYONG Y200

4. Remove the fixing bolt of middle bearing (center).
YAD3C070
5. Remove the rear axle housing flange yoke bolts/ nuts of rear propeller shaft. Pull out the rear propeller shaft assembly.
YAD3C080
Installation
1. Check the disassembled parts visually. 2. Align the assembly mark of each propeller shaft. 3. Install the front propeller shaft. Installation Notice Tightening Torque 81 - 89 Nm (60 - 66 lb-ft)
YAD3C090
4. Set up the rear propeller shaft between the transmission and axle housing. Tighten the center bearing manually. Installation Notice Tightening Torque 80 - 95 Nm (59 - 70 lb-ft)
YAD3C100
SSANGYONG Y200

5. Align the rear propeller shaft to the assembly mark. Tighten the bolts/nuts and then the center bearing bolts. Installation Notice Tightening Torque 70 - 80 Nm (52 - 59 lb-ft)
YAD3C110
SSANGYONG Y200
UNIT REPAIR
PROPELLER SHAFT
Disassembly
1. Mark the assembly mark and remove the propeller shaft. 2. Do alignment mark before separating the spider.
YAD3C120
3. Remove the snap ring using the snap ring plier.
YAD3C130
4. Slightly tapping the yoke shoulder using a brass hammer, remove the bearing. Remove the remaining bearing in the same way.
YAD3C140
5. If it is not removed, clamp the welding part of yoke in the vise.
YAD3C150
SSANGYONG Y200

6. Disassemble the universal joint parts. As axles move up and down, universal joints allow drive angle to change without bending of propeller shaft.
YAD3C160
7. Remove the center bearing bracket and center bearing using the special tool.
YAD3C170
Inspection
1. Visual Check Check the disassembled parts for wear and crack. Replace them if necessary. 2. Spider outer diameter standard Limit 16.647 mm 16.668 mm
YAD3C180
3. Clearance between the spider and bearing

standard Limit 0.03 ~ 0.098 mm 0.25 mm
YAD3C190
SSANGYONG Y200

4. Propeller Shaft runout Using a dial gauge, measure propeller shaft runout by turning the shaft. If runout exceeds limit, adjust the propeller shaft using a press or replace it. Limit 0.4 mm
YAD3C200
5. Universal joint starting torque Specified Value 3 ~ 8 kgcm
YAD3C210
6. Major cause of vibration Separation of balance weights Excessive runout of the propeller shaft Using the general bolts Excessive wear of universal joint Sticks in sleeve joint Vibration is caused by front & rear universal joint, pinion angle change and is generally broke out when the vehicle speed is around 60 ~ 100km/h.
Assembly
Clean the disassembled parts and replace then if damaged. 1. Align the alignment marks of the yoke and assemble the spider, bearing and snap ring.
YAD3C220
SSANGYONG Y200

2. Apply the grease to the inner of bearing cap of needle roller bearing and assemble the needle roller.
YAD3C230
3. Install the bearing cap to the yoke and insert the spider. Install the opposite cap by tapping with a plastic hammer.
YAD3C240
4. Assembly the center bearing to the rear propeller shaft.
YAD3C250
SSANGYONG Y200
SECTION 3D
REAR AXLE
TABLE OF CONTENTS
General Description and Operation ............... 3D-2 Specifications ................................................... 3D-2 Diagnostic Information and Procedures ........ 3D-3 Component Locator ......................................... 3D-4 Rear Axle Assembly ......................................... 3D-4 Cross Sectional View ........................................ 3D-5 Rear Axle Shaft Assembly ............................... 3D-6 Maintenance and Repair .................................. 3D-8 On-Vehicle Service .............................................. 3D-8 Axle Shaft Assembly (With Disc Brake) .......... 3D-8 Axle Shaft Assembly (With Drum Brake) ...... 3D-11 Rear Axle Housing .......................................... 3D-13 Unit Repair ....................................................... 3D-18 Axle Assembly ............................................... 3D-18 Differential Gear Assembly ............................ 3D-19
3D-2 REAR AXLE

SPECIFICATIONS
Axle Shaft Type Axle Housing Type Differential Reduction Ratio Type Gear Gasoline + A/T Diesel + A/T Gasoline + A/T Diesel + A/T Oil Capacity Specification Semi-floating Build up Conventional Type Hypoid Gear 3.73 4.27 4.56 4.89 1.9L SAE 80W/90 or API GL-5
SSANGYONG Y200
REAR AXLE 3D-3

Phenomena Noise (During Straight Driving) Lack of Oil Low Viscosity of Oil Inferior Oil Excessive Backlash of Ring Gears Worn or Damaged Tooth of Ring and Pinion Gear Worn or Damaged Tooth of Drive Pinion Gear Wear of Side Bearing and Side Gear Spline Bending of Axle Housing Distortion of Differential Case Wear of Pinion Shaft Incorrect Drive Pinion Preload. Incorrect Contact of Ring Gear and Pinion Oil Leakage Excessive Oil Fault Seal of Carrier Contact Surface Axle Housing Crack Worn or Damaged Oil Seal Noise (During Turning) Worn or Damaged Tooth of Pinion or Side Gear Wear of Pinion Shaft Excessive Backlash of Pinion Gear and Side Gear Excessive End-Play of Rear Axle Shaft Incorrect Contact of Side Gear and Differential Case Axle Housing Crack Distortion or Poor Installation of Drive pinion Oil Seal Damaged of Torn Drive Pinion Oil Seal Loosened Bearing Collar Worn or Damaged Universal Joint Worn or damaged Axle Shaft Bearing Heating Lock of Oil Insufficient Backlash of Gears Excessive Preload of Bearing Checks Replenish Replace Replace Adjust Replace Replace Replace Replace Replace Replace Adjust Reassembly Adjust Correct Replace Replace Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replenish Adjust Adjust Action
SSANGYONG Y200
3D-4 REAR AXLE
COMPONENT LOCATOR
REAR AXLE ASSEMBLY
YAD3D101
1 2 3 4
Axle Shaft/Tube Stabilizer Bar Spring Seat & Spring Upper Arm
5 6 7 8
Shock Absorber Lateral Rod Input Shaft Axle Housing
SSANGYONG Y200
REAR AXLE 3D-5
YAD3D020
1 2 3 4 5
Rear Axle Shaft Assembly Bracket Assembly Hub Oil Seal Bolt Axle Shaft Tube
6 7 8 9 10
Coil Spring Seat (Lower) Caliper Assembly Input Shaft/Flange Rod Mounting Bracket Wheel Speed Sensor
SSANGYONG Y200
3D-6 REAR AXLE
REAR AXLE SHAFT ASSEMBLY

With disc brake
YAD3D030
1 2 3 4 5 6
Brake Disc Plug Rear Axle Shaft Nut Washer Parking Brake Cable
7 8 9 10 11
Parking Brake Lining & Back Plate Assembly Brake Caliper Assembly Spring Washer Bolt Rear Axle Housing
SSANGYONG Y200
REAR AXLE 3D-7

With drum brake
YAD3D150
1 2 3 4 5 6 7 8
Brake Drum Plug Rear Axle Shaft Wheel Bolt Nut Washer Retainer Plate Oil Seal
9 10 11 12 13 14 15
Bearing Snap Ring Snap Ring Oil Seal Brake Shoe & Back Plate Assembly Bolt Rear Axle Housing
SSANGYONG Y200
3D-8 REAR AXLE

AXLE SHAFT ASSEMBLY (WITH DISC BRAKE)
Removal
1. Remove the tire.
YAD3D040
2. Release the parking brake. 3. Remove the fixing pin of parking brake. 4. After detaching the parking brake lever, detach the cable.
YAD3D050
5. Remove the two fixing bolt of brake caliper. Notice: Be careful not to damage the brake oil hose. 6. Remove the brake caliper assembly. Notice: If replacing the brake pad only, remove the upper fixing bolt of caliper pad and lower it.
YAD3D060
SSANGYONG Y200
REAR AXLE 3D-9

7. Remove the brake disc.
YAD3D070
8. Remove the four fixing bolt of dust shield cover and then pull out the dust shield cover.
YAD3D080
9. Remove the two plastic plug in the axle shaft flange. 10. Remove the four fixing bolts & washers of axle housing flange from the retainer plate.
YAD3D090
11. Remove the rear axle drive shaft.
YAD3D100
SSANGYONG Y200
3D-10 REAR AXLE
Installation
Clean the detached axle shaft, check the damage or wear. 1. After checking the spline & shaft of rear axle shaft, assemble the shaft into the rear axle housing.
YAD3D110
2. Tighten the flange fixing bolts and washers with the retainer plate. Installation Notice Tightening torque 50 - 65 Nm (37 - 48 lb-ft)
YAD3D120
3. Assemble the plastic plug n the rear axle flange and install the dust shield. Installation Notice Tightening torque 4 - 8 Nm (35 - 71 lb-in)
YAD3D130
4. Install the brake disc and caliper assembly. Installation Notice Tightening torque 85 - 105 Nm
5. Install the parking brake cable and tire.
YAD3D140
SSANGYONG Y200
REAR AXLE 3D-11
AXLE SHAFT ASSEMBLY (WITH DRUM BRAKE)

Removal
1. Release the parking brake. 2. Remove the tire.
YAD3D160
3. Remove the brake drum. Notice: Insert the bolt into the ser vice hole, while tightening the both side bolts uniformly, remove the brake drum. 4. Remove the fixing pin of parking brake. 5. After detaching the cover of parking brake, disconnect the cable.
YAD3D170
YAD3D180
6. After pulling out the two plastic plug of axle shaft flange, remove the fixing nuts of inner bracket.
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YAD3D190
SSANGYONG Y200
3D-12 REAR AXLE

7. Remove the axle shaft.
YAD3D200
Installation
YAD3D210
1. Check the rear axle shaft. 2. Insert the rear axle shaft into the axle housing and tighten the fixing nuts of axle shaft flange. Installation Notice Tightening Torque 50 - 65 N m (37 - 48 lb-ft)
3. Connect the brake cable and install the brake drum.
YAD3D220
4. Install the tire and test the braking force.
YAD3D230
SSANGYONG Y200
REAR AXLE 3D-13
REAR AXLE HOUSING

Removal
1. Remove the tire. 2. Remove the connecting rod of LCRV assembly & fixing nut of axle housing bracket.
YAD3D240
3. Disconnect the brake oil hose & oil line (pipe) 1 Brake pipe nut. 2 Brake pipe mounting clip 3 3-way connector 4 Brake pipe assembly
YAD3D250
4. Detach the air breather.
YAD3D260
5. Remove the propeller shaft from rear axle input shaft. Notice: Do alignment marks before removing.
YAD3D270
SSANGYONG Y200
3D-14 REAR AXLE

6. Pull out the fixing pin of parking brake. 7. After removing the parking brake lever, pull out the cable.
YAD3D280
8. Remove the lower arm mounting nuts and remove the lower arm from the axle housing.
YAD3D290
9. Detach the lower mounting of shock absorber from the axle housing.
YAD3D300
10. Remove the upper arm mounting nuts and remove the upper arm from the axle housing.
YAD3D310
SSANGYONG Y200
REAR AXLE 3D-15

11. Remove the stabilizer bar.
YAD3D320
12. Remove the lateral rod mounting nut and detach the lateral rod from the axle housing.
YAD3D330
13. Lowering the axle slowly, remove the coil spring & spring seat. 14. Lower the axle housing by using the safety jack.
YAD3D340
Installation
1. Placing the rear axle housing on the assembly position, install both coil springs.
YAD3D350
SSANGYONG Y200
3D-16 REAR AXLE

2. Install the lateral rod in axle hosing. Notice: Do not tighten the nuts completely. Installation Notice Tightening Torque 150 - 180 Nm
3. Install the shock absorber in axle housing. Installation Notice Tightening Torque
YAD3D360
30 - 45 N m (22 - 33 lb-ft)
4. Install the stabilizer bar and upper/lower arm in axle housing Installation Notice Stabilizer bar cap bolt Upper arm nut Lower arm nut 30 - 45 Nm (22 - 33 lb-ft) 150 - 180 Nm 150 - 180 Nm
YAD3D370
5. Install the propeller shaft of rear axle side and tighten above the fixing bolts/nuts. Installation Notice Tightening Torque 70 - 80 N m (52 - 59 lb-ft)
YAD3D380
6. Install the brake cable, air bleeder hose, oil pipe, LCRV unit in rear axle assembly with assembled completely. Installation Notice LCRV Mounting Bolt Air Breather Hose Bolt Brake Oil Pipe (M10)
YAD3D390
12 - 23 Nm (9 - 17 lb-ft) 6 - 8 Nm (53 - 71 lb-in) 15 - 19 Nm (11 - 14 lb-ft)
7. Bleeding the air in brake, install the tire.

SSANGYONG Y200
REAR AXLE 3D-17 Inspection

1. Check the shaft spline for the wear and damage.
YAD3D400
2. Measure the run-out of shaft. Specified value Within 1.0 mm
YAD3D410
3. Measure the run-out of shaft flange. Specified value Within 0.13 mm
YAD3D420
4. Install the axle shaft and measure the clearance of shaft direction. Specified value Within 0.38 mm
YAD3D430
SSANGYONG Y200
3D-18 REAR AXLE
UNIT REPAIR
AXLE ASSEMBLY
YAD3D440
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Drive Pinion Lock Nut .................. 240 - 310 N m Washer Companion Flange Pinion Oil Seal Bearing Slinger Bearing Shim Shim Bearing Cup Breather Nipple Rear Axle Housing Oil Drain Plug ................................... 28 - 42 N m Shim Bearing Drive Pinion Bearing Cap
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Bolt ................................................. 87 - 124 N m Bearing Shim Ring Gear Shaft Lock Pin Differential Case Ring Gear Mounting Bolt ................. 75 - 90 N m Thrust Washer Differential Pinion Thrust Washer Side Gear Differential Shaft Housing Cover Bolt ................................................... 38 - 46 N m Oil Filler Plug ................................... 28 - 42 N m
SSANGYONG Y200
REAR AXLE 3D-19
DIFFERENTIAL GEAR ASSEMBLY

Disassembly
1. Remove the drain plug and drain oil. Reinstall the drain plug. Installation Notice Tightening Torque 28 - 42 N m (21 - 31 lb-ft)
YAD3D450
2. Remove the axle housing cover. Notice: Clean the cover and housing contact surface.
YAD3D460
3. Remove the bearing cap bolts and remove the bearing cap. Pull out the differential carrier assembly. Notice: Do alignment marks on the bearing cap not to change the caps before removal. When pulling out, be careful to damage the axle housing.
YAD3D470
4. Disassemble the parts of differential carrier assembly.
YAD3D480
SSANGYONG Y200
3D-20 REAR AXLE

5. Remove the drive pinion lock nut. Disassemble the parts of drive pinion
YAD3D490
SSANGYONG Y200
REAR AXLE 3D-21
Inspection of Ring Gear Tooth Contact Pattern

1. Normal Contact Apply gear-marking compound (prussian blue/red lead) on the ring rear teeth. Rotate the ring gear and check the to the contact pattern.
YAD3D500
2. Abnormal contact Tooth contact pattern

1. Heel contact
Possible cause Excessive backlash Noise can be occurred
Remedy
Adjust backlash (Drecrease backlash) Select proper shin to move the drive pinion toward the ring gear (toward toe)
YAD3D510
YAD3D520
2. Toe contact
Insufficient backlash Tooth can be damaged or broken under heavy load
Adjust backlash (Increase backlash) Select proper shim to move the drive pinion against the ring gear (toward heel) B
A
YAD3D530
YAD3D540
3. Face contact
Excessive backlash Drive pinion shaft is apart from the ring gear Noise can be occurred
Adjust backlash (Increase pinion shim) Move the drive pinion toward the ring gear (toward center of ring gear)
YAD3D550
YAD3D560
4. Flank contact
Insufficient backlash Gear contacts on the low flank Gear can be damaged or worn Noise can be occurred
YAD3D570
Adjust backlash (Decrease pinion shim) Move the ring gear toward the drive pinion (toward ring gear center line)
YAD3D580
SSANGYONG Y200
3D-22 REAR AXLE Assembly

1. Clean all parts and check the followings. Check the ring gear, drive pinion for wear and damage. If damaged, replace it as a set. Check the bearing for sticks, wear, noise and turning resistance. Check the side gear, pinion, pinion shaft and thrust washer for wear and damage. Check the differential carrier for crack and wear (bearing contact surface). Check the gear case for crack.
YAD3D590
2. Assemble the drive pinion assembly to the axle housing and then tighten the pinion lock nut. Installation Notice Tightening torque 240 - 310 Nm
YAD3D600
3. Assemble the differential carrier assembly. Align the ring gear to the mark of differential carrier, tighten the fixing bolts. Installation Notice Tightening Torque 75 - 90 N m (55 - 66 lb-ft)
YAD3D610
4. Measure the backlash of side gear and pinion gear. Specified value 0 - 0.5 mm
YAD3D620
SSANGYONG Y200
REAR AXLE 3D-23

5. Install the differential carrier assembly into the axle housing. Set up the bearing cap and then tighten the cap bolts. Installation Notice Tightening Torque 48 - 69 N m (35 - 51 lb-ft)
Notice: Be careful not to change the caps. Be sure to keep the original position of the caps.
YAD3D630
6. Measure the backlash of drive pinion and ring gear. Specified value 0.13 - 0.20 mm
YAD3D640
7. Install the axle housing cover. Tighten the fixing bolts. Installation Notice Tightening Torque 39 - 46 N m (29 - 34 lb-ft)
YAD3D650
SSANGYONG Y200
4E-40 ABS AND TCS
YAD4E170
DIAGNOSTIC TROUBLE CODE (DTC) 035 LEFT FRONT WHEEL SPEED SENSOR FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The wheel speed sensor is defective. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 6. This step tests the wiring for a short to voltage. 8. This step tests the wiring for a short to ground. 10. This step tests for an open or a high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction. Use the scan tool to monitor wheel speeds during a road test. Watch the wheel speeds being displayed on the scan tool to see if any of the readings are unusual, such as one sensor varying in speed from the other three, a signal going intermittently high or low, etc. If this does not identify the intermittent, wet the speed sensor harness on the underside of the vehicle and perform a road test, monitoring wheel speeds with the scan tools.
There is a problem in the wiring. There is a problem with a connector.
Action Taken When the DTC Sets ABS action is disabled, and the ABS warning lamp is ON.
SSANGYONG Y200
ABS AND TCS 4E-41 DTC 035 - Left Front Wheel Speed Sensor Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the left front wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 F)? Replace the wheel speed sensor. Is the repair complete? 1. Switch the DVM to the AC mV. 2. Measure the voltage output between the wheel speed sensor terminals while rotating the wheel about 1 revolution per second. Is the output within the specified value? Replace the speed sensor or the toothed wheel, as required. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Measure the resistance to ground from terminal 6 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 7 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? Repair the short to ground in the affected circuit. Is the repair complete? 1. Measure the resistance between terminal 7 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 6 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or the high resistance in the affected circuit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 4 System OK
Go to Step 3 -
70 mV
Go to Step 10
Go to Step 9
System OK
>1V -
Go to Step 8 -
Go to Step 10 -
10
>5
Go to Step 11
Go to Step 12
11
System OK System OK
12
SSANGYONG Y200
4E-42 ABS AND TCS
YAD4E170
DIAGNOSTIC TROUBLE CODE (DTC) 07 - LEFT FRONT WHEEL SPEED SENSOR CONTINUITY FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The wheel speed sensor is defective. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 4. This step tests the wiring for a short to voltage. 6. This step tests the wiring for a short to ground. 8. This step tests for an open or high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
SSANGYONG Y200
ABS AND TCS 4E-43 DTC 07 - Left Front Wheel Speed Sensor Continuity Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the left front wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 F)? Replace the wheel speed sensor. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition go LOCK. 2. Measure the resistance to ground from terminal 6 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 7 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? Repair the short to ground in the affected circuit. Is the repair complete? 1. Measure the resistance between terminal 6 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 7 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
>1V -
Go to Step 6 -
Go to Step 8 -
>5
Go to Step 9
Go to Step 10
System OK System OK
10
SSANGYONG Y200
4E-44 ABS AND TCS
YAD4E180
DIAGNOSTIC TROUBLE CODE (DTC) 040 - RIGHT FRONT WHEEL SPEED SENSOR FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The wheel speed sensor is defective. There is a problem in the wiring. There is a problem with a connector. Action Taken When the DTC Sets ABS action is disabled, and the ABS warning lamp is ON. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 6. This step tests the wiring for a short to voltage. 8. This step tests the wiring for a short to ground. 10. This step tests for an open or a high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction. Use the scan tool to monitor wheel speeds during a road test. Watch the wheel speeds being displayed on the scan tool to see if any of the readings are unusual, such as one sensor varying in speed from the other three, a signal going intermittently high or low, etc. If this does not identify the intermittent, wet the speed sensor harness on the underside of the vehicle and perform a road test, monitoring wheel speeds with the scan tools.
SSANGYONG Y200
ABS AND TCS 4E-45 DTC 040 - Right Front Wheel Speed Sensor Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the right front wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure the resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 F)? Replace the wheel speed sensor. Is the repair complete? 1. Switch the DVM to the AC mV. 2. Measure the voltage output between the wheel speed sensor terminals while rotating the wheel about 1 revolution per second. Is the output within the specified value? Replace the speed sensor or the toothed wheel, as required. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Measure the resistance to ground from terminal 4 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 5 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? Repair the short to ground in the affected circuit. Is the repair complete? 1. Measure the resistance between terminal 4 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 5 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
70 mV
Go to Step 6
Go to Step 5
System OK
>1V -
Go to Step 8 -
Go to Step 9 -
Go to Step 10 -
10
>5
Go to Step 11
Go to Step 12
11
System OK System OK
12
SSANGYONG Y200
4E-46 ABS AND TCS
YAD4E180
DIAGNOSTIC TROUBLE CODE (DTC) 08 - RIGHT FRONT WHEEL SPEED SENSOR CONTINUITY FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The wheel speed sensor is defective. There is a problem in the wiring. There is a problem with a connector. Action Taken When the DTC Sets ABS action is disabled, and the ABS warning lamp is ON. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 4. This step tests the wiring for a short to voltage. 6. This step tests the wiring for a short to ground. 8. This step tests for an open or high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
SSANGYONG Y200
ABS AND TCS 4E-47 DTC 08 - Right Front Wheel Speed Sensor Continuity Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the right front wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure the resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 F)? Replace the wheel speed sensor. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition go LOCK. 2. Measure the resistance to ground from terminal 4 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 5 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? 1. Measure the resistance between terminal 4 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 5 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
>1V -
Go to Step 6 -
System OK
Go to Step 7
>5
Go to Step 8
Go to Step 9
8 9
System OK System OK
SSANGYONG Y200
4E-48 ABS AND TCS
YAD4E190
DIAGNOSTIC TROUBLE CODE (DTC) 045 - LEFT REAR WHEEL SPEED SENSOR FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The wheel speed sensor is defective or disconnected. There is a problem in the wiring. There is a problem with a connector. Action Taken When the DTC Sets ABS action is disabled, and the ABS warning lamp is ON. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 4. This step tests the wiring for a short to voltage. 6. This step tests the wiring for a short to ground. 8. This step tests for an open or a high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction. Use the scan tool to monitor wheel speeds during a road test. Watch the wheel speeds being displayed on the scan tool to see if any of the readings are unusual, such as one sensor varying in speed from the other three, a signal going intermittently high or low, etc. If this does not identify the intermittent, wet the speed sensor harness on the underside of the vehicle and perform a road test, monitoring the wheel speeds with the scan tool.
SSANGYONG Y200
ABS AND TCS 4E-49 DTC 045 - Left Rear Wheel Speed Sensor Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the left rear wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure the resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 F)? Replace the wheel speed sensor. Is the repair complete? 1. Switch the DVM to the AC mV. 2. Measure the voltage output between the wheel speed sensor terminals while rotating the wheel about 1 revolution per second. Is the output within the specified value? Replace the speed sensor or the toothed wheel, as required. Is the repair complete? 1. Disconnect the from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Measure the resistance to ground from terminal 8 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 9 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? Repair the short to ground in the affected circuit. Is the repair complete? 1. Measure the resistance between terminal 8 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 9 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
70 mV
Go to Step 6
Go to Step 5
System OK
>1V -
Go to Step 8 -
Go to Step 10 -
10
>5
Go to Step 11
Go to Step 12
11
System OK System OK
12
SSANGYONG Y200
4E-50 ABS AND TCS
YAD4E190
DIAGNOSTIC TROUBLE CODE (DTC) - LEFT REAR WHEEL SPEED SENSOR CONTINUITY FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The wheel speed sensor is defective. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 4. This step tests the wiring for a short to voltage. 6. This step tests the wiring for a short to ground. 8. This step tests for an open or high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
SSANGYONG Y200
ABS AND TCS 4E-51 DTC Right Front Wheel Speed Sensor Continuity Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the left rear wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure the resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 C)? Replace the wheel speed sensor. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition go LOCK. 2. Measure the resistance to ground from terminal 8 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 9 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? 1. Measure the resistance between terminal 8 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 9 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
>1V -
Go to Step 6 -
System OK
Go to Step 7
>5
Go to Step 8
Go to Step 9
8 9
System OK System OK
SSANGYONG Y200
4E-52 ABS AND TCS
YAD4E200
DIAGNOSTIC TROUBLE CODE (DTC) 050 - RIGHT REAR WHEEL SPEED SENSOR FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 6. This step tests the wiring for a short to voltage. 8. This step tests the wiring for a short to ground. 10. This step tests for an open or a high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction. You can use the scan tool to monitor wheel speeds during a road test. Watch the wheel speeds being displayed on the scan tool to see if any of the readings are unusual, such as one sensor varying in speed from the other three, a signal going intermittently high or low, etc. If this does not identify the intermittent, wet the speed sensor harness on the underside of the vehicle and perform a road test, monitoring the wheel speeds with the scan tool.
The wheel speed sensor is defective or disconnected. There is a problem in the wiring. There is a problem with a connector.
SSANGYONG Y200
ABS AND TCS 4E-53 DTC 050 - Right Rear Wheel Speed Sensor Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the right rear wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure the resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 F)? Replace the wheel speed sensor. Is the repair complete? 1. Switch the DVM to the AC mV. 2. Measure the voltage output between the wheel speed sensor terminals while rotating the wheel about 1 revolution per second. Is the output within the specified value? Replace the speed sensor or the toothed wheel, as required. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Measure the resistance to ground from terminal 1 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 2 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? Repair the short to ground in the affected circuit. Is the repair complete? 1. Measure the resistance between terminal 1 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 2 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
70 mV
Go to Step 6
Go to Step 5
System OK
>1V -
Go to Step 8 -
Go to Step 10 -
10
>5
Go to Step 11
Go to Step 12
11
System OK System OK
12
SSANGYONG Y200
4E-54 ABS AND TCS
YAD4E200
DIAGNOSTIC TROUBLE CODE (DTC) - RIGHT REAR WHEEL SPEED SENSOR CONTINUITY FAULT
Circuit Description The toothed wheel generates a voltage pulse as it moves past the sensor. Each tooth-gap-tooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine the wheel speed. The voltage generated depends on the air gap between the sensor and the toothed wheel, and on the wheel speed. Diagnosis This procedure checks for a malfunctioning wheel speed sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins an examination for a defective wheel speed sensor. 6. This step tests the wiring for a short to voltage. 8. This step tests the wiring for a short to ground. 10. This step tests for an open or high resistance in the wiring. Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained. This will help to prevent false signals due to the pickup of electrical noise. It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
The wheel speed sensor is defective or disconnected. There is a problem in the wiring. There is a problem with a connector.
SSANGYONG Y200
ABS AND TCS 4E-55 Right Rear Wheel Speed Sensor Continuity Fault
Step 1 Action Examine the wheel speed sensor. Are there any signs of physical damage? 1. Turn the ignition to LOCK. 2. Disconnect the right rear wheel speed sensor connector. 3. Use a digital voltmeter (DVM) to measure the resistance between the sensor terminals. Is the resistance within the specified value at approximately 25 C (77 C)? Replace the wheel speed sensor. Is the repair complete? 1. Disconnect the harness from the EBCM. 2. Connect a DVM between ground and one terminal of the wheel speed connector. 3. Turn the ignition to ON. 4. Repeat the above test for the other terminal of the wheel speed connector. Is the voltage for either of these terminals within the specified value? Repair the short to voltage in the affected circuit. Is the repair complete? 1. Turn the ignition go LOCK. 2. Measure the resistance to ground from terminal 1 at the harness EBCM connector. 3. Measure the resistance to ground from terminal 2 at the harness EBCM connector. Is the resistance at either circuit less than the specified value? 1. Measure the resistance between terminal 1 at the harness EBCM connector and the harness wheel speed sensor connector. 2. Measure the resistance between terminal 2 at the harness EBCM connector and the harness wheel speed sensor connector. Is the resistance on either circuit within the specified value? Repair the open or high resistance in the affected circuit as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
1280 - 1920 -
Go to Step 3 -
>1V -
Go to Step 6 -
System OK
Go to Step 7
>5
Go to Step 8
Go to Step 9
8 9
System OK System OK
SSANGYONG Y200
4E-56 ABS AND TCS
YAD4E210
DIAGNOSTIC TROUBLE COED (DTC) 245 - WHEEL SPEED SENSOR FREQUENCY ERROR
Circuit Description The toothed wheel generates a voltage pulse as it moves past the wheel speed sensor. Each tooth-gaptooth series on the wheel generates the pulses. The electronic brake control module (EBCM) uses the frequency of these pulses to determine wheel speed. The voltage generated depends on the air gap between the wheel speed sensor and the toothed wheel, and on the wheel speed. Diagnosis This DTC will set when the EBCM cannot identify which wheel speed sensor is causing the malfunction. It is necessary to check all wheel speed sensors and associated wiring to determine the cause of the DTC. Cause Incorrect number of teeth on the toothed wheel. Damaged or broken teeth on the toothed wheel. Open or short in speed wheel speed sensor wiring. Action Taken When the DTC Sets Antilock brake system (ABS) action is disabled and the ABS warning lamp is ON. Test Description The number(s) below refer to Step(s) on the diagnostic table. 1. This step begins the examination of the front wheel speed sensor sensors. 3. This step checks for a problem with one of the front toothed rings. 5. This step checks the front wheel speed sensors. 7. This step checks for shorts in a front wheel speed sensor harness. 9. This step checks for opens in a front wheel speed sensor harness. 11. This step begins a check of the rear wheel speed sensors. 13. This step checks for a problem with one of the rear toothed rings. 15. This step checks the rear wheel speed sensors. 17. This step checks for shorts in a rear wheel speed sensor harness. 19. This step checks for opens in a rear wheel speed sensor harness.
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ABS AND TCS 4E-57

Diagnostic Aids DTC 11 may be set by running the scan tool auto test if the throttle angle readings are not updating while in the date list mode. If this is the case, clear the DTCs, disconnect the scan tool, and road test the vehicle to at least 25 km/h (15 mph) to see if the DTC resets. Check the toothed wheels for any large grooves, gouges, marks, etc. that might influence the tooths signal at the wheel speed sensor. Also, check for a buildup of foreign material in the gaps between the teeth in the toothed wheel, as this material may cause this malfunction. A badly worn hub/bearing assembly may cause this malfunction. The wheel speed sensor-to-toothed wheel air gap may change excessively due to bearing play. If an improper rear hub assembly or front outer constant velocity joint is installed, one with a toothed wheel containing the incorrect number of teeth, this DTC can set. Be sure that all the toothed wheels have 52 teeth.
DTC 245 - Wheel Speed Sensro Frequency Error

Step 1 2 Action Visually inspect the wiring for the front wheel speed sensors. Is there any damage? Repair or replace components, as required. Is the repair complete? Check that the correct outer constant velocity (CV) joints are installed on the vehicle, They should have speed rings with 52 teeth. Is one of these incorrect? Replace the incorrect outer CV joint with the proper unit. Is the repair complete? 1. Disconnect the wheel speed sensor harnesses from the wheel speed sensor connectors. 2. Measure the wheel speed sensor resistance at the wheel speed sensor connector terminals. Does the resistance fall within the specified values for both wheel speed sensors? Replace the faulty wheel speed sensor. Is the repair complete? 1. Disconnect the ABS control module connector. 2. Check each wheel speed sensor harness for a short circuit between its wires with a digital ohmmeter attached to the two terminals at the harness side of the wheel speed sensor connector. 3. Also check each wheel speed sensor harness wire for a short to ground from the connector terminals. Is there any short circuit in either wheel speed sensor harness? Repair the short circuit tin the wiring or from a wiring harness to ground. Is the repair complete? Check the continuity of the wiring in both front wheel speed sensor circuits between the EBCM connector and the wheel speed sensor connector an each side of the vehicle. The left side uses terminals 7 and 6 at the EBCM connector. The right side uses terminals 4 and 5 at the EBCM connector. Is continuity good for both harnesses? Value Yes No
Go to Step 3 -
Go to Step 4
Go to Step 5
System OK
1280 - 1920 -
Go to Step 6 -
Go to Step 8
Go to Step 9
System OK
Go to Step 11
Go to Step 10
SSANGYONG Y200
4E-58 ABS AND TCS DTC 245 - Wheel Speed Sensro Frequency Error (Contd)
Step 10 Action Repair the discontinuity found in the front wheel speed sensor harness or connector C110. Is the repair complete? 1. Visually inspect the wiring for the rear wheel speed sensors. 2. Check that the wheel speed sensors are properly mounted and that the retaining belts are properly tightened. Is there any damage? Remove each wheel speed sensor from the rear axle and inspect the toothed ring through the wheel speed sensor mounting holes. Make sure that the toothed ring has 52 teeth. Check for any damaged or missing teeth. Check that the ring is properly positioned under the wheel speed sensor. Is there any damage or other fault with either speed ring? Replace the rear wheel hub with the proper unit. Is the repair complete? 1. Disconnect the rear wheel speed sensor harnesses from the wheel speed sensor connectors. 2. Measure the wheel speed sensor resistance at the wheel speed sensor connector terminals. Does the resistance fall within the specified values for both wheel speed sensors? Replace the faulty wheel speed sensor. Is the repair complete? 1. The ABS control module connector should still be disconnected. Disconnect it now if it is not. 2. Check each wheel speed sensor harness for a short circuit between its wires with a digital ohmmeter attached to the two terminals at the harness side of the wheel speed sensor connector. 3. Also, check each wheel speed sensor harness wire for a short to ground from the connector terminals. Is there any short circuit in either wheel speed sensor harness? Repair the short circuit in the wiring or from a wire to ground. Is the repair complete? Check the continuity of the wiring in both rear wheel speed sensor circuits between the EBCM connector and the wheel speed sensor connector on each side of the vehicle. The left side uses terminals 8 and 9 at the EBCM connector. The right side uses terminals 2 and 1 at the EBCM connector. Is continuity good for both harnesses? Value Yes No
System OK
11
System OK
Go to Step 12
12
Go to Step 14 -
13
14
1280 - 1920 -
Go to Step 15 -
15
16
Go to Step 17
Go to Step 18
17
System OK
Go to Step 19
18
Go to Step 20
SSANGYONG Y200
ABS AND TCS 4E-59 DTC 245 - Wheel Speed Sensro Frequency Error (Contd)
Step 19 20 Action Repair the discontinuity found in the rear wheel speed sensor harness. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
System OK System OK
SSANGYONG Y200
4E-60 ABS AND TCS
YAD4E220
DIAGNOSTIC TROUBLE CODE (DTC) 930 - ACCELERATION SENSOR FAULT

Circuit Description The acceleration sensor provides a voltage signal that changes in relation to the acceleration of vehicle. The signal voltage will vary from about 1.95 to 3.45 volt. The electronic brake control module (EBCM) monitor a signal voltage of deceleration in the vehicle. Diagnosis This procedure checks for a malfunctioning acceleration sensor, a short to ground or to voltage in the wiring or a contact problem in a connector. Cause The vertical acceleration sensor is defective or disconnected. There is a problem in the wiring. There is a problem with a connector Wrong installed vertical acceleration sensor Fail Action ABS action is disabled, and the ABS warning lamp is ON. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks for the voltage reference from the EBCM. 5. This step checks for the voltage signal from the acceleration sensor. Diagnostic Aids Be sure that the acceleration sensor wiring is properly routed and retained. It is very important to perform a thorough inspection of the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction. You can use the scan tool to monitor acceleration sensor during a road test. Watch the acceleration sensor being display on the scan tool to see if any of the reading is unusual.
SSANGYONG Y200
ABS AND TCS 4E-61 DTC 930 - Acceleration Sensor Fault

Step 1 Action Examine the acceleration sensor. Are there any signs of physical damage? 1. Turn the ignition switch to ON. 2. Use a digital voltmeter (DVM) to measure the voltage between terminal 28 and 23 of EBCM. Is the voltage within the specified value? Replace the acceleration sensor. Is the repair complete? Repair the open in the affected circuit or replace the acceleration sensor, if necessary. Is the repair complete? 1. Place the acceleration sensor horizontally and let the acceleration sensor. 2. Turn the ignition switch to ON. 3. Use a digital voltmeter (DVM) to measure the voltage between terminal 28 and 10 of EBCM. Is the voltage within the specified value? Repair the open in the affected circuit or replace the acceleration sensor, if necessary. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
4.75 - 5.25 V -
Go to Step 4 -
3 4
System OK
1.95 - 3.45 V
Go to Step 7
Go to Step 6
System OK System OK
SSANGYONG Y200
4E-62 ABS AND TCS
YAD4E220
DIAGNOSTIC TROUBLE CODE (DTC) - ACCELERATION SENSOR CONTINUITY FAULT

Circuit Description The acceleration sensor provides a voltage signal that changes in relation to the acceleration of vehicle. The signal voltage will vary from about 1.95 to 3.45 volt. The electronic brake control module (EBCM) monitor a signal voltage of deceleration in the vehicle. Diagnosis This procedure checks for a malfunctioning acceleration sensor, a short to ground or to voltage in the wiring, or a contact problem in a connector. Cause The vertical acceleration sensor is defective or disconnected. There is a problem in the wiring. There is a problem with a connector Wrong installed vertical acceleration sensor Action Taken When the DTC Sets ABS action is disabled, and the ABS warning lamp is ON. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks for the voltage reference from the EBCM. 5. This step checks for the voltage signal from the acceleration sensor. Diagnostic Aids Be sure that the acceleration sensor wiring is properly routed and retained. It is very important to perform a thorough inspection of the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction. You can use the scan tool to monitor acceleration sensor during a road test. Watch the acceleration sensor being display on the scan tool to see if any of the reading is unusual.
SSANGYONG Y200
ABS AND TCS 4E-63 DTC - Acceleration Sensor Continuity Fault

Step 1 Action Examine the acceleration sensor. Are there any signs of physical damage? 1. Turn the ignition switch to ON. 2. Use a digital voltmeter (DVM) to measure the voltage between terminal 28 and 23 of EBCM. Is the voltage within the specified value? Replace the acceleration sensor. Is the repair complete? Repair the open in the affected circuit or replace the acceleration sensor, if necessary. Is the repair complete? 1. Place the acceleration sensor horizontally and let the acceleration sensor. 2. Turn the ignition switch to ON. 3. Use a digital voltmeter (DVM) to measure the voltage between terminal 28 and 10 of EBCM. Is the voltage within the specified value? Repair the open in the affected circuit or replace the acceleration sensor, if necessary. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes Go to Step 3 No Go to Step 2
4.75 - 5.25 V -
Go to Step 4 -
3 4
System OK
1.95 - 3.45 V
Go to Step 7
Go to Step 6
System OK System OK
SSANGYONG Y200
4E-64 ABS AND TCS
YAD4E230
DIAGNOSTIC TROUBLE COED (DTC) 060/065 - LEFT FRONT INLET AND OUTLET VALVE SOLENOID FAULT
Circuit Description The solenoid valve coil circuits are supplied with power from the battery when the valve relay is energized. Switched ground is provided by the electronic brake control module (EBCM) to each coil. Diagnosis This procedure checks whether the left front inlet and outlet valves are functioning. Cause A valve has failed. A solenoid coil is open or shorted. Action Taken When the DTC Sets ABS is disabled, and the ABS warning lamp is turned ON for the remainder of the ignition cycle. If the failure is intermittent, the EBCM will enable the system at the next ignition cycle and set a history DTC. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step begins the test of the inlet valve 3. This step tests the outlet valve.
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ABS AND TCS 4E-65 DTC 060/065 - Left Front Inlet and Outlet Valve Solenoid Fault
Step Action 1. Raise and suitably support the vehicle at the corner being tested. 2. Turn the ignition to ON. 3. Install the scan tool to the data link connector (DLC) and select Wheel front left to begin the solenoid tests at that wheel. This will test both the inlet and the outlet valves. 4. When the scan tool indicates Pressure hold, press and hold the brake pedal until the end of the test. 5. Have an assistant attempt to rotate the wheel. Can the wheel be rotated? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure increase, have an assistant attempt to rotate the wheel again. Can the wheel be rotated now? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure release on, have an assistant attempt to rotate the wheel again. Can the wheel be rotated? 1. Release brake pedal pressure when the scan tool indicates Pressure release off 2. Clear all DTCs. 3. Road test the vehicle. Does the DTC set again? 1. Check the wiring harness and connector terminals for an intermittent problem. 2. Repair any problem found. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
Go to Step 2
Go to Step 6
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 5
System OK System OK
SSANGYONG Y200
4E-66 ABS AND TCS
YAD4E230
DIAGNOSTIC TROUBLE COED (DTC) 070/075 - RIGHT FRONT INLET AND OUTLET VALVE SOLENOID FAULT
Circuit Description The solenoid valve coil circuits are supplied with power from the battery when the valve relay is energized. Switched ground is provided by the electronic brake control module (EBCM) to each coil. Diagnosis This procedure checks whether the right front inlet and outlet valves are functioning. Cause A solenoid coil is open or shorted. Action Taken When the DTC Sets ABS is disabled, and the ABS warning lamp is turned ON for the remainder of the ignition cycle. If the failure is intermittent, the EBCM will enable the system at the next ignition cycle and set a history DTC. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This begins the test of the inlet valve 3. This tests the outlet valve.
SSANGYONG Y200
ABS AND TCS 4E-67 DTC 070/075 - Right Front Inlet and Outlet Valve Solenoid Fault
Step Action 1. Raise and suitably support the vehicle at the corner being tested. 2. Turn the ignition to ON. 3. Install the scan tool to the data link connector (DLC) diagnostic and select Wheel front right to begin the solenoid tests at that wheel. This will test both the inlet and the outlet valves. 4. When the scan tool indicates Pressure hold, press and hold the brake pedal until the end of the test. 5. Have an assistant attempt to rotate the wheel. Can the wheel be rotated? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure increase, have an assistant attempt to rotate the wheel again. Can the wheel be rotated now? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure release on, have an assistant attempt to rotate the wheel again. Can the wheel be rotated? 1. Release brake pedal pressure when the scan tool indicates Pressure release off 2. Clear all DTCs. 3. Road test the vehicle. Does the DTC set again? 1. Check the wiring harness and connector terminals for an intermittent problem. 2. Repair any problem found. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
Go to Step 2
Go to Step 6
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 5
System OK System OK
SSANGYONG Y200
4E-68 ABS AND TCS
YAD4E230
DIAGNOSTIC TROUBLE COED (DTC) 080/085 - LEFT REAR INLET AND OUTLET VALVE SOLENOID FAULT
Circuit Description The solenoid valve coil circuits are supplied with power from the battery when the valve relay is energized. Switched ground is provided by the electronic brake control module (EBCM) to each coil. Diagnosis This procedure checks whether the left rear inlet and outlet valves are functioning. Cause(s) A valve has failed. A solenoid coil is open or shorted. Action Taken When the DTC Sets ABS is disabled, and the ABS warning lamp is turned ON for the remainder of the ignition cycle. If the failure is intermittent, the EBCM will enable the system at the next ignition cycle and set a history DTC. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This begins the test of the inlet valve 3. This tests the outlet valve.
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ABS AND TCS 4E-69 DTC 080/085 - Left Rear Inlet and Outlet Valve Solenoid Fault
Step Action 1. Raise and suitably support the vehicle. 2. Turn the ignition to ON. 3. Install the scan tool to the data link connector (DLC) and select Wheel rear left to begin the solenoid tests at that wheel. This will test both the inlet and the outlet valves. 4. When the scan tool indicates Pressure hold, press and hold the brake pedal until the end of the test. 5. Have an assistant attempt to rotate the wheel. Can the wheel be rotated? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure increase, have an assistant attempt to rotate the wheel again. Can the wheel be rotated now? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure release on, have an assistant attempt to rotate the wheel again. Can the wheel be rotated? 1. Release brake pedal pressure when the scan tool indicates Pressure release off. 2. Clear all DTCs. 3. Road test the vehicle. Does the DTC set again? 1. Check the wiring harness and connector terminals for an intermittent problem. 2. Repair any problem found. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
Go to Step 2
Go to Step 6
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 5
System OK System OK
SSANGYONG Y200
4E-70 ABS AND TCS
YAD4E230
DIAGNOSTIC TROUBLE COED (DTC) 090/095 - RIGHT REAR INLET AND OUTLET VALVE SOLENOID FAULT
Circuit Description The solenoid valve coil circuits are supplied with power from the battery when the valve relay is energized. Switched ground is provided by the electronic brake control module (EBCM) to each coil. Diagnosis This procedure checks whether the right rear inlet and outlet valves are functioning. Cause(s) A valve has failed. A solenoid coil is open or shorted. Action Taken When the DTC Sets ABS is disabled, and the ABS warning lamp is turned ON for the remainder of the ignition cycle. If the failure is intermittent, the EBCM will enable the system at the next ignition cycle and set a history DTC. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This begins the test of the inlet valve 3. This tests the outlet valve.
SSANGYONG Y200
ABS AND TCS 4E-71 DTC 090/095 Right Rear Inlet and Outlet Valve Solenoid Fault
Step Action 1. Raise and suitably support the vehicle. 2. Turn the ignition to ON. 3. Install the scan tool to the data link connector (DLC) and select Wheel rear right to begin the solenoid tests at that wheel. This will test both the inlet and the outlet valves. 4. When the scan tool indicates Pressure hold, press and hold the brake pedal until the end of the test. 5. Have an assistant attempt to rotate the wheel. Can the wheel be rotated? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure increase, have an assistant attempt to rotate the wheel again. Can the wheel be rotated now? 1. Maintain pressure on the brake pedal. 2. When the scan tool indicates Pressure release on, have an assistant attempt to rotate the wheel again. Can the wheel be rotated? 1. Release brake pedal pressure when the scan tool indicates Pressure release off. 2. Clear all DTCs. 3. Road test the vehicle. Does the DTC set again? 1. Check the wiring harness and connector terminals for an intermittent problem. 2. Repair any problem found. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
Go to Step 2
Go to Step 6
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 5
System OK System OK
SSANGYONG Y200
4E-72 ABS AND TCS
YAD4E230
DIAGNOSTIC TROUBLE COED (DTC) 141/146 - LEFT REAR PRIME LINE AND TRACTION CONTROL SYSTEM (TCS) PILOT VALVE FAULT
Circuit Description The solenoid valve coil circuits are supplied with power from the battery when the valve relay is energized. Switched ground is provided by the electronic brake control module (EBCM) to each coil. Diagnosis This procedure checks whether the left rear TCS valves are functioning. Cause(s) A solenoid coil is open or shorted. Action Taken When the DTC Sets Antilock brake system (ABS) is disabled, and the ABS warning lamp is turned ON for the remainder of the ignition cycle. If the failure is intermittent, the EBCM will enable the system at the next ignition cycle and set a history DTC.
SSANGYONG Y200
ABS AND TCS 4E-73 DTC 141/146 - Left Rear Prime Line and TCS Pilot Valve Fault
Step Action 1. Raise and suitably support the vehicle at the corner being tested. 2. Turn the ignition to ON. Important: Do not step on the brake pedal at any time during this test. 3. Install the scan tool to the data link connector (DLC). 4. Select the TCS function and Wheel rear left to begin the solenoid tests at that wheel. This will test both the prime and pilot valves. 5. When the scan tool indicates a pressure increase, attempt to rotate the wheel. Can the wheel be rotated? When the scan tool indicates that the prime valve was turned OFF, attempt to rotate the wheel again. Can the wheel be rotated now? When the scan tool indicates that the pilot valve and the pump motor were switched OFF, attempt to rotate the wheel again. Can the wheel be rotated? 1. Clear all DTCs. 2. Road test the vehicle. Does the DTC set again? 1. Check the wiring harness and connector terminals for an intermittent problem. 2. Repair any problem found. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
Go to Step 6
Go to Step 2
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 5
System OK System OK
SSANGYONG Y200
4E-74 ABS AND TCS
YAD4E240
DIAGNOSTIC TROUBLE CODE (DTC) 121 - VALVE RELAY CIRCUIT FAULT

Circuit Description When the ABS is active, the valve relay provides voltage to actuate the solenoid valves. The valves do not use this voltage unless the ABS control module provides the ground for each solenoid coil. DTC 12 will set if the valve relay voltage is low or if the relay supply line is at 12 volts when the ABS control module is not requesting it. This DTC will also set if the ABS control module detects three or more solenoid valve circuits are open or shorted during the self-test. Diagnosis This procedure checks whether there is a poor ground connection for the electronic brake control module (EBCM). Cause(s) A connector terminal is corroded. The wiring harness is damaged. The ground terminal is not conducting properly. The valve relay is defective. The EBCM is defective. Action Taken When the DTC Sets ABS/TCS is disabled, and the ABS warning lamp is turned ON for the remainder of the ignition cycle. If the failure is intermittent, the control module will enable the system at the next ignition cycle and set a history DTC 12. Diagnostic Aids It is very important to perform a thorough inspection of the wiring and the connectors. Failure to do so may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
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ABS AND TCS 4E-75 DTC 121 - Valve Relay Circuit Fault
Step 1 Action 1. Use a scan tool to clear all DTCs. 2. Road test the vehicle. Does DTC 121 set again? 1. Check all system wiring harness connectors and terminals, especially the electronic brake control module (EBCM), for any problem that could cause an intermittent condition. 2. Repair any intermittent problem found. Is the repair complete? Check fuse SB2. Is fuse SB2 blown? 1. Check for a short circuit and repair it, if necessary. 2. Replace fuse SB2. Is the repair complete? 1. Disconnect the valve relay. 2. Check the voltage between the valve relay connector terminal 15 and ground of EBCM. Is the voltage equal to the specified valve? Repair the open circuit between the valve relay connector terminal 15 and terminal SB2 of EBCM. Is the repair complete? Replace the hydraulic modulator. Is the repair complete? Value Yes No
Go to Step 3
Go to Step 2
System OK Go to Step 4
Go to Step 5
3 4
System OK
11 - 14 V
Go to Step 7
Go to Step 6
6 7
System OK System OK
SSANGYONG Y200
4E-76 ABS AND TCS
YAD4E250
DIAGNOSTIC TROUBLE CODE (DTC) 110 - RETURN PUMP MOTOR CIRCUIT FAULT
Circuit Description When the electronic brake control module (EBCM) grounds the pump motor relay, it closes and provides battery voltage to the pump motor. The EBCM senses the voltage applied to the pump motor verify motor operation. Diagnosis This DTC sets when the EBCM detects B+ without motor relay activation or if the EBCM does not detect B+ after motor relay activation. Cause There is a faulty terminal in the pump motor connector. There is faulty terminal in EBCM connector. There is high resistance in the chassis ground. Action Taken When the DTC Sets ABS is disabled, and the ABS warning lamp is ON. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks for poor connection. 5. This step checks for the motor relay. 13. This step checks for the hydraulic modulator. Diagnostic Aids It is very important to perform a thorough inspection of the wiring and the connectors. Failure to do so may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
The EBCM defective. There is a problem in the wiring from the pump motor connector to the motor.
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ABS AND TCS 4E-77 DTC 110 - Pump Motor or Pump Motor Relay Fault
Step 1 Action 1. Use a scan tool to clear all DTCs. 2. Road test the vehicle. Does DTC 110 set again? 1. Check all system wiring harness connectors and terminals, especially the electronic brake control module (EBCM), for any problem that could cause an intermittent condition. 2 Repair any intermittent problem found. Is the repair complete? Check fuse SB2. Is fuse SB2 blown? 1. Check for a short circuit and repair it, if necessary. 2. Replace fuse SB2. Is the repair complete? 1. Disconnect the motor relay. 2. Check the resistance between the motor relay connector terminal 17 and terminal 18 of EBCM. Is the resistance equal to the specified value? Repair the open circuit between the motor relay connector terminal 17 and fuse SB2 of EBCM. Is the repair complete? 1. Turn the ignition to ON. 2. Check the voltage between the motor relay connector terminal 15 and ground of EBCM. Is the voltage equal to the specified value? 1. Repair the open circuit between the motor relay connector terminal 87 and terminal 14 of hydraulic modulator. 2. Road test the vehicle Does DTC 110 clear? 1. Replace the hydraulic modulator/EBCM. 2. Road test the vehicle Does DTC 110 clear? Value Yes No
Go to Step 3
Go to Step 2
Go to Step 5
System OK
11 - 14 V
Go to Step 7
Go to Step 6
System OK
11 - 14 V
Go to Step 9
Go to Step 8
System OK
Go to Step 9
System OK
SSANGYONG Y200
4E-78 ABS AND TCS
YAD4E260
DIAGNOSTIC TROUBLE CODE (DTC) 161 - STOPLAMP SWITCH FAULT

Circuit Description When the brake pedal is pressed, the contacts on the brake light switch close to illuminate the brake lights. Battery voltage is also applied to terminal 14 of the electronic brake control module (EBCM), which signals the ABS controller that the brakes are applied and ABS may be needed. Without this, signals from a wheel speed sensor that may indicate the need for ABS intervention are questionable. When the brake pedal is not pressed, the EBCM terminal 14 is grounded through the stoplamps. Diagnosis This procedure will check whether there is no output or constant output from the stoplamp switch and will determine the cause as a faulty switch or a problem in the circuitry. Cause The ground connection or the positive connection at the EBCM has failed.
There is an open, short to ground, of short to positive in the vehicle wiring. The stoplamp switch has failed.
Action Taken When the DTC Sets The system records a DTC 161. ABS operation is not disabled. Test description The number(s) below refer to step(s) on the diagnostic table. 12. This step begins the process of troubleshooting stoplamps that are always on. Diagnostic Aids Inspect the wiring and the connectors carefully and thoroughly. Failure to do so could result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
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ABS AND TCS 4E-79 DTC 161 - Stoplamp Switch Fault

Step 1 2 Action Observe the stoplamps when the brakes are applied. Do the stoplamps turn on? Check fuse SB8. Is fuse SB8 blown? 1. Check for a short circuit and repair it, if necessary. 2. Replace fuse SB8. Is the repair complete? Check the voltage at fuse SB8. Is the voltage equal to the specified value? Repair the power supply circuit for fuse SB8. Is the repair complete? Check the voltage at fuse F16. Is fuse F16 blown? 1. Check for a short circuit between terminal SB8 and fuse F16 in the I/P fuse block and repair it, if necessary. 2. Replace fuse F16. Is the repair complete? Check the voltage at terminal 1 of the stoplamps switch. Is the voltage equal to the specified value? Repair the open circuit between fuse F16 and terminal 1 of the stoplamp switch. Is the repair complete? With the brakes applied, check the voltage at terminal 2 or 4 of the stoplamp switch. Is the voltage equal to the specified value? Replace the stoplamp switch. Is the repair complete? 1. Disconnect the electronic brake control module (EBCM) connector. 2. Visually inspect the EBCM and its connector for damaged pins or terminals. Are there any damaged pins or terminals? Repair the damaged pins or terminals. Is the repair complete? 1. With the EBCM connector disconnected, applied the brake. 2. Check the voltage at terminal 14 of the EBCM. Is the voltage equal to the specified value? Repair the open circuit between 1 of the stoplamp switch and terminal 14 of the EBCM connector. Is the repair complete? With the EBCM disconnected, use an ohmmeter to measure the resistance between ground and terminal 16 of the EBCM connector. Is the resistance equal to the specified value? Value Yes Go to Step 12 Go to Step 3 No Go to Step 2 Go to Step 4
11 - 14 V -
System OK Go to Step 6 System OK Go to Step 7
Go to Step 5 Go to Step 8
4 5 6
System OK
11 - 14 V
Go to Step 10
Go to Step 9
System OK
10 11
11 - 14 V -
Go to Step 11 -
12
Go to Step 14 -
13
14
11 - 14 V
Go to Step 16
Go to Step 15
15
System OK
16
Go to Step 18
Go to Step 17
SSANGYONG Y200
4E-80 ABS AND TCS DTC 161 - Stoplamp Switch Fault (Contd)
Step 17 18 Action Repair the open circuit between ground and terminal 14 of the EBCM. Is the repair complete? Replace the ABS unit. Is the repair complete? Value Yes No
System OK System OK
SSANGYONG Y200
ABS AND TCS 4E-81
BLANK
SSANGYONG Y200
4E-82 ABS AND TCS
YAD4E270
DIAGNOSTIC TROUBLE CODE (DTC) 800 - LOW VOLTAGE FAULT

Circuit Description Proper operation of the electronic brake control module (EBCM) requires a certain minimum voltage. The EBCM monitors the ignition feed circuit to determine if the voltage falls below a minimum level. Diagnosis This test checks for battery output, proper grounding, blown fuses, faulty ignition switch, and problems in the circuitry. Cause The battery is defective. There is a defective ground connection. A connector is damaged. A wire is broken or shorted. A fuse is blown. The ignition switch is malfunctioning. Action Taken When the DTC Sets ABS action is disabled during the period of low voltage, and the ABS warning lamp is ON for the remainder of the ignition cycle. If the failure is intermittent, the EBCM will enable the system at the next ignition cycle and set a history DTC 800. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step determines whether there is voltage at the battery and at the high current source. 7. This step checks for voltage at the ignition 1 source. 15. This step begins the check for voltage at the EBCM end of the ABS harness. Diagnostic Aids It is very important to perform a thorough inspection of the wiring and the connectors. Failure to do so may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
SSANGYONG Y200
ABS AND TCS 4E-83 DTC 800 - Low Voltage Fault

Step 1 2 3 4 Action Check the voltage at the battery. Is the voltage within the specified value? Charge or replace the battery, as required. Is the repair complete? Check fuse SB2 in the engine fuse block. Is the fuse blown? 1. Replace fuse SB2. 2. Turn the ignition to ON. Does the fuse blow again? 1. Turn the ignition to OFF. 2. Trace the wires in the ABS wiring harness from terminal SB2 at the engine fuse block to the terminal 17, 18 in EBCM. 3. Repair any short circuit found along this path. Is the repair complete? 1. Turn the ignition to OFF. 2. Install the scan tool. 3. Clear all DTCs. 4. Road test the vehicle. Does DTC 800 reset? Check terminal 1 in the C101 connector. Is the connection good? Repair the terminal. Is the repair complete? 1. Turn the ignition to OFF. 2. Install the scan tool. 3. Clear all DTCs. 4. Rood test the vehicle. Does DTC 800 reset? Check fuse F7 in the I/P fuse block. Is fuse F7 blown? 1. Replace fuse F7. 2. Turn the ignition to ON. Does fuse F7 blow again? 1. Turn the ignition to OFF. 2. Trace the WHT/RED wires in the ABS wiring harness from fuse F7 to terminal 15 of the EBCM connector. 3. Repair any short circuit found along this path. Is the repair complete? 1. Turn the ignition to OFF 2. Install the scan tool. 3. Clear all DTCs. 4. Rood test the vehicle. Does DTC 800 reset? Value 11 - 14 V Yes Go to Step 3 System OK Go to Step 4 No Go to Step 2 Go to Step 7
Go to Step 5
Go to Step 6
System OK
System OK Go to Step 8 System OK
7 8
Go to Step 14
10
11
Go to Step 12
Go to Step 13
12
System OK
13
System OK
SSANGYONG Y200
4E-84 ABS AND TCS DTC 800 - Low Voltage Fault (Contd)
Step Action 1. Disconnect the connector from the EBCM. 2. Turn the ignition to ON. 3. Check the voltage between ground and terminal 17, and between ground and terminal 18. Is the voltage within the specified value? 1. Turn the ignition to OFF. 2. Trace the WHT/RED wires between terminals 17 and 18 of the EBCM connector to fuse F7 and SB2 in the I/P fuse block. 3. Repair the open in this circuit. Is the repair complete? 1. Turn the ignition ON. 2. Check the voltage at fuse SB2. Is the voltage within the specified value? Repair the power supply circuit for fuse SB2. Is the repair complete? 1. Turn the ignition to OFF. 2. Check the resistance between ground and terminals 16 and 19 of the ABS harness EBCM connector. Is the resistance equal to the specified value? Examine terminals 15, 16, 17, 18 and 19 of the EBCM connector. Is there a defective terminal? Repair the defective terminal or replace the connector or wiring harness, as required. Is the repair complete? Repair the defective ground connection. Is the repair complete? 1. Install the scan tool. 2. Clear all DTCs. 3. Road test the vehicle. Does DTC 800 set again? Replace the ABS unit. Is the repair complete? 1. Examine the wiring harness and connectors for causes of intermittent problems. 2. Repair any intermittent problem found. Is the repair complete? Value Yes No
14
11 - 14 V
Go to Step 16
15
System OK
16 17
11 - 14 V -
Go to Step 17
18
Go to Step 19
19
Go to Step 20
Go to Step 21
20 21
System OK System OK
Go to Step 22 -
22
Go to Step 24 -
23
24
System OK
SSANGYONG Y200
ABS AND TCS 4E-85
BLANK
SSANGYONG Y200
4E-86 ABS AND TCS
YAD4E270
DIAGNOSTIC TROUBLE CODE (DTC) 550 - EBCM INTERNAL FAULT

Circuit Description The ABS control module performs various diagnostic checks on itself. If it finds a problem, it sets DTC 550. Diagnosis This procedure checks whether there is a poor ground connection for the electronic brake control module (EBCM). Cause A connector terminal is corroded. The EBCM is malfunctioning. Action Taken When the DTC Sets ABS is disabled, and the ABS warning lamp is turned ON. If the failure is intermittent, the control module will enable the system at the next ignition cycle and will store a history DTC 550. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step begins the testing for a poor voltage or ground connection. Diagnostic Aids It is very important to perform a thorough inspection of the wiring and the connectors. Failure to inspect the wiring and the connectors carefully and completely may result in misdiagnosis, causing part replacement with the reappearance of the malfunction.
SSANGYONG Y200
ABS AND TCS 4E-87 DTC 550 - EBCM Internal Fault

Step Action Use the scan tool to determine if any other DTCs are set. Are other DTCs set? 2 Clear all DTCs and road test the vehicle. Does DTC 550 set again? 1. Check all wiring harness connectors and terminals, especially those at the EBCM, for any condition that could cause an intermittent. 2. Repair any problems found. Is the repair complete? 1. Turn the ignition to OFF. 2. Disconnect the EBCM connector. 3. Turn the ignition to ON. 4. Measure the voltage between ground and terminals 15, 17 and 18 of the EBCM harness connector. Is the voltage equal to the specified value? 1. Check the voltage supply and the ground connections to the EBCM. 2. Repair any open or high resistance found. Is the repair complete? Check the EBCM connector for any damaged terminals. Are there any problems? Repair any connector problem found. Is the repair complete? Clear all DTCs and road test the vehicle. Does DTC 550 set again? Replace the EBCM. Is the repair complete? Value Yes Go to the applicable Diagnostic Table Go to Step 4 No
System OK
11 - 14 V
Go to Step 6
Go to Step 5
System OK
6 7 8 9
Go to Step 7 System OK Go to Step 9 System OK
Go to Step 8 System OK -
SSANGYONG Y200
4E-88 ABS AND TCS
ABS 5.3 CIRCUIT
YAD4E280
SSANGYONG Y200
ABS AND TCS 4E-89
ABD 5.3 CIRCUIT
YAD4E290
SSANGYONG Y200
4E-90 ABS AND TCS
CONNECTOR END VIEWS

EBCM (HYDRAULIC MODULATOR/UNIT INTEGRATED)
YAD4E300
Pin Wire Color 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 WHT BLK/GRN BLK/RED WHT/RED BRN BLK/WHT BRN/BLK BRN/WHT RED/BLK BLU/BLK WHT/GRN YEL BRN/RED BLK
Circuit Right Rear Speed Sensor Ground Right Rear Speed Sensor Not Used Right Front Speed Sensor Ground Right Front Speed Sensor Left Front Speed Sensor Ground Left Front Speed Sensor Left Rear Speed Sensor Ground Left Rear Speed Sensor Acceleration Sensor Signal Data Link Connector Not Used TOD Stoplamp SW Ignition Ground
Pin Wire Color 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 RED/WHT RED/WHT BLK GRN/BRN GRN/BLK BLU YEL/GRN RED/GRN Battery Battery Ground
Circuit
ABS Warning Lamp EBD Warning Lamp TCS Warning Lamp Acceleration Sensor Supply Voltage (5V) Not Used Not Used Not Used Not Used Acceleration Sensor Ground Not Used Not Used Not Used
SSANGYONG Y200
ABS AND TCS 4E-91

SERVICE PRECAUTIONS
Caution: Brake Fluid may irritate eyes and skin. In case of contact, take the following actions:
Eye contact - rinse thoroughly with water. Skin contact - wash with soap and water. Ingestion - consult a physician immediately.
Caution : To help avoid personal injury due to poor braking. DO NOT Tap into the vehicles brake system to operate a trailer brake system. Notice : When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread-locking compound will be called out. The correct torque values must be used when installing fasteners that require them. If the above procedures are not followed, parts or system damage could result. Notice : Use only DOT-3 equivalent hydraulic brake fluid. The use of DOT-5 (silicone) brake fluid is not recommended. Reduced brake performance or durability may result. Notice : Avoid spilling brake fluid on any the vehicles painted surfaces, wiring, cables or electrical connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, flush the area with water to lessen the damage.
Electronic System Service Precautions

Take care to avoid electronic brake control module (EBCM) circuit overloading. In testing for opens or shorts, do not ground or apply voltage to any circuit unless instructed to do so by the diagnostic procedure. Test circuits only with a high-impedance multi-meter. Never remove or apply power to any control module with the ignition switch in the ON position. Always turn the ignition to the OFF position before removing or connecting battery cables, fuses or connectors.
General Service Precautions

Disconnect the EBCM connector before performing any vehicle welding work using an electric arc welder. Do not attempt to disassemble any component designated as nonserviceable. The hydraulic modulator and the EBCM can be separated from each other and replaced separately but cannot be serviced. They have no replaceable parts, and there is no replaceable parts, and there is no access to the components they contain.
SSANGYONG Y200
4E-92 ABS AND TCS
Bleeding System
Replacement modulators are shipped already filled and bled. In normal procedures requiring removal of the modulator, such as to replace the EBCM, air will not enter the modulator, and normal bleeding will be all that is needed. If air enters the hydraulic modulator, or if an unfilled modulator is installed, use the brake bleeding program in the scan tool to bleed the modulator. Manual bleeding of the hydraulic modulator is not possible.
HYDRAULIC MODULATOR/EBCM ASSEMBLY

1. Disconnect the negative battery cable. 2. Disconnect the ABS wiring harness connector from its socket on the EBCM. 3. Cover the connector and the socket with shop cloths to protect them from brake fluid.
YAD4E310
Notice: Take care not to allow air into the hydraulic modulator. If air gets into the hydraulic unit, it will require a bleeding procedure using a scan tool programmed for the ABS 5.3 system. As long as no air enters the hydraulic unit, a simple bleeding procedure is all the system will require. 4. Remove the brake pipes from the hydraulic modulator. Installation Notice Tightening Torque
YAD4E320
14 Nm (124 lb-in)
5. Loosen the mounting nuts on the hydraulic unit. 6. Move the brake pipes aside far enough to allow for lifting the ABS 5.3 unit out of the mounting bracket. 7. Cap the brake pipes. Installation Notice Tightening Torque 6 Nm (53 lb-in)
Bleed the hydraulic system. 8. Installation should follow the removal procedure in the reverse order.
YAD4E330
SSANGYONG Y200
ABS AND TCS 4E-93
FRONT WHEEL SPEED SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the front wheel speed sensor electrical connector.
YAD4E340
3. Raise and suitably support the vehicle. 4. Turn the steering wheel to expose the front wheel speed sensor. It is located at the rear of the steering knuckle near tie rod end. 5. Remove the bolt and the front wheel speed sensor from the steering knuckle. Installation Notice Tightening Torque 7 Nm (62 lb-in)

YAD4E350
REAR WHEEL SPEED SENSOR

1. Disconnect the negative battery cable. 2. Disconnect the rear wheel speed sensor electrical connector.
YAD4E360
3. Raise and suitably support the vehicle. 4. Remove the rear wheel speed sensor. Installation Notice Tightening Torque 7 Nm (62 lb-in)
YAD4E370
SSANGYONG Y200
4E-94 ABS AND TCS
ACCELERATION SENSOR
1. Disconnect the negative battery cable. 2. Disconnect the acceleration sensor connector. 3. Remove the acceleration sensor mounting bolts. Installation Notice Tightening Torque 7 N m (62 lb-in)
SYSTEM FUSE
The ABS/TCS system fuse, SB2, is located in the engine fuse blcok. Counting from the battery toward the surge tank, it is the first system fuse in the row.
YAD4E380
INDICATORS
The indicator lamps ABS and TCS are part of the instrument cluster.
YAD4E390
SSANGYONG Y200
ABS AND TCS 4E-95
UNIT REPAIR
ABS FRONT TOOTH WHEEL
Tool Requires 661 589 16 33 00 ABS Tooth Wheel Puller
Removal Procedure
1. Remove the disc brake rotor. Refer to Front Disc Brakes Section. 2. Remove the ABS front toothed wheel using the ABS tooth wheel puller 661 589 16 33 00.
YAD4E400
1. Install the ABS front toothed wheel using the ABS tooth wheel installer 661 589 17 33 00.
YAD4E410
SSANGYONG Y200
4E-96 ABS AND TCS

SPECIAL TOOLS TABLE
661 589 16 33 00 ABS Tooth Wheel Puller
661 589 17 33 00 ABS Tooth Wheel Installer
YAD4E420
YAD4E430
SSANGYONG Y200
SECTION 4A
BRAKE SYSTEM
TABLE OF CONTENTS
Description and Operation ................................... 4A-2 Braking System Testing ....................................... 4A-2 Hydraulic Brake System ...................................... 4A-2 Brake Pedal ......................................................... 4A-2 Master Cylinder ................................................... 4A-2 Brake Booster ..................................................... 4A-3 Specifications ...................................................... 4A-4 Diagnostic Information and Procedures .............. 4A-5 Maintenance and Repair ..................................... 4A-6 Bleeding the Brakes ............................................ 4A-6 Brake Pedal ......................................................... 4A-7 Stoplamp Switch .................................................. 4A-8 Brake Booster Functional Check ........................... 4A-9 LCRV (Load Conscious Reducing Valve) .............. 4A-9 Component Locator ........................................... 4A-11 Hydraulic Line .................................................... 4A-11 Brake System (W/CBS) ...................................... 4A-12 Master Cylinder and Booster .............................. 4A-13 Repair Instructions .............................................. 4A-14 On-Vehicle Service ............................................. 4A-14 Vacuum Hose .................................................... 4A-14 Brake Oil Level Switch ....................................... 4A-15 Brake Fluid Reservoir ......................................... 4A-16 Master Cylinder ................................................. 4A-17 Brake Booster ................................................... 4A-19 Stoplamp Switch ................................................ 4A-20 Brake Pedal ....................................................... 4A-20 Brake Hose & Pipe ............................................ 4A-21 LCRV (Load Conscious Reducing Valve) ............ 4A-24
4A-2 BRAKE SYSTEM

BRAKING SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy or covered with loose dirt which can cause tires not to grip the road unequally. Testing also will be inaccurate on a crowned roadway because the wheels tend to bounce. Test the brakes at different vehicle speeds with both light-and heavy-pedal pressure; however, avoid locking the brakes and sliding the tires. Locked brakes and sliding tires do not indicate brake efficiency since heavily braked but turning wheels will stop the vehicle in less distance than locked brakes. More tire-to-road friction is present with a heavily braked, turning tire than with a sliding tire. There are three major external conditions that affect brake performance: Tires having unequal contact and grip of the road will cause unequal braking. Tires must be equally inflated and the tread pattern of the right and the left tires must be approximately equal. Unequal loading of the vehicle can affect the brake performance since the most heavily loaded wheels require more braking power and thus more braking effort than the others. Misalignment of the wheels, particularly conditions of excessive camber and caster, will cause the brakes to pull to one side.
BRAKE PEDAL
YAD4A020
Brake pedal uses the principle of the leverage and increases the pressure into the master cylinder in order to generate the braking forces.
MASTER CYLINDER
HYDRAULIC BRAKE SYSTEM

YAD4A030
YAD4A010
This system uses the principle of the leverage and PASCALs. When you pushes the brake pedal, the pressure by adapting the pedal increases through the power booster and delivers it into the master cylinder to generate hydraulic pressure. Hydraulic pressure generated by the master cylinder delivers to the caliper through the brake pipe or hose. This hydraulic pressure allows the caliper pad to push the disc plate. Thus it generates the braking forces.
The master cylinder is designed for use in a diagonally split system. One front and one diagonally opposite rear brakes are served by the primary piston. The opposite front and rear brakes are served by the secondary piston. The master cylinder incorporates the functions of the standard dual master cylinder, plus a low fluid level indicator and the proportioning valves in the nonantilock braking system. The proportioning valves limit the outlet pressures to the rear brakes after a predetermined master cylinder pressure has been reached. The brake master cylinder sensor is attached under the body of the plastic brake master cylinder reservoir.
SSANGYONG Y200
BRAKE SYSTEM 4A-3
BRAKE BOOSTER
The brake booster is a double-diaphragm, vacuumsuspended unit. In normal operating mode, with the service brakes in the release position, a vacuumsuspended booster operates with a vacuum on both sides of its diaphragm. When the brakes are applied, air at atmospheric pressure is admitted to one side of the diaphragm to provide the power assist. When the brakes are released, atmospheric air is shut off from that side of the diaphragm. The air is then drawn from the booster through the vacuum check valve by the vacuum source.
2. Pressure Distribution After working
1. Pressure Distribution At working

YAD4A050
When it pushes off the brake pedal, the valve plunger (3) returns back to the original position by return spring (4) resulted in closing the air valve (6) and open the vacuum valve (9) in order to balance the pressures between (A) and (B) of the power cylinder. And then the power piston (5) returns back to the original position by the master cylinder reaction and the diaphragm return spring (8) pressure.
YAD4A040
When it pushes the brake pedal, the booster pushrod (1) pushes the poppet (2) and valve plunger (3) and the poppet (2) goes closely to the power piston (5) resulting in closing the vacuum valve (9). The power cylinder (A) and (B) is isolated and the valve plunger (3) is separated from the poppet (2). And then the air valve (6) opens in order to flow air into (B) through the filter and thus, the power piston (5) enables to push the master cylinder pushrod (7) for pressure distribution.
SSANGYONG Y200
4A-4 BRAKE SYSTEM
SPECIFICATIONS
Application Brake Pedal Pedal Ratio Pedal Stroke Pedal Freeplay Master Cylinder Type Inner Diameter Brake Booster Type Ratio Front Brake Type I.D. of Caliper Cylinder Thickness of Brake Pad Thickness of Disc Plate Rear Brake Type I.D of Drum Shoe Type Lining I.D. of Wheel Cylinder I.D. of Caliper Cylinder Thickness of Brake Pad Thickness of Disc Plate Parking Brake Brake Fluid Type Type Spec. Drum Type 254 mm Leading End Trailing Type 55 x 243 x 5 mm 23.87 mm MANDO Brake Drum Type Disc Type 4.3 : 1 138 mm 1 ~ 4 mm Tandem Type (/W Lever Sensor) 25.4 mm Vacuum Booster Type 7:1 Ventilated Disc Type 60 mm 10 mm 24 mm Solid Disc 42.9 mm 10 mm 10.4 mm KDAC Brake Drum Type Disc Type Drum Type 254 Leading End Trailing Type 55 x 243 23.81 mm 60 mm 42 mm 10 mm 10.4 mm
Rear Wheel Internal Expansion Mechanical DOT4 or DOT3
SSANGYONG Y200
BRAKE SYSTEM 4A-5

Symptom Noise Or Vehicle Vibration When Applied Brake Check Incorrectly Mounted Back Plate or Caliper Loosened Bolt of Back Plate or Caliper Crack or Uneven Wear of Brake Drum or Disc Foreign Material Inside the Brake Drum Pad or Lining Sticking to Contact Surface Excessive Clearance Between Caliper and Pad Uneven Contact of Pad Lack of Lubrication Loosened Suspension Pulls To One Side When Braking Incorrect Tire Pressure Between Left and Right Poor Contact of Pad or Lining Oil or Grease is Applied to Pad or Lining Bent or Uneven Wear of Drum Incorrectly Mounted Wheel Cylinder Faulty Auto Adjuster Poor Braking Dirty or Lack of Fluid Air in Brake System Faulty Brake Booster Poor Contact of Pad or Lining Oil or Grease on Pad Faulty Auto Adjuster Over Heated Rotor Due to Dragging Pad or Lining Clogging Brake Line Faulty Proportioning Valve Increasing Pedal Stroke (Pedal Goes To Floor) Air in Brake System Fluid Leaking Excessive Clearance Between Push Rod and M/Cylinder Brake Dragging Parking Brake is not Fully Released Incorrect Adjustment of Parking Brake Weak Return Spring of Brake Pedal Incorrect Pedal Free-play Broken Rear Drum Brake Shoe Return Spring Lack of Lubrication Damaged Master Cylinder Check Valve or Piston Return Spring Insufficient Clearance Between Push Rod and Master Cylinder Poor Parking Brake Worn Brake Lining Dirty Brake Lining Surface by Grease or Oil Binding Parking Brake Cable Faulty Auto Adjuster Excessive Lever Stroke Action Repair Retighten Replace Clean Replace Repair Repair Lubrication Retighten Adjust Repair Replace Replace Repair Repair Replenish or Replace Bleeding Repair Repair Replace Repair Repair Repair Repair Bleeding Repair Adjust Repair Adjust Replace Repair Replace Lubrication Replace Adjust Replace Replace Replace Repair Adjust Lever Travel or Check the Cable
SSANGYONG Y200
4A-6 BRAKE SYSTEM
MAINTENANCE AND REPAIR

BLEEDING THE BRAKES
For Master Cylinder and Wheel Cylinder Replacement
Notice: The bleeding sequence is as follows; right rear, left rear, right front and left front. Check the fluid level and add fluid during the bleeding operation. 1. Raise the vehicle with the assistance worker riding up to replenish the oil in the brake oil reservoir tank. 2. Remove the bleeder screw and cap. 3. Attach a transparent tube over the valve. Allow the tube to hang submerged in brake fluid in a transparent container. 4. Slowly push the brake pedal several times and hold the brake pedal. 5. Tighten the bleeder screw after loosening the bleeder screw and draining the fluid. Notice: Hold the brake pedal until tightening the bleeder screw. 6. Repeat the step 5, 6 until all the air is removed. 7. Check the leaks for the bleeder screw.
YAD4A070
8. Bleed air in the system at four wheels in order as shown in the figure if pressure building is not enough by depressing the pedal after above air bleeding. Notice: Always bleed the air after replacing brake fluid or master cylinder, caliper, brake hose and pipe. Do not reuse the bled brake fluid. Rapid pumping of the brake pedal pushes the master cylinder secondary piston down the bore in a manner that makes it difficult to bleed the system. Care must be taken to prevent the brake fluid contacting any painted surface to prevent damage to the paint finish. Check any leak for the applicable portion after bleeding.
YAD4A080
SSANGYONG Y200
BRAKE SYSTEM 4A-7

For Master Cylinder Replacement
1. Add oil after master cylinder replacement. 2. Run the engine and depress the brake pedal several times to build pressure and then keep the pedal fully depressed. 3. Loosen the screw of primary and secondary pipe at the master cylinder outlets to bleed air. 4. Repeat above step No.3 several times until there are no more air bubbles. 5. Bleed air in the system at the hydraulic unit outlet pipe and wheel if pressure building is not enough by depressing the pedal only after above air bleeding.
YAD4A090
For Hydraulic Unit Replacement

1. Add oil after hydraulic unit replacement. 2. Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed. 3. Loosen hydraulic pipe screws at the hydraulic unit outlets to bleed air. 4. Repeat above step No.3 several times until there are no more air bubbles. 5. Bleed air in the system from the wheel if pressure building is not enough by pressing the pedal only after above air bleeding.
YAD4A100
BRAKE PEDAL
Pedal Travel Check
1. Start the engine. 2. Push the pedal three times. 3. With the brake depressed by about 30 kg (66.15 lb) load, measure the clearance between the pedal pad and the lower dash panel. 4. Check pad or shoe wear, any leak for the brake system when the measured value is below the specified value. 5. If the pedal height is not in the specified value, loosen the lock nut of the brake booster push rod and adjust the push rod length.
YAD4A110
SSANGYONG Y200
4A-8 BRAKE SYSTEM

Pedal Height
Specification (A) 177 mm (From the floor mat) Notice: If the pedal height is not in the specified value, loosen the lock nut and adjust the height.
YAD4A120
Pedal Free Play

Specification (C) 138 mm Notice: If the pedal free play is not in the specified value, loosen the stop bolt and the lock nut and adjust free play up to max. travel.
Brake Pedal Free Play

Push the brake pedal several times to discharge the vacuum of the power booster. Measure the pedal movement until the hardness is felt when pushing the brake pedal by hand. Specification 3 - 8 mm
YAD4A130
If clearance is less than the specified value, verify that the clearance between the outer case of the stop lamp and the brake pedal within the specified value. If clearance is beyond on the specified value, it means that the clearance between the clevis pin and brake pedal arm is beyond. Check the faulty and repair, adjust as needed.
STOPLAMP SWITCH
The multi-meter connects the stoplamp switch connector and push the plunger. When the stoplamp switch does not connected with pushing the plunger, the stoplamp switch is normal.
YAD4A140
SSANGYONG Y200
BRAKE SYSTEM 4A-9
BRAKE BOOSTER FUNCTIONAL CHECK

1. With the engine stopped, eliminate vacuum in the booster by pumping the brake pedal several times. 2. Push the pedal down and hold in this position. 3. Start the engine. 4. The booster is OK if the pedal drops further because of extra force produced.
YAD4A150
If the brake pedal does not drop, the vacuum system is probably defective and should be checked. If no defect is revealed by checking the vacuum system, the defect is in the booster itself.
YAD4A160
LCRV (LOAD CONSCIOUS REDUCING VALVE)

LCRV consists of sensing part and hydraulic control part. 1. Sensing Part It detects the changes of vehicle height caused by vehicle load. It consists of load sensing spring and control lever which change according to vehicle load.
YAD4A170
2. Hydraulic Control Part It consists of valve stem devices which controls hydraulic pressure according to load detected by sensing part.
YAD4A180
SSANGYONG Y200
4A-10 BRAKE SYSTEM

Setting Method
1. Install the connecting rod (a) to the No.1 hole. 2. Adjust the clearance X to be 0mm and tighten the bolt (c) using the lock nut (b). Installation Notice Tightening Torque 14 - 18 Nm (10 - 13 lb-ft)
3. Remove the connecting rod (a) from the No.1 hole and reinstall it to the No.2 hole. Installation Notice
YAD4A190
Tightening Torque
14 - 18 Nm (10 - 13 lb-ft)
4. Place alignment marks between the lock nut (b) and adjusting screw (c) after the valve setting. 5. LCRV setting should be performed with unloaded vehicle condition.
Inspection
When it occurs the malfunction in the LCRV, the sensor spring, valve body assembly, rear axle or rear spring may be replaced. For these replacement, the following inspection should perform; Symptom Poor Braking Performance Possible Cause Air in Brake System Poor Adjustment of Sensor Spring Damaged Sensor Spring Fluid Leaking from LCRV Rear Wheels Lock Early Poor Adjustment of Sensor Spring Internal Fluid Leaking of LCRV Action Bleeding Adjust Replace Replace Adjust Replace
Notice: Fluid leaking from LCRV results from poor valve open/close or sealing wear caused by the foreign materials in the LCRV. When you change or repair the LCRV, it may affect the braking performance. Thus, ensure to use the approved part.
SSANGYONG Y200
BRAKE SYSTEM 4A-11
COMPONENT LOCATOR
HYDRAULIC LINE
YAD4A060
1 2 3 4
Brake Booster Brake Reservoir and Master Cylinder ABS Control Unit Front Disc Brake and Caliper
5 Hydraulic Pressure Control Valve (LCRV) 6 3-way Connector 7 Rear Drum (Disc) and Wheel Cylinder (Caliper)
SSANGYONG Y200
4A-12 BRAKE SYSTEM
BRAKE SYSTEM (W/CBS)
YAD4A200
1 2 3 4 5 6 7 8 9 10 11 12 13
Brake Booster Brake Booster Boot Cotter Pin Clevis Clevis Pin Packing (1) Master Cylinder Assembly Brake Oil Tank Assembly Brake Oil Tank Cap Brake Oil Tank Grommet Seal Master Cylinder Brake Stoplamp Switch
14 15 16 17 18 19 20 21 22 23 24 25
Pedal Assembly Pedal Bracket Assembly Clutch Pedal Pad Clutch Pedal Brake Pedal Pad Brake Pedal Brake Pedal Spring Rear Brake Hose Clip Front Brake Hose Union Bolt Plain Washer
SSANGYONG Y200
BRAKE SYSTEM 4A-13
MASTER CYLINDER AND BOOSTER

KDAC (Delphi Korea)
YAD4A210
MANDO
YAD4A220
SSANGYONG Y200
4A-14 BRAKE SYSTEM

VACUUM HOSE
Removal Procedure
1. Disconnect the vacuum hose from the brake booster.
YAD4A230
2. Disconnect the vacuum hose from the vacuum pump.
YAD4A240
3. Remove the vacuum hose with the vacuum hose bracket.
YAD4A250
SSANGYONG Y200
BRAKE SYSTEM 4A-15
1. Install the vacuum hose between the vacuum pump and the power booster (Diesel Engine). Tightening Torque Bracket Mounting Bolt Union Bolt to Vacuum Pump 35 - 45 Nm (26 - 33 lb-ft) 35 - 45 Nm (26 - 33 lb-ft)
YAD4A260
2. Install the vacuum hose between the vacuum pump and the power booster. (Gasoline Engine) Tightening Torque Bracket Mounting Bolt Union Bolt to Vacuum Pump 35 - 45 Nm (26 - 33 lb-ft) 35 - 45 Nm (26 - 33 lb-ft)
YAD4A270
BRAKE OIL LEVEL SWITCH

1. Disconnect the brake fluid level switch connector.
YAD4A280
2. Disconnect the switch wiring connector. 3. Disconnect the switch from the brake oil tank.
YAD4A290
SSANGYONG Y200
4A-16 BRAKE SYSTEM

YAD4A300
BRAKE FLUID RESERVOIR

1. Remove the reservoir tank cap and drain the brake fluid completely. 2. Remove the brake reservoir tank using the driver. Notice: Note that pulling the reservoir tank out excessively result in damage of the tank on removal.
YAD4A310
3. Remove the grommet from the master cylinder.
YAD4A320
4. Installation should follow the removal procedure in the reverse order. Notice: Lubricate the new brake fluid reservoir seals with clean brake fluid. After the installation, bleed the brake system.
YAD4A330
SSANGYONG Y200
BRAKE SYSTEM 4A-17
MASTER CYLINDER
Removal Procedure
1. Disconnect the brake lines from the master cylinder. Notice: The brake fluid may damage paintwork, if spillage onto paintwork, wash with cold water immediately.
YAD4A340
2. Loosen the mounting nut of the master cylinder and remove the master cylinder from the power booster.
YAD4A350
3. Remove the master cylinder. Retain the master cylinder in the vice and remove the retainer ring from the master cylinder using the snap ring plier.
YAD4A360
Remove the 1st piston and 2nd piston assembly from the master cylinder assembly.
YAD4A370
SSANGYONG Y200
4A-18 BRAKE SYSTEM
Check the cylinder for excessive wear. Notice:
Replace the cylinder assembly when there occurs any damage or wear in the cylinder. Clean the contaminated oil of the assembly.
Install the 1st piston and 2nd piston assembly from the master cylinder assembly.
YAD4A380
1. Install the retainer ring using the snap ring plier.
YAD4A390
2. Install the master cylinder into the booster. Installation Notice Tightening Torque 8 - 12 Nm (71 - 106 lb-in)
YAD4A400
3. Install the master cylinder completely and then connect the brake pipe. Installation Notice Tightening Torque 15 - 18 Nm (11 - 13 lb-ft)
YAD4A410
SSANGYONG Y200
BRAKE SYSTEM 4A-19
BRAKE BOOSTER
Removal Procedure
1. Remove the master cylinder assembly and pull out the cotter pin from the push rod of the brake booster. 2. Remove the clevis pin.
YAD4A420
3. Remove the nuts mounting the booster.
YAD4A430
4. Remove the brake booster from the vehicle.
YAD4A440
1. Installation should follow the removal procedure in the reverse order. 2. Bleed the brake system after the installation.
YAD4A450
SSANGYONG Y200
4A-20 BRAKE SYSTEM
STOPLAMP SWITCH
1. Disconnect the negative battery cable. 2. Separate the stoplamp switch from the connector.
YAD4A460
3. Remove the stoplamp switch nut and disconnect the switch.
YAD4A470
4. Installation should follow the removal procedure in the reverse order. Tightening Torque 21 - 35 N m (15 - 26 lb-ft)
YAD4A480
BRAKE PEDAL
1. Remove the bolts/nuts mounting the brake pedal and disconnect the cotter pin.
YAD4A490
SSANGYONG Y200
BRAKE SYSTEM 4A-21

2. Remove the brake pedal assembly.
YAD4A500
3. Installation should follow the removal procedure in the reverse order. Tightening Torque 16 - 32 N m (12 - 24 lb-ft)
YAD4A510
BRAKE HOSE & PIPE

Removal Procedure
1. Remove the brake pipe. Remove the pipe from the master cylinder.
YAD4A520
For ABS/ABD, remove the brake pipe from the control unit.
YAD4A530
SSANGYONG Y200
4A-22 BRAKE SYSTEM
Remove the bracket of the connecting pipe from the 3-way connector.
YAD4A540
2. Remove the front brake hose. Remove the brake pipe nut. Remove the E-ring. Disconnect the strut from the brake mounting.
Remove the union bolt from the caliper and remove the brake hose.
YAD4A550
3. Remove the rear brake hose. Remove the brake pipe nut. Remove the E-ring. Disconnect the strut from the brake mounting. Remove the union bolt from the caliper and remove the brake hose. - For disc type : from the caliper
YAD4A560
- For drum type : from the cylinder
YAD4A570
SSANGYONG Y200
BRAKE SYSTEM 4A-23

4. For non-ABS/ABD, remove the brake pipe to the rear brake at LCRV side.
YAD4A580
1. Install the rear brake hose and tighten the union bolts. Tightening Torque at the caliper Tightening Torque at the wheel cylinder 15 - 18 N m (11 - 13 lb-ft) 15 - 19 N m (11 - 13 lb-ft)
YAD4A590
YAD4A600
2. Install the front brake hose and tighten the union bolts. Tightening Torque 15 - 18 N m (11 - 13 lb-ft)
YAD4A610
SSANGYONG Y200
4A-24 BRAKE SYSTEM

3. Install the brake pipe to the correct position. 3-way Connector LCRV System ABS/ABD Control Unit Port (M12) 15 - 19 N m (11 - 14 lb-ft) 15 - 19 N m (11 - 14 lb-ft) 15 - 19 N m (11 - 14 lb-ft) 20 - 24 N m (15 - 18 lb-ft)
YAD4A620
4. Bleed the brake system after replacement of the pipes/hoses.
LCRV (LOAD CONSCIOUS REDUCING VALVE)

1. Remove the nut mounting the stud from the LCRV connecting rod.
YAD4A630
2. Remove the brake pipe retaining the LCRV.
YAD4A640
3. Remove the LCRV mounting bolt from the LCRV bracket and remove the LCRV.
YAD4A650
SSANGYONG Y200
BRAKE SYSTEM 4A-25

4. Installation should follow the removal procedure in the reverse order. Valve Body Mounting nut Bracket Mounting Bolt Stud Mounting Nut 14 - 18 N m (10 - 13 lb-ft) 10 - 13 N m (89 - 115 lb-in) 14 - 18 N m (10 - 13 lb-ft)
Notice: Bleed the brake system.
YAD4A660
SSANGYONG Y200
SECTION 4B
FRONT BRAKE
TABLE OF CONTENTS
Description and Operation ................................... 4B-2 Caliper ................................................................ 4B-2 Clearance Calibration ........................................... 4B-2 Specifications ...................................................... 4B-2 Diagnostic Information and Procedures .............. 4B-3 Inspection ............................................................. 4B-4 Pad Thickness ..................................................... 4B-4 Brake Disc Thickness .......................................... 4B-4 Brake Disc Run Out ............................................. 4B-5 Caliper Housing I.D .............................................. 4B-5 Component Locator ............................................. 4B-6 Cross-Sectional View ........................................... 4B-6 Front Caliper Brake .............................................. 4B-7 Repair Instructions ................................................ 4B-8 On-Vehicle Service ............................................... 4B-8 Front Brake .......................................................... 4B-8 Brake Pad Replacement .................................... 4B-10 Unit Repair .......................................................... 4B-13 Brake Caliper .................................................... 4B-13
4B-2 FRONT BRAKE

CALIPER
This caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to slide the caliper inward, resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle. However, as a part of the piston seal is fixed into a grove in the cylinder shape of the seal is as shown in below figure, distorted toward the piston moving direction. When the pressure is taken off from the brake pedal and the hydraulic pressure is released from the piston, a restoring elastic force is generated at the seal and pushes the piston rightward and back it in original position. As the pads wear away and the clearance between rotor and pads become larger, the piston moves larger. The seal then could change in shape further, but since end of the seal is fixed into the groove in the cylinder, the distortion is limited to the same amount as previously described. The piston moves further to cover the distance of clearance. As the piston returns by the same distance and the rubber seal recovers its original shape, the clearance between the rotor and pads are maintained in original condition.
YAD4B010
CLEARANCE CALIBRATION
When the hydraulic pressure is applied to the piston, the piston moves leftward. The piston seal, which extent considerable pressure against the piston, moves with cylinder.
YAD4B020
SPECIFICATIONS
MANDO Application Caliper Cylinder I.D. Pad Thickness Disc Thickness Ventilated Disc Type 60 mm 10 mm 24 mm Delphi Korea
SSANGYONG Y200
FRONT BRAKE 4B-3

Condition Poor Braking Possible Cause Pad Wear, Hardening Oil Or Water Contamination On The Pad Inoperative Caliper Uneven Braking Pad Wear, Hardening Oil Or Water Contamination On The Pad Uneven Wear Or Twisted Of The Disc Inoperative Caliper Dragging Brake Excessive Pedal Travel Noise and Vibration When Brake Applied Inoperative Caliper Returning Pad Wear Pad Wear, Hardening Damage On The Disc Interference Of The Dust Cover Loose Caliper Mounting Bolts Action Replace Replace and Repair Replace Replace Replace and Repair Replace Replace Replace Replace Replace Replace Repair Tighten
SSANGYONG Y200
4B-4 FRONT BRAKE
INSPECTION
Clean the dissembled parts and visually check the followings;
Wear, rust and damage on the cylinder and piston Damage, crack on the caliper body and damage, wear on the guide pin Pad uneven wear and oil contamination Boots damage and tear Disc plates scratch and bending
PAD THICKNESS
1. Remove the front wheel. 2. Measure the thickness and replace as needed.
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YAD4B040
Thickness 10 mm
Max wear Limit 2 mm
BRAKE DISC THICKNESS

1. Measure the thickness of the rotor at four or more points around the circumference of the rotor. 2 If the thickness of the rotor is below the specified value, replace the brake rotor. Thickness 24 mm Max wear Limit 22 mm
YAD4B050
SSANGYONG Y200
FRONT BRAKE 4B-5
BRAKE DISC RUN OUT

1. Fasten a dial indicator to the brake disc side and measure the run out by rotating the disc. 2. If lateral run out exceeds the specification, replace the brake disc to prevent the pedals vibration at braking. Run Out Limit 0.03 mm (Disc only) 0.07 mm (On vehicle)
YAD4B060
CALIPER HOUSING I.D

Application Non-ABS/ABS I.D Wear Limit Spec. 60.0 mm 61.0 mm
YAD4B070
SSANGYONG Y200
4B-6 FRONT BRAKE
COMPONENT LOCATOR
YAD4B030
1 2 3 4 5
Brake Disc Wheel (Rim) Hub Range Knuckle Dust Shield
6 7 8 9 10
Vacuum Hose Nipple Caliper Brake Fluid Nipple Caliper Guide Bolt Caliper Bolt
SSANGYONG Y200
FRONT BRAKE 4B-7
FRONT CALIPER BRAKE
YAD4B080
1 2 3 4 5
Brake Caliper Assembly Guide Rod Set Brake Pad Brake Pad Spring Caliper Mounting Bolt
6 7 8 9 10
Piston Seal Piston Piston Boot Caliper Guide Rod Bolt Bleeder Screw
SSANGYONG Y200
4B-8 FRONT BRAKE

FRONT BRAKE
Removal Procedure
1. Remove the front wheel and remove the brake hose from the brake caliper. Notice: Be carefully to prevent the brake fluid loss and contamination.
YAD4B090
2. Remove the cylinder mounting bolt and remove the disc pad and the cylinder.
YAD4B100
3. Remove the caliper mounting bolt and remove the caliper assembly.
YAD4B110
SSANGYONG Y200
FRONT BRAKE 4B-9

4. Remove the brake disc (Full-time 4WD) 5. Pull out the cotter pin from the front hub assembly and remove the lock nut. (Full-time 4WD)
YAD4B120
6. Remove the hub assembly mounting bolt and remove the hub assembly.
YAD4B130
Notice: For part-time 4WD, remove the locking hub assembly and hub range before removing the brake disc.
YAD4B140
SSANGYONG Y200
4B-10 FRONT BRAKE
BRAKE PAD REPLACEMENT

1. Remove lower mounting bolt of the brake caliper cylinder.
YAD4B150
2. Move the caliper cylinder assembly upward and fix it to prevent hose damage.
YAD4B160
3. Remove the brake pad and replace the new pad. 4. Install the caliper cylinder assembly and fasten the lower bolt.
YAD4B170
Full-time
YAD4B180
Part-time
SSANGYONG Y200
FRONT BRAKE 4B-11 Installation Procedure

1. Install the front brake disc assembly to the knuckle and fasten the lock nut as specified torque (fulltime 4WD).
YAD4B190
Install the front brake disc to the knuckle and install the locking hub & hub range. Fasten the mounting bolt (part-time 4WD).
YAD4B200
2. Install the caliper assembly to the front disc and fasten the caliper mounting bolt. Installation Notice Tightening Torque 85 - 105 Nm (63 - 79 lb-ft)
YAD4B210
YAD4B220
SSANGYONG Y200
4B-12 FRONT BRAKE

3. Connect the brake hose to the caliper cylinder. Installation Notice Tightening Torque 7 - 13 Nm (62 - 115 lb-in)
Notice: The washer should be replaced new part. 4. Bleed the brake system after replacement.
YAD4B230
SSANGYONG Y200
FRONT BRAKE 4B-13
UNIT REPAIR
BRAKE CALIPER
1. Remove the caliper assembly. 2. Separate the cylinder assembly and carrier. Remove the guide rod bolt. Separate the cylinder assembly and carrier.
YAD4B240
3. Disassemble the carrier. Remove the pad. Remove the spring. Remove the guide rod and the boot.
YAD4B250
4. Remove the cylinder assembly. Remove the bleeder plug. Remove the bleeder plug cap. Remove the piston boot.
YAD4B260
Using the compressed air, blow out the piston from housing. Notice: Do not face in the direction of removing.
Remove the piston. Remove the piston seal.
YAD4B270
SSANGYONG Y200
4B-14 FRONT BRAKE Assembly Procedure

1. Installation should follow the removal procedure in the reverse order. Notice: Clean all the parts in denatured alcohol or brake fluid. Dry the parts with unlubricated compressed air and blow out all the passages in the housing and the bleeder valve. Apply the brake fluid on the surface of the piston and cylinder. 2. Fasten the guide rod bolt as specified torque.
YAD4B280
Installation Notice Tightening Torque 22 - 32 Nm (16 - 24 lb-ft)
3. Fasten the bleeder screw as specified torque. Installation Notice Tightening Torque 7 - 13 Nm (62 - 115 lb-in)
YAD4B290
SSANGYONG Y200
SECTION 4C
REAR BRAKE
TABLE OF CONTENTS
Description and Operation ................................... 4C-2 Drum Brake ......................................................... 4C-2 Wheel Cylinder .................................................... 4C-2 Brake Lining ........................................................ 4C-2 Disc Brake .......................................................... 4C-3 Specifications ...................................................... 4C-3 Diagnostic Information and Procedures .............. 4C-4 Inspection ............................................................. 4C-5 Drum Brake Type................................................. 4C-5 Disc Brake Type .................................................. 4C-5 Cross Sectional View ........................................... 4C-7 Drum Brake (KDAC) ............................................. 4C-7 Disc Brake .......................................................... 4C-8 Component Locator ............................................. 4C-9 Drum Brake ......................................................... 4C-9 Disc Brake ........................................................ 4C-10 Rerair Instructions .............................................. 4C-11 On-Vehicle Service ............................................. 4C-11 Disc Brake Assembly ........................................ 4C-11 Drum Brake Assembly ....................................... 4C-16 Unit Repair .......................................................... 4C-21 Wheel Cylinder .................................................. 4C-21 Parking Brake Lever ........................................... 4C-22
4C-2 REAR BRAKE

DRUM BRAKE
This drum brake assembly is a leading/trailing shoe design.
WHEEL CYLINDER
Both wheel cylinder diameters are same in order to balance the friction forces of both shoes. The hydraulic pressure from the master cylinder is provided to the wheel cylinder and the piston in the wheel cylinder allows to push both shoes toward the drum resulted in generating the braking force.
YAD4C010
Both brake shoes are held against the wheel cylinder pistons by the lower return spring and the fixed anchor plate near the lower return spring. When the brakes are applied, the wheel cylinder pistons move both shoes out to contact the drum. With forward wheel rotation, the forward brake shoe will wrap into the drum and become selt-energized. With reverse wheel rotation, brake shoes is transferred to the anchor plate through the braking plate to the axle flange. Adjustment is automatic and occurs on any service brake application. Do not switch the position of shoes that have been in service, as this may render the selfadjustment feature inoperative and result in increased pedal travel. The brake drum must have high abrasion resistance, heatproof, high stiffness, fatigue stiffness and strength enough not to make any deformation. The temperature of the drum surface comes up to 500 - 700 C on brake operation by the friction with the lining. When the temperature of the drum surface continues to keep high, the friction coefficient goes down and the fade development occurs. When the brake is applied often on the hill, any accident may be occur.
YAD4C020
1 2 3 4 5 6
Cylinder Housing Boot Spring Piston Cup Piston Air Bleeder
1 2 3 4 5 6
Cylinder Housing Boot Spring Piston Cup Piston Air Bleeder
BRAKE LINING
The brake lining is installed with the brake shoe and pushed toward the drum for applying the brake pedal. Thus, lining must have high-heat tolerance, abrasion resistance and high friction coefficient.
Brake Lining and Drum Clearance Automatic Control System

If the linings wear is excessive, the piston moves to long distance and the pedal travel increases. The clearance between the drum and the brake lining should be adjusted. Generally the drum brake must be adjusted regularly and thus the clearance automatic control system enables to adjust the clearance between the brake lining and the drum resulting from brake lining wear.
SSANGYONG Y200
REAR BRAKE 4C-3
DISC BRAKE
The disc brake uses at front wheel generally and recently has been using at rear wheel. The floating type caliper disc brake installed by this vehicle installs only brake cylinder per caliper at one side. When the master cylinder generates the hydraulic pressure, the piston pushes the pad in order to compress to the disc and at this time, the caliper is moved by this reaction resulted in pushing the pad at the other side to compress to the disc. Because the brake disc contacts atmospheric conditions and effect on good radiation, the braking variation keeps uniform forces, the uneven braking may not be generated on high speed driving.
YAD4C030
SPECIFICATIONS
Application Drum I.D. Shoe Type Lining Width x Length x Thickness Wheel Cylinder I.D. Caliper Cylinder I.D. Brake Pad Thickness Disc Thickness Drum Brake 254 mm Leading and Trailing 55 x 243 x 4.7 mm 23.81 mm Disc Brake MANDO Delphi Korea 42.9 mm 10 mm 10.4 mm 42 mm 10 mm 10.4 mm
SSANGYONG Y200
4C-4 REAR BRAKE

Symptom Poor Braking Possible Cause Lining Wear, Hardening Oil Or Water Contamination On The Lining Inoperative Wheel Cylinder Inoperative Clearance Automatic Control System Uneven Braking Lining Wear, Hardening Oil Or Water Contamination On The Lining Inoperative Wheel Cylinder Inoperative Clearance Automatic Control System Dragging Brake Excessive Pedal Travel Noise and Vibration When Brake Applied Damage Of The Brake Shoe Return Spring Inoperative Wheel Cylinder Returning Lining Wear Inoperative Clearance Automatic Control System Lining Wear, Hardening Foreign Material Inside Drum Loosen The Brake Plate Bolt Drum Deformation Or Surface Damage Inoperative Parking Brake Lining Wear, Hardening Oil Contamination On The Lining Inoperative Clearance Automatic Control System Action Replace Replace or Repair Replace Repair Adjust Replace or Repair Replace Repair Replace Replace Replace Repair Replace Clean Tighten Replace Replace Replace Repair
SSANGYONG Y200
REAR BRAKE 4C-5
INSPECTION
DRUM BRAKE TYPE
1. Inspect the drum for crack or damage or deformation. 2. Measure the inside diameter. Inside Diameter 254 mm Wear Limit 255.5 mm
Measure two more position.
YAD4C060
Brake Lining
1. Inspect the surface hardening or excessive wear of the lining. Inspect the lining for stain with oil. 2. Measure the lining thickness. Wear Limit 1 mm
If the measured value is below the limit value, replace the brake lining.
YAD4C070
DISC BRAKE TYPE

Pad Thickness
1. Remove the front wheel. 2. If the measured value is below the limit value, replace the pad. Wear Limit 2 mm
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YAD4C080
SSANGYONG Y200
4C-6 REAR BRAKE
Brake Disc Thickness

1. Measure the thickness of the rotor at four or more points around the circumference of the disc. 2. If the thickness of the brake disc is below the specified value, replace the brake disc. Disc Thickness Limit 8.5 mm
YAD4C090
Brake Disc Run Out

1. Set a dial indicator to the brake disc side and measure the run out by rotating the disc. Run Out Limit On-Vehicle Disc only
Max. 0.07 mm Max. 0.03 mm
2. If lateral run out exceeds the specification, replace the brake disc to prevent the pedals vibration at braking.
YAD4C100
SSANGYONG Y200
REAR BRAKE 4C-7

DRUM BRAKE (KDAC)
YAD4C040
1 2 3 4 5 6 7
Backing Plate Wheel Cylinder Brake Shoe Lining Brake Shoe Lower Return Spring (Lower Shoe Spring) Retainer Spring Pin Compression Spring
8 9 10 11 13 14 15
Retainer Spring Plate Adjuster Assembly Adjuster Lever Return Spring (Adjuster) Upper Return Spring (Upper Shoe Spring) Bolt Air Bleeder Nipple
SSANGYONG Y200
4C-8 REAR BRAKE
DISC BRAKE
YAD4C050
1 2 3 4
Backing Plate Parking Cable Parking Cable Lever Caliper Assembly
5 6 7 9
Disc Wheel Air Bleeder Nipple Shaft Assembly
SSANGYONG Y200
REAR BRAKE 4C-9
COMPONENT LOCATOR
DRUM BRAKE
YAD4C280
1 2 3 4 5 6
Bleeder Screw Bleeder Screw Cap Rear Brake Assembly Rear Brake Plate Wheel Cylinder Strut Assembly (Clearance Automatic Control System) 7 Brake Leading Shoe 8 Middle Return Spring
9 10 11 12 13 14 15 16
Upper Return Spring Brake Shoe Retaining Spring Pin Trailing Shoe Brake Shoe Retaining Spring Brake Shoe Retaining Spring Cap Lower Return Spring Hub Bolt Rear Brake Drum
SSANGYONG Y200
4C-10 REAR BRAKE
DISC BRAKE
YAD4C110
1 2 3 4 5
Rear brake disc assembly Brake pad Brake caliper Gasket.................................................... Replace Bolt ........................................... 20 N m (15 lb-ft)
6 7 8 9
Gasket.................................................... Replace Brake hose Gasket.................................................... Replace Hose bolt ........................................... 8 - 18 N m
SSANGYONG Y200
REAR BRAKE 4C-11
RERAIR INSTRUCTIONS ON-VEHICLE SERVICE

DISC BRAKE ASSEMBLY
Removal Procedure
1. Remove the rear wheel. Notice: Park the vehicle on the flat ground and fix the vehicle not to move it. Release the parking brake. Position the transmission in NEUTRAL.
YAD4C120
2. Remove the brake hose from the rear brake caliper. Notice: Be carefully to prevent the brake fluid loss and contamination.
YAD4C130
3. Remove the caliper cylinder mounting bolt and remove the disc pad and the cylinder.
YAD4C140
SSANGYONG Y200
4C-12 REAR BRAKE

4. Remove the caliper mounting bolt and remove the caliper assembly.
YAD4C150
5. Disconnect the parking brake cable from the parking brake lever.
YAD4C160
6. Remove the brake disc.
YAD4C170
7. Using the rubber hammer, hit to separate the parking brake lining lightly and move the lining upward.
YAD4C180
SSANGYONG Y200
REAR BRAKE 4C-13
Inspection
1. Clean the dissembled parts and visually check the followings; Wear, rust and damage on the cylinder and piston Damage, crack on the caliper body and damage, wear on the guide pin Pad uneven wear and oil contamination Boots damage and tear
YAD4C190
2. Inspect the brake pad thickness. Pad Thickness 10 mm Max wear Limit 2 mm
Notice: If the thickness of both pads is not same, replace both pads at the same time.
3. Inspect the disc thickness. Pad Thickness 10.4 mm Max wear Limit 8.5 mm
4. Inspect the disc plates scratch and deformation.
YAD4C200
Brake Pad
1. Remove the cylinder mounting bolt (lower) at the brake caliper. 2. Raise and fix the caliper assembly at the proper position not to cause any damage in the hoses or others.
YAD4C210
SSANGYONG Y200
4C-14 REAR BRAKE

3. Remove the brake pad and replace the new pad.
YAD4C220
4. Install the caliper cylinder assembly and tighten the retaining bolt.
YAD4C230
1. Install the brake lining between the backing plate and the flange. Installation Notice Tightening Torque 4 - 8 Nm (35 - 71 lb-in)
Notice: Apply a certain amount of grease on the parking brake lining surface.
YAD4C240
2. Install the brake disc and connect the parking brake cable to the lever.
YAD4C250
SSANGYONG Y200
REAR BRAKE 4C-15

3. Install the caliper to the brake disc. Installation Notice Tightening Torque 4 - 8 Nm (35 - 71 lb-in)
YAD4C260
4. Install the brake hose. Notice: The washer should be replaced new part. 5. Tighten the air bleeder screw. Installation Notice Tightening Torque 7 - 13 N m (62 - 115 lb-in)
6. Bleed the brake system after replacement.
YAD4C270
SSANGYONG Y200
4C-16 REAR BRAKE
DRUM BRAKE ASSEMBLY

1. Remove the tires Notice: Park the vehicle on the flat ground and fix the vehicle not to move it. Position the transmission in NEUTRAL.
YAD4C120
2. Disconnect the brake pipe from the rear brake. Notice: Be carefully to prevent the brake fluid loss and contamination.
YAD4C290
3. Insert the bolt (M8) to the service hole of the brake drum and remove the brake drum.
YAD4C300
4. Remove the service hole plug of the axle shaft.
YAD4C310
SSANGYONG Y200
REAR BRAKE 4C-17

5. Remove the return spring. (1) Disconnect the upper return spring. (2) Disconnect the lower return spring. (3) Disconnect the lever spring. (4) Disconnect the adjuster lever from the adjuster.
YAD4C320
YAD4C330
6. Rotate the lining shoe hold down-washer in the plug hole of the axle shaft flange and disconnect the pin and the spring.
YAD4C340
7. Disconnect the parking cable from the parking lever.
YAD4C350
SSANGYONG Y200
4C-18 REAR BRAKE

8. Disconnect the brake lining and adjuster lever.
YAD4C360
9. Remove the wheel cylinder mounting bolt and remove the wheel cylinder.
YAD4C370
Inspection
1. Measure the inside diameter of the brake drum and replace as needed. I.D. 254 mm Wear Limit 255.5 mm
Notice: Measure two more position.
YAD4C380
2. Inspect the surface between the lining and brake. Mark the brake drum inside using chalk and scrub the shoe & lining assembly. If there is excessive contact problem, replace the shoe & lining assembly or the brake drum. Notice: Clean any chalk mark after inspection complete.
YAD4C390
SSANGYONG Y200
REAR BRAKE 4C-19
1. Install the wheel cylinder to the backing plate. Installation Notice Tightening Torque 8 - 12 N m (71 - 106 lb-in)
YAD4C400
2. Install both brake linings between the wheel cylinder and the bottom anchor plate. And then install adjuster and each return spring.
YAD4C410
3. Connect the parking cable.
YAD4C420
4. The outside diameter of the lining set to 253.08 - 253.50 mm by rotating the adjuster screw.
YAD4C430
SSANGYONG Y200
4C-20 REAR BRAKE

5. Install the plate and drum to the axle shaft sequently. 6. Check that the brake drum is rotated properly by hand. Notice: Adjust the adjuster screw as needed.
YAD4C440
7. Connect the brake pipe to the wheel cylinder. Installation Notice Tightening Torque 15 - 19 N m (11 - 14 lb-ft)
8. Bleed the brake system and verify the parking brake operation. Install the tire.
YAD4C450
SSANGYONG Y200
REAR BRAKE 4C-21
UNIT REPAIR
WHEEL CYLINDER
1. Remove the upper brake return spring and remove the wheel cylinder with pulling the upper lining outside.
YAD4C460
2. Disassembly the wheel cylinder assembly. Remove the dust boot and do not reuse them (1). Remove the piston (2).
Remove the piston cup and do not reuse it (3). Remove the spring assembly (4). Remove the bleeder screw (5).
3. Clean all the parts with the denatured alcohol. Dry the parts with unlubricated compressed air.
YAD4C470
4. Installation should follow the removal procedure in the reverse order. 5. Tighten the bleeder screw and wheel cylinder as specified torque. Bleeder Screw Wheel Cylinder Mounting Bolt 7 - 10 N m (62 - 89 lb-in) 8 - 12 N m (71 - 106 lb-in)
Notice: Lubricate the new seals, the piston, the piston cup and the wheel cylinder bore with clean brake fluid before assembly.
YAD4C480
SSANGYONG Y200
4C-22 REAR BRAKE
PARKING BRAKE LEVER

1. Disconnect the parking brake lever and the adjuster lever from the lining.
YAD4C490
2. Pull out the lever pin (arrow) and Disconnect the the parking brake lever and the adjuster lever. 3. Installation should follow the removal procedure in the reverse order.
YAD4C500
SSANGYONG Y200
SECTION 4D
PARKING BRAKE
TABLE OF CONTENTS
Description and Operation ................................... 4D-2 Parking Brake ...................................................... 4D-2 Parking Brake Switch and Indicator ...................... 4D-2 Braking Inspection .............................................. 4D-2 Specifications ...................................................... 4D-3 Diagnostic Information and Procedure ............... 4D-4 Component Locator ............................................. 4D-5 Cross Sectional View ........................................... 4D-5 Parking Brake Lever and Cable ............................ 4D-6 Repair Instructions ................................................ 4D-7 On-Vehicle Service ............................................... 4D-7 Parking Brake ...................................................... 4D-7
4D-2 PARKING BRAKE

PARKING BRAKE
When the brake is firmly applied, the parking brake should the vehicle with ample pedal travel remaining. Check for frayed cables, rust, etc. or any condition that may inhibit present (or future) free movement of the parking brake lever assembly.
PARKING BRAKE SWITCH AND INDICATOR

When the parking brake lever is pulled out with the ignition ON, the parking brake indicator turns on via lever switch.
YAD4D010
BRAKING INSPECTION
Inspect the parking brake as following; 1. Count the number of the notch sounds on pulling out the parking brake at 19kg force. Specified Notch 5
2. If the notch number is over the specified value, adjust the notch number by the parking brake cable adjusting nut. 3. Check the parking brake force after adjusting the specified value.
YAD4D030
4. If the braking force is not operated properly, check the parking brake lever and cable and replace them as needed.
YAD4D040
SSANGYONG Y200
PARKING BRAKE 4D-3
SPECIFICATIONS
Parking Brake Application Type Operation Spec. Mechanical Rear-Wheel Drive Internal Expanded Manual
SSANGYONG Y200
4D-4 PARKING BRAKE

Symptom Poor Braking Possible Cause Lining Wear, Hardening Oil Or Water Contamination On The Lining Brake Cable Sticked Or Damage Excessive Pedal Travel Inoperative Clearance Automatic Control System Action Replace Replace Or Repair Replace Notch Adjustment Repair
SSANGYONG Y200
PARKING BRAKE 4D-5
COMPONENT LOCATOR
YAD4D020
1 2 3 4
Parking Brake Lever Parking Brake Cable Bracket (Rear) Parking Brake Cable Bracket (Front) Parking Brake Cable Bracket (Center)
5 Cable 6 With Drum Brake 7 With Disc Brake
SSANGYONG Y200
4D-6 PARKING BRAKE
PARKING BRAKE LEVER AND CABLE
YAD4D050
1 2 3 4 5 6
Parking Brake Lever Parking Brake Warning Lamp Switch Bolt Bolt Front Parking Brake Cable Equalizer
7 8 9 10 11
Nut Bolt Rear Parking Brake Cable Brake Disc (Rear Disc Brake Type) Brake Drum (Rear Drum Brake Type)
SSANGYONG Y200
PARKING BRAKE 4D-7

PARKING BRAKE
Removal Procedure
1. Remove the console assembly.
YAD4D060
2. Disconnect the parking brake warning lamp connector.
YAD4D070
3. Disconnect the cable from the parking brake lever with parking brake released.
YAD4D080
SSANGYONG Y200
4D-8 PARKING BRAKE

4. Remove the parking brake lever bracket mounting bolt and remove the lever assembly.
YAD4D090
5. Remove the cable plate at the under floor.
YAD4D100
6. Disconnect the parking brake cable from the rear brake. Disc Type Disconnect the cable from the parking brake lever. Remove the clip from the brake plate.
YAD4D110
Drum Type Remove the clip from the brake plate.
Move the parking brake lever as shown using driver etc. and then disconnect the cable.
7. Disconnect the cable bracket and the cable.
YAD4D120
SSANGYONG Y200
PARKING BRAKE 4D-9 Installation Procedure

1. Connect the parking brake cable to the parking brake lever. 2. Install the bracket with the parking brake cable to the body.
YAD4D130
3. Install the parking brake lever assembly. Installation Notice Tightening Torque 22 Nm (16 lb-ft)
YAD4D140
4. Insert the parking brake cable to the lever hole and install the cable plate. Installation Notice Tightening Torque 6 Nm (53 lb-in)
YAD4D150
5. Install the parking brake switch and check the warning lamp and brake operation.
YAD4D160
SSANGYONG Y200
4D-10 PARKING BRAKE

6. If there is any operation problem in the parking brake, adjust the cable tension at the equalizer position. 7. Install the console assembly and perform the braking test.
YAD4D170
SSANGYONG Y200
SECTION 4E
ABS SYSTEM AND TRACTION CONTROL SYSTEM

TABLE OF CONTENTS
Description and Operation ................................... 4E-2 ABS (Anti-Lock Brake System) ............................ 4E-2 TCS (Traction Control System) Description ............ 4E-3 EBD (Electronic Brake Force Distribution) System ........................................................................ 4E-5 Tire and ABS/TCS ................................................ 4E-9 Hydraulic Circuit ................................................. 4E-10 ABS 5.3............................................................. 4E-10 ABS/TCS 5.3 ..................................................... 4E-13 Component Locator ........................................... 4E-16 ABS, ABS/TCS 5.3 ............................................ 4E-16 Diagnostic Information and Procedures ............ 4E-18 Diagnostic Circuit Check .................................... 4E-18 ABS Indicator Lamp Inoperative ......................... 4E-20 TCS Indicator Lamp Inoperative ......................... 4E-24 EBD Indicator Lamp Inoperative ........................ 4E-28 Power Supply To Control Module, No Dtcs Stored ...................................................................... 4E-32 ABS Indicator Lamp Illuminated Continuously, No Dtcs Stored ............................................... 4E-36 Self-Diagnostics ................................................ 4E-38 Intermittent and Poor Connections ...................... 4E-38 DTC 035-Left Front Wheel Speed Sensor Fault ............................................................... 4E-40 DTC 07-Left Front Wheel Speed Sensor Continuity Fault ............................................... 4E-42 DTC 040-Right Front Wheel Speed Sensor Fault ............................................................... 4E-44 DTC 08-Right Front Wheel Speed Sensor Continuity Fault ............................................... 4E-46 DTC 045-Left Rear Wheel Speed Sensor Fault .... 4E-48 DTC-Left Rear Wheel Speed Sensor Continuity Fault ............................................................... 4E-50 DTC 050-Right Rear Wheel Speed Sensor Fault ............................................................... 4E-52 DTC-Right Rear Wheel Speed Sensor Continuity Fault ............................................................... 4E-54 DTC 245-Wheel Speed Sensor Frequency Error ............................................................... 4E-56 DTC 930-Acceleration Sensor Fault ..................... 4E-60 DTC-Acceleration Sensor Continuity Fault ........... 4E-62 DTC 060/065-Left Front Inlet and Outlet Valve Solenoid Fault ................................................. 4E-64 DTC 070/075-Right Front Inlet and Outlet Valve Solenoid Fault ................................................. 4E-66 DTC 080/085-Left Rear Inlet and Outlet Valve Solenoid Fault ................................................. 4E-68 DTC 090/095-Right Rear Inlet and Outlet Valve Solenoid Fault ................................................. 4E-70 DTC 141/146-Left Rear Prime Line and TCS Pilot Valve Fault ..................................................... 4E-72 DTC 121-Valve Relay Circuit Fault ...................... 4E-74 DTC 110-Return Pump Motor Circuit Fault........... 4E-76 DTC 161-Stoplamp Switch Fault ......................... 4E-78 DTC 800-Low Voltage Fault ................................ 4E-82 DTC 550-EBCM Internal Fault ............................. 4E-86 Schematic and Routing Diagrams ..................... 4E-88 ABS 5.3 Circuit .................................................. 4E-88 ABD 5.3 Circuit .................................................. 4E-89 Connector End Views ......................................... 4E-90 EBCM (Hydraulic Modulator/Unit Integrated) ...... 4E-90 Repair Instructions .............................................. 4E-91 On-Vehicle Service ............................................. 4E-91 Service Precautions ........................................... 4E-91 Hydraulic Modulator/Ebcm Assembly ................ 4E-92 Front Wheel Speed Sensor ................................. 4E-93 Rear Wheel Speed Sensor ................................. 4E-93 Acceleration Sensor ........................................... 4E-94 System Fuse ..................................................... 4E-94 Indicators .......................................................... 4E-94 Unit Repair .......................................................... 4E-95 ABS Front Tooth Wheel ...................................... 4E-95 Special Tools and Equipment ............................ 4E-96 Special Tools Table............................................ 4E-96
4E-2 ABS AND TCS

ABS(ANTI-LOCK BRAKE SYSTEM)
When wheel slip is noted during a brake application, the ABS enters antilock mode. During antilock braking, hydraulic pressure in the individual wheel circuits is controlled in order to prevent any wheel from slipping. A separate hydraulic line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold or increase hydraulic pressure to each wheel brake. However, the ABS cannot increase hydraulic pressure above the amount which is transmitted by the master cylinder during braking. During antilock braking, a series of rapid pulsations will be felt in the brake pedal. These pulsations are caused by the rapid changes in position of the individual solenoid valves as they respond to their desired wheel speed. This pedal pulsation is present during antilock braking and stops when normal braking is resumed or when the vehicle comes to a stop. A ticking or popping noise may also be heard as the solenoid valves rapidly cycle. During antilock braking on dry pavement, the tires may make intermittent chirping noises as they approach slipping. These noises and pedal pulsations should be considered normal during antilock operation. The vehicle may be stopped by applying normal force to the brake pedal. Brake pedal operation during normal braking should be no different than previous systems. Maintaining a constant force on the pedal will provide the shortest stopping distance while maintaining vehicle stability. The inlet valve and the outlet valve close/open by the electrical signal and control the hydraulic pressure as increase, decrease and hold.
YAD4E010
ABS System Components

The ABS 5.3 Antilock Braking System (ABS) consists of a conventional hydraulic brake system plus antilock components. The conventional brake system includes a vacuum booster, master cylinder, front disc brakes, rear disc brakes, interconnecting hydraulic brake pipes and hoses, brake fluid level switch and the BRAKE indicator. The ABS components include a hydraulic unit, an electronic brake control module (EBCM), two system fuses, four wheel speed sensors (one at each wheel), interconnecting wiring, the ABS indicator, the EBD indicator and the TCS indicator, See ABS Component Locator in this section for the general layout of this system. The basic hydraulic unit configuration consists of hydraulic check valves, two solenoid valves for each wheel, a hydraulic pump, and two accumulators. The hydraulic unit controls hydraulic pressure to the front calipers and rear calipers by modulating hydraulic pressure to prevent wheel lockup. Units equipped with TCS add two more valves for each drive wheel for the purpose of applying the brake to a wheel that is slipping. This is done with pressure from the hydraulic pump in the unit. There is also a TCS indicator lamp on the instrument panel to alert the driver to the fact that the TCS system is active. The components identified in the drawing are those added to the basic ABS 5.3 system to provide traction control. Nothing the hydraulic unit or the EBCM is serviceable. In the event of any failure, the entire ABS unit with attached EBCM must be replaced. For more information, refer to Base Braking Mode and Antilock Braking Mode in the section.
Basic Knowledge Required

Before using this section, it is important that you have a basic knowledge of the following items. Without this knowledge, it will be difficult to use the diagnostic procedures contained in this section. Basic Electrical Circuits - You should understand the basic theory of electricity and know the meaning of voltage, current (amps) And resistance (ohms). You should understand what happens in a circuit with an open or shorted wire. You should be able to read and understand a wiring diagram. Use of Circuit Testing Tools - You should know how to use a test light and how to bypass components to test circuits using fused jumper wires. You should be familiar with a digital multimeter. You should be able to measure voltage, resistance, and current, and be familiar with the controls and how to use them correctly.
Basic Hydraulic System

Each solenoid valve consists of one inlet valve and one outlet valve in order to become the channel.
SSANGYONG Y200
ABS AND TCS 4E-3
TRACTION CONTROL SYSTEM (TCS) DESCRIPTION

General Information
The traction control system (TCS) is a traction system by means of brake intervention only, available in a low speed range (< 60 kph). It works on -split roads with sidewise different friction coefficients. The spinning driven wheel is braked and the drive torque can be transferred to the wheel on the high- side. During TCS active, the TCS information lamp is blinking.
The temperature of the brakes is calculated by a mathematical model and TCS is switched passive if the calculated temperature is greater than a threshold value (500 C). TCS is permitted again, when the calculated temperature is less than 350 C.
Lamp Concepts
The system is equipped with an TCS information lamp, which is blinking during TCS operation. The activation of the EBD, TCS warning lamp and the TCS info lamp is summarized in the following table:
Ignition ON ABS Warning Lamp TCS Info Lamp EBD Warning Lamp 2 second on for lamp check 2 second on for lamp check 2 second on for lamp check
ABS Operation OFF
TCS Operation OFF Blinking (FLASHING) OFF
System Failure (EBD, ABS or TCS are Not Distinguished) ON
TCS Passive Due to Temperature Model OFF
OFF EBD operation/OFF
OFF
ON
ON
OFF
SSANGYONG Y200
4E-4 ABS AND TCS
Automatic Brake Differential (ABD)

ABD (Automatic Brake Differential) system is a type of the TCS (ASR) system and substitutes the function of the mechanical LSD (Limited Slip Differential) system. ABD system operates by controlling the braking forces only under 60km/h.
Control Algorithm
The input signals for the control algorithm are the filtered wheel speed signals from the ABS speed processing. With the speed difference of the driven wheels, the control deviation is calculated. If the control deviation exceeds a certain threshold value, the wheel with the greater slip is braked actively. The threshold value depends on the vehicle speed: It is reduced with increasing vehicle speed down to a constant value.
TCS System Function

Traction control does not have any effect on the operation of the vehicle until the control module detects one or both of the front wheels rotating faster than the rear wheels. At this time, the electronic brake control module (EBCM) requests the powertrain control module to reduce the amount of torque applied to the drive wheels. The powertrain control module does this by retarding timing and selectively turning off fuel injectors. The EBCM applies the front brakes, thus reducing torque to the front wheels. Once the front wheel begins to rotate at the same speed as the rear wheels, the system returns full control to the driver. During traction control mode, if the brake is applied to only one front wheel, most of the torque from the engine is directed to the other front wheel which improves the traction of the vehicle.
YAD4E020
Pressure Modulation
Depending on the control deviation and the wheel acceleration of the spinning wheel, pressure increase, hold and decrease are made. The pressure modulation is done with the conventional control with the valves. Prime valve, inlet valve and outlet valve according to the following table: Increase Prime Valve Pilot Valve Inlet Valve Outlet Valve Open Closed Open Closed Hold Open Closed Closed Closed Decrease Open Closed Closed Open
V = Faster rear wheel speed - Slower rear wheel speed V = Vehicle speed * TCS is switched passive if the calculated temperature is greater than a threshold value (500 C). TCS (ABD) Indicator turns on but TCS is permitted again, when the calculated temperature is less than 350 C.
Temperature Model
TCS operation is a high thermal load for the brakes. To avoid any damages at the brakes, the disk temperature is calculated with a mathematical model for each driven wheel separately, After ignition on, the calculation starts with 30 C and then three different phases are evaluated separately and added: TCS operation, braking and cooling phase. If the temperature is higher than 500 C, TCS is disabled for this wheel. It is permitted again, if the model has calculated down the 350 C.
Speed Range
TCS is available in the speed range 60 kph. Above 60 kph vehicle speed, TCS is passive. It is possible to initiate TCS operation up to a vehicle speed of 55 kph.
SSANGYONG Y200
ABS AND TCS 4E-5
EBD (ELECTRONIC BRAKE FORCE DISTRIBUTION) SYSTEM

System Description
As an add-on logic to the ABS base algorithm, EBD works in a range in which the intervention thresholds for ABS control are not reached yet. EBD ensures that the rear wheels are sensitively monitored for slip with respect to the front axle. If slip is detected, the inlet valves for the rear wheels are switched to pressure hold to prevent a further increase in pressure at the rear-wheel breaks, thus electronically reproducing a pressure-reduction function at the rearwheel brakes. ABS features an enhanced algorithm which includes control of the brake force distribution between the front and rear axles. This is called Electronic Brake Distribution. In an unloading car condition the brake efficiency is comparable to the conventional system but for a fully loaden vehicle the efficiency of the EBD system is higher due to the better use of rear axle braking capability.
YAD4E030
Service Precautions Observe the following general precautions during any ABS/TCS service. Failure to adhere to these precautions may result in ABS/TCS system damage. 1. Disconnect the EBCM harness connector before performing the electric welding procedures. 2. Carefully note the routing of the ABS/TCS wiring and wring components during removal. The ABS/ TCS components are extremely sensitive to EMI (eletromagnetic interference). Proper mounting is critical during component service. 3. Disconnect the EBCM connector with the ignition OFF. 4. Do not hang the suspension components from the wheel speed sensor cables. The cables may be damaged. 5. Do not use petroleum based fluids in the master cylinder. Do not use any containers previously used for petroleum based fluids. Petroleum causes swelling and distortion of the rubber components in the hydraulic brake system, resulting in water entering the system and lowering the fluid boiling point.
The Benefits of EBD
Elimination of conventional proportioning valve EBD utilizes the existing rear axle wheel speed sensor to monitor rear wheel slip. Based on many variables in algorithm a pressure hold, increase and/or decrease pulsetrain may be triggered at the rear wheels insuring vehicle stability. Vehicle approaches the ideal brake force distribution (front to rear). Constant brake force distribution during vehicle lifetime. EBD function is monitored via ABS safety logic (conventional proportioning valves are not monitorable). Keep alive function.
SSANGYONG Y200
4E-6 ABS AND TCS
Electronic Brake-Force Distribution (EBD) Failure Matrix
SSANGYONG Y200
YAD4E040
ABS AND TCS 4E-7 Hydraulic Fluid Flow Diagrams

For normal brake mode, during non-antilock braking, pressure is applied through the brake pedal and fluid comes from the master cylinder into the hydraulic unit. The normally open isolation cartridge and normally closed dump cartridge would remain in these positions to allow fluid pressure to the calipers and the wheel cylinders. And each wheel begins locking.
YAD4E050
SSANGYONG Y200
4E-8 ABS AND TCS
Electronic Brake-Force Distribution (EBD) Failure Matrix For Malfunction
SSANGYONG Y200
YAD4E060
ABS AND TCS 4E-9
TIRES AND ABS/TCS

Replacement Tires
Tire size is important for proper performance of the ABS system. Replacement tires should be the same size, load range, and construction as the original tires. Replace tires in axle sets and only with tires of the same tire performance criteria (TPC) specification number. The use of any other size or type of tire may seriously affect the ABS operation.
Front Wheel Speed Sensor Rings

The toothed ring mentioned above is pressed onto the wheel-side (outer) constant velocity joint. Each ring contains 52 equally spaced teeth. Exercise care during service procedures to avoid prying or contacting this ring. Excessive contact may cause damage to one or more teeth. If the ring is damaged, the wheel-side constant velocity joint must be replaced.
Rear Wheel Speed Sensors And Rings

The rear wheel speed sensors operate in the same manner as the front wheel speed sensor. They incorporate a length of flexible harness with the connector attached to the end of the harness. The rear wheel speed rings are incorporated into the hub assemblies and cannot be replaced separately, require replacement of the rear hub/bearing assembly.
Electronic Brake Control Module (EBCM)

Notice: There is on serviceable or removable EEPROM. The EBCM must be replaced as an assembly (Only ABS). ABS/TCS is separated hydraulic modulator and EBCM. The EBCM is attached to the hydraulic unit in the engine compartment (ABS). The controlling element of ABS 5.3 is a microprocessor-based EBCM. Inputs to the system include the four wheel speed sensors, the stoplamp switch, the ignition switch, and the unswitched battery voltage. There is an output to a be-directional serial data link, located in pin K of Assembly Line Diagnostic Link (ALDL) for service diagnostic tools and assembly plant testing. The EBCM monitors the speed of each wheel. If any wheel begins to approach lockup and the brake switch is closed (brake pedal pressed), the EBCM controls the solenoids to reduce brake pressure to the wheel approaching lockup. Once the wheel regains traction, brake pressure is increased until the wheel again begins to approach lockup. This cycle repeats until either the vehicle comes to a stop, the brake pedal is released, or no wheels approach lockup. Additionally, the EBCM monitors itself, each input (except the serial data link), and each output for proper operation. If it detects any system malfunction, the EBCM will store a DTC in nonvolatile memory (EERPOM) (DTCs will not disappear if the battery is disconnected). Refer to Self Diagnostics in this section for more detailed information.
Valve Realy And Pump Motor Relay

The valve relay and the motor pump relay are located inside the electronic brake control module (EBCM) and are not replaceable. If one should fail, replace the EBCM.
Wiring Harness
The wiring harness is the mechanism by which the electronic brake control module (EBCM) is electrically connected to power and to ground, to the wheel speed sensors, the fuses, the switches, the indicators, and the serial communications port. The components, considered part of the wiring harness, are the wires that provide electrical interconnection, and connectors (terminals, pins, contacts, or lugs) that provide an electrical/mechanical interface from the wire to a system component.
Indicators
The electronic brake control module (EBCM) continuously monitors itself and the other ABS components If the EBCM detects a problem with the system, the amber ABS indicator will light continuously to alert the driver to the problem. An illuminated ABS indicator indicates that the ABS system has detected a problem that affects the operation of ABS. On antilock braking will be available. Normal, non-antilock brake performance will remain. In order to regain ABS braking ability, the ABS must be serviced. The red BRAKE indicator will be illuminated when the system detects a low brake fluid level in the master cylinder or when the parking brake switch is closed (the parking brake is engaged). The EBD indicator will light continuously to alert the driver to the problem in the basic brake system. The EBD system must be serviced.
Front Wheel Speed Sensors

The front wheel speed sensors are of a variable reluctance type. Sensor is attached to the steering knuckle, close to a toothed ring. The result, as teeth pass by the sensor, is an AC voltage with a frequency proportional to the speed of the wheel. The magnitude of the voltage and frequency increase with increasing speed. The sensor is not repairable, nor is the air gap adjustable.
SSANGYONG Y200
4E-10 ABS AND TCS
HYDRAULIC CIRCUIT
ABS 5.3
Pressure Increase
YAD4E070
1 2 3 4 5
Master Cylinder Hydraulic Modulator Damper Pump Pump Motor
6 7 8 9 10
Accumulator Inlet Valve for each wheel Outlet Valve for each wheel Front Wheel Rear Wheel
SSANGYONG Y200
ABS AND TCS 4E-11 Pressure Hold
YAD4E080
1 2 3 4 5
6 7 8 9 10
SSANGYONG Y200
4E-12 ABS AND TCS
Pressure Decrease
YAD4E090
1 2 3 4 5
6 7 8 9 10
SSANGYONG Y200
ABS AND TCS 4E-13
ABS/TCS 5.3
Pressure Increase
YAD4E100
1 2 3 4 5 6 7
Master Cylinder Hydraulic Modulator Damper Pump Pump Motor Accumulator Inlet Valve for each wheel
8 9 10 11 12 13
Outlet Valve for each wheel Wheel Prime Valve Pilot Valve Check Valve ISD (Integrated Suction Damper)
SSANGYONG Y200
4E-14 ABS AND TCS Pressure Hold
YAD4E110
1 2 3 4 5 6 7
8 9 10 11 12 13
SSANGYONG Y200
ABS AND TCS 4E-15 Pressure Decrease
YAD4E120
1 2 3 4 5 6 7
8 9 10 11 12 13
SSANGYONG Y200
4E-16 ABS AND TCS
COMPONENT LOCATOR
ABS, ABS/TCS 5.3
3 4 2
YAD4E130
1 ABS/TCS Hydraulic Unit and Control Unit 2 Rear Wheel Speed Sensor 3 ABS Warning Indicator
4 Diagnosis connector 5 Front Wheel Speed Sensor
SSANGYONG Y200
ABS AND TCS 4E-17
BLANK
SSANGYONG Y200
4E-18 ABS AND TCS
YAD4E140
DIAGNOSTIC CIRCUIT CHECK

The Diagnostic Circuit Check is an organized approach to identifying a problem created by an antilock brake system (ABS) malfunction. If must be the starting point for any ABS complaint diagnosis because it directs the service technician to the next logical step in diagnosing the complaint. Diagnostic Process Perform the following steps in order when servicing the ABS/TCS system. Failure to do so may result in the loss of important diagnostic data and may lead to difficulties and time-consuming diagnosis procedures. 1. Perform the tests of the table below. 2. Perform a road test if directed by the table. Test drive the vehicle while using the snapshot feature of the scan tool. Perform normal acceleration, stopping, and turning maneuvers. If this does not reproduce the malfunction, perform an ABS stop or TCS maneuver on a low friction surface such as gravel. 3. Clear the diagnostic trouble codes (DTCs) after all system malfunctions have been corrected.
SSANGYONG Y200
ABS AND TCS 4E-19 Diagnostic Circuit Check

Step Action 1. Install the scan tool. 2. Turn ignition switch to ON. 3. Select the Data List mode. Is the scan tool receiving data from the electronic brake control module (EBCM)? Check the display. Are there any current DTCs displayed? 1. Turn the ignition to LOCK for 10 seconds. 2. Turn the ignition to On and observe the ABS indicator. Does the indicator light for 2 seconds and then go off? Check the ABS indicator. Did the ABS indicator turn on and stay on? Value Yes No
Go to Step 2 Refer to the applicable DTC table
Go to Step 7
Go to Step 3
Go to Step 5
Go to Step 4
5 Check whether the vehicle is equipped with traction control. Is the vehicle equipped with traction control? 1. Turn the ignition to LOCK for 10 seconds. 2. Turn the ignition to ON and observe the TCS indicator. Does the indicator light for 2 seconds and then go off? 1. Turn the ignition to LOCK. 2. Disconnect the EBCM harness connector. 3. Turn the ignition to ON. 4. Use a digital voltmeter (DVM) to measure the voltage from ground to terminal 15 of the EBCM harness connector. Is the voltage equal to the specified valve? 1. Turn the ignition to LOCK. 2. Use a DVM to measure the resistance from the EBCM harness connector, terminals 16 and 19 to ground. Is the resistance equal to the specified value? Repair the open in the circuit that failed. Is the repair complete? Use a DVM to measure the resistance between terminal 11 of the EBCM harness connector and terminal 8 of the data link connector (DLC). Is the resistance below the specified valve? Replace the ABS unit. Is the repair complete? Repair the open or high resistance in circuit between terminal 11 of the EBCM harness connector and terminal 8 of the DLC. Is the repair complete? Perform the road test described above. Are any DTC set?
Go to ABS Indicator Lamp Go to ABS Illuminated Indicator Lamp Constantly Inoperative
Go to Step 6
Go to Step 13
Go to TCS Indicator Lamp Go to Step 13 Inoperative
11 - 14 V
Go to Step 8
Go to Power Supply to Control Module, No DTCs Stored
0 -
Go to Step 9 -
10
2 -
Go to Step 12 -
11
12
Go to Step 1 Go to the DTC table
System OK
13
SSANGYONG Y200
4E-20 ABS AND TCS
YAD4E150
ABS INDICATOR LAMP INOPERATIVE

Circuit Description Battery voltage is supplied to the ABS lamp with the ignition switch in the ON or START positions. The warning lamp can be activated only by the ABS control module internally supplying ground to terminal 20 or by the shorting bar in the ABS module connector if the connector in disconnected from the module. Diagnosis This procedure checks for a problem in the wiring, a faulty ground, a voltage supply problem, a burned out indicator lamp, or a contact problem in a connector. Cause A fuse has blown. The indicator lamp has burned out. There is a corroded or broken connector terminal. There is a faulty ground connection. There is a broken wire in a wring harness. The EBCM is faulty. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This test checks for any DTCs that may cause the ABS indicator lamp to be inoperative. 2. This test verifies an inoperative lamp condition. 3. This test checks for voltage on the lamp circuit. 4. This begins a series of tests of the circuit from the indicator lamp to the EBCM and ground. 19. This begins a series of tests of the voltage supply circuits that power the indicator lamp.
SSANGYONG Y200
ABS AND TCS 4E-21 ABS Indicator Lamp Inoperative

Step 1 Action Install the scan tool and check for any DTCs. Is any DTC set? 1. Turn the ignition to LOCK. 2. Disconnect the scan tool. 3. Turn the ignition to ON. 4. Observe the ABS indicator lamp. Does the lamp illuminate for about 2 seconds, then turn off? With the ignition still ON, observe the oil pressure lamp. Is the oil pressure lamp illuminated? 1. Turn the ignition to LOCK. 2. Disconnect the connector from the electronic brake control module (EBCM). 3. Turn the ignition switch to ON. Does the ABS indicator illuminate? 1. Turn the ignition to LOCK. 2. Examine terminals 16 and 20 at the EBCM connector on both the ABS wiring harness and on the EBCM. Is there a poor connection at any of these terminals? Repair the faulty terminals or replace the ABS unit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Disconnect the wire from the negative battery terminal. 3. Measure the resistance between the negative battery wire, which is attached to ground, and the shorting bar in the EBCM connector. Is the resistance equal to the specified valve? Repair the open or high resistance in the circuit from EBCM connector, terminal 16 to ground G106. Is the repair complete? 1. Remove the I/P cluster. 2. Remove and check the ABS indicator bulb. Is the bulb burned out? 1. Replace the ABS indicator bulb. 2. Install the I/P cluster. Is the repair complete? Check the continuity at the I/P cluster connector terminal B7. Is the continuity equal to the specified value? Repair the contact at the I/P cluster connector terminal B7. Is the repair complete? Value Yes Go to the DTC table No Go to Step 2
Go to Intermittent and Poor Connections
Go to Step 3
Go to Step 4
Go to Step 19
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
6 7
System OK System OK
Go to Step 10
Go to Step 9
System OK
10
Go to Step 11
Go to Step 12
11
System OK
12
Go to Step 14
Go to Step 13
13
System OK
SSANGYONG Y200
4E-22 ABS AND TCS ABS Indicator Lamp Inoperative (Contd)

Step Action Check the wiring harnesses and the connectors in circuit from the I/P cluster terminal B7 to terminal 20 of the EBCM connector. Is the voltage equal to the specified value? Repair the open or the resistance found. Is the repair complete? Check for continuity between terminal 16 of the EBCM connector and ground G106. Is the continuity equal to the specified value? Replace the ABS unit. Is the repair complete? Repair the continuity problem between terminal 16 of the EBCM connector and ground G106. Is the repair complete? 1. Turn the ignition to LOCK. 2. Check fuse F2 in the I/P fuse block. Is fuse F2 blown? Replace fuse F2. Is the repair complete? 1. Turn the ignition on. 2. Check the voltage at Fuse 2. Is the voltage equal to the specified value? Repair the power supply to Fuse 2. Is the repair complete? 1. Remove the instrument cluster. 2. Check the circuit from fuse F2 to terminal B15 of the I/P cluster connector. 3. Repair any open or high resistance found in a wiring harness, splice pack, or connector. Is the repair complete? Value Yes No
14
Go to Step 16 -
15 16 17 18
0 -
Go to Step 9 -
System OK
19 20
Go to Step 21 -
21
11 - 14 V -
Go to Step 21 -
22
23
System OK
SSANGYONG Y200
ABS AND TCS 4E-23
BLANK
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4E-24 ABS AND TCS
YAD4E160
TRACTION CONTROL SYSTEM (TCS) INDICATOR LAMP INOPERATIVE

Circuit Description Battery voltage is supplied to the TCS warning lamp with the ignition in ON or START. The warning lamp can be activated only by the ABS control module internally supplying ground to terminal 22. Diagnosis This procedure checks for a problem in the wiring, a faulty ground, a voltage supply problem, a burned out indicator lamp, or a contact problem in a connector. Cause A fuse has blown. The indicator lamp has burned out. There is a corroded or broken connector terminal. There is a faulty ground connection. There is a broken wire in a wiring harness. The EBCM is faulty. Test description The number(s) below refer to step(s) on the diagnostic table. 1. This test checks for any DTCs that may cause the TCS indicator lamp to be inoperative. 2. This test verifies an inoperative lamp condition. 3. This test checks for voltage on the lamp circuit. 4. This begins a series of tests of the circuit from the indicator lamp to the EBCM and ground. 19. This begins a series of tests of the voltage supply circuits that power the indicator lamp.
SSANGYONG Y200
ABS AND TCS 4E-25 Traction Control System (TCS) Indicator Lamp Inoperative
Step 1 Action Install the scan tool and check for any DTCs. Is any DTC set? 1. Turn the ignition to LOCK. 2. Disconnect the scan tool. 3. Turn the ignition to ON. 4. Observe the TCS indicator lamp. Does the lamp illuminate for about 2 seconds, then turn off? With the ignition still ON, observe the oil pressure lamp. Is the oil pressure lamp illuminated? 1. Turn the ignition to LOCK. 2. Disconnect the connector from the EBCM. 3. Connect a jumper form terminal 22 to the grounding bar in the connector. 4. Turn the ignition to ON. Does the TCS indicator illuminate? 1. Turn the ignition to LOCK. 2. Examine terminals 16, 19 at the EBCM connector on both the ABS wiring harness and on the EBCM. Is there a poor connection at any of these terminals? Repair the faulty terminals or replace the ABS unit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Disconnect the wire from the negative battery terminal. 3. Measure the resistance between the negative battery wire, which is attached to ground, and the shorting bar in the EBCM connector. Is the resistance equal to the specified value? Repair the open or high resistance in the circuit from EBCM connector, terminal 16, 19 to ground G106. Is the repair complete? 1. Remove the I/P cluster. 2. Remove and check the TCS indicator bulb. Is the bulb burned out? 1. Replace the TCS indicator bulb. 2. Replace the I/P cluster. Is the repair complete? Check continuity at the I/P cluster connector terminal B10. Is the continuity equal to the specified value? Repair the contact at the I/P cluster connector terminal B10. Is the repair complete? Value Yes Go to the DTC table No Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 19
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
6 7
System OK System OK
Go to Step 10
Go to Step 9
System OK
10
Go to Step 11
Go to Step 12
11
System OK
12
Go to Step 14
Go to Step 13
13
System OK
SSANGYONG Y200
4E-26 ABS AND TCS Traction Control System (TCS) Indicator Lamp Inoperative (Contd)
Step Action Check the wiring harnesses and connectors in circuit from the I/P cluster terminal B10 to terminal 22 of the EBCM connector. Is the voltage equal to the specified value? Repair the open or high resistance. Is the repair complete? Check for continuity between terminal 16, 19 of the ABS connector and ground G106. Is the continuity equal to the specified value? Replace the ABS unit. Is the repair complete? Repair the continuity between terminal 16, 19 of the EBCM connector and ground G106. Is the repair complete? 1. Turn the ignition to LOCK. 2. Check fuse F2 in the I/P fuse block. Is fuse F2 blown? Replace fuse F2. Is the repair complete? 1. Turn the ignition ON. 2. Check the voltage at fuse F2. Is the voltage equal to the specifies value? Repair the power supply to fuse F2. Is the repair complete? 1. Remove the I/P cluster. 2. Check circuit from fuse F2 to terminal 15 of the I/P cluster connector. 3. Repair any open or high resistance found in a wiring harness, a splice pack, or a connector. Is the repair complete? Value Yes No
14
0 -
Go to Step 16 -
15 16 17 18
0 -
Go to Step 18 -
System OK
19 20
Go to Step 21 -
21
11 - 14 V -
Go to Step 23 -
22
23
System OK
SSANGYONG Y200
ABS AND TCS 4E-27
BLANK
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4E-28 ABS AND TCS
YAD4E150
ELECTRONIC BRAKE-FORCE DISTRIBUTION SYSTEM (EBD) INDICATOR LAMP INOPERATIVE

Circuit Description Battery voltage is supplied to the EBD warning lamp with the ignition in ON or START. The warning lamp can be activated only by the ABS control module internally supplying ground to terminal 21. Diagnosis This procedure checks for a problem in the wiring, a faulty ground, a voltage supply problem, a burned out indicator lamp, or a contact problem in a connector. Cause A fuse has blown. The indicator lamp has burned out. There is a corroded or broken connector terminal. There is a faulty ground connection. There is a broken wire in a wiring harness. The EBCM is faulty. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This test checks for any DTCs that may cause the EBD indicator lamp to be inoperative. 2. This test verifies an inoperative lamp condition. 3. This test checks for voltage on the lamp circuit. 4. This begins a series of tests of the circuit from the indicator lamp to the EBCM and ground. 19. This begins a series of tests of the voltage supply circuits that power the indicator lamp.
SSANGYONG Y200
ABS AND TCS 4E-29 Electronic Brake-Force Distribution System (EBD) Indicator Lamp Inoperative
Step 1 Action Install the scan tool and check for any DTCs. Is any DTC set? 1. Turn the ignition to LOCK. 2. Disconnect the scan tool. 3. Turn the ignition to ON. 4. Observe the EBD indicator lamp Does the lamp illuminate for about 2 seconds, then turn off? With the ignition still ON, observe the oil pressure lamp. Is the oil pressure lamp illuminated? 1. Turn the ignition to LOCK. 2. Disconnect the connector from the EBCM. 3. Connect a jumper form terminal 16, 19 to the grounding bar in the connector. 4. Turn the ignition to ON. Does the EBD indicator illuminate? 1. Turn the ignition to LOCK. 2. Examine terminals 16, 19 and 28, 29 at the EBCM connector on both the ABS wiring harness and on the EBCM. Is there a poor connection at any of these terminals? Repair the faulty terminals or replace the ABS unit, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? 1. Turn the ignition to LOCK. 2. Disconnect the wire from the negative battery terminal. 3. Measure the resistance between the negative battery wire, which is attached to ground, and the shorting bar in the EBCM connector. Is the resistance equal to the specified value? Repair the open or high resistance in the circuit from EBCM connector, terminal 16, 19 to ground G106. Is the repair complete? 1. Remove the I/P cluster. 2. Remove and check the EBD indicator bulb. Is the bulb burned out? 1. Replace the EBD indicator bulb. 2. Replace the I/P cluster. Is the repair complete? Check continuity at the I/P cluster connector terminal A6. Is the continuity equal to the specified value? Repair the contact at the I/P cluster connector terminal A6. Is the repair complete? Value Yes Go to the DTC table No Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 19
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
6 7
System OK System OK
Go to Step 10
Go to Step 9
System OK
10
Go to Step 11
Go to Step 12
11
System OK
12
Go to Step 14
Go to Step 13
13
System OK
SSANGYONG Y200
4E-30 ABS AND TCS Electronic Brake-Force Distribution System (EBD) Indicator Lamp Inoperative (Contd)
Step Action Check the wiring harnesses and connectors in circuit from the I/P cluster terminal A6 to terminal 21 of the EBCM connector. Is the voltage equal to the specified value? Repair the open or high resistance. Is the repair complete? Check for continuity between terminal 16, 19 of the ABS connector and ground G106. Is the continuity equal to the specified value? Replace the ABS unit. Is the repair complete? Repair the continuity between terminal 16, 19 of the EBCM connector and ground G106. Is the repair complete? 1. Turn the ignition to LOCK. 2. Check fuse F2 in the I/P fuse block. Is fuse F2 blown? Replace fuse F2. Is the repair complete? 1. Turn the ignition ON. 2. Check the voltage at fuse F2. Is the voltage equal to the specifies value? Repair the power supply to fuse F2. Is the repair complete? 1. Remove the I/P cluster. 2. Check circuit from fuse F2 to terminal 15 of the I/P cluster connector. 3. Repair any open or high resistance found in a wiring harness, a splice pack, or a connector. Is the repair complete? Value Yes No
14
Go to Step 16 -
15 16 17 18
0 -
Go to Step 18 -
System OK
19 20
Go to Step 21 -
21
11 - 14 V -
Go to Step 23 -
22
23
System OK
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ABS AND TCS 4E-31
BLANK
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4E-32 ABS AND TCS
YAD4E140
POWER SUPPLY TO CONTROL MODULE, NO DTCS STORED

Circuit Description Battery voltage is supplied to the electronic brake control module (EBCM) through fuse F3 and F2 in the I/P fuse block, to terminal 15 and 20 of the EBCM connector. The voltage is present when the ignition switch is in ON or START. Diagnosis This test checks for battery output, proper grounding, blown fuses, a faulty ignition switch, and problems in the circuitry. Cause Action Taken When the DTC Sets ABS action is disabled during the period of low voltage, and the ABS warning lamp is ON for the remainder of the ignition cycle. Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step determines whether there is voltage at the battery and the high current source. 7. This step checks for voltage at the ignition 1 source. Diagnostic Aids It is very important to perform a thorough inspection of the wiring and the connectors. Failure to do so may result in misdiagnosis, causing part replacement with a reappearance of the malfunction.
The battery is defective. There is a defective ground connection. A wire is broken or shorted. A fuse is blown. The ignition switch is malfunctioning.
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ABS AND TCS 4E-33 Power Supply to Control Module, No DTCs Stored
Step 1 2 3 Action Check the voltage at the battery. Is the voltage equal to the specified value? Charge or replace the battery, as required. Is the repair complete? Check fuse F7 in the I/P fuse block. Is the fuse blown? 1. Replace fuse F7. 2. Turn the ignition to ON. Does the fuse blow again? Check the ABS function. Is the repair complete? 1. Turn the ignition to OFF. 2. Remove fuse F7. 3. Disconnect the ABS connector from the EBCM. 4. Measure the resistance to ground at terminals 15. Does the ohmmeter show the specified value? Repair the short to ground in circuit between F7 and the ABS harness EBCM connector. Is the repair complete? 1. Turn the ignition to ON. 2. Check the voltage at fuse F2. Is the voltage equal to the specified value? Repair the power supply to fuse 2. Is the repair complete? Check fuse F2 in the I/P fuse block. Is the fuse F2 blown? 1. Replace fuse F2. 2. Turn the ignition to ON. Does the fuse blow again? Check the ABS function. Is the repair complete? 1. Turn the ignition to OFF. 2. Remove fuse F2. 3. Disconnect the ABS connector from the EBCM. 4. Measure the resistance between ground and terminal 20. Is the resistance equal to the specified value? Repair the short to ground in circuit fuse F2 of the I/P fuse block and terminal 20 of the ABS harness EBCM connector. Is the repair complete? 1. Disconnect the EBCM connector from the EBCM. 2. Turn the ignition to ON. 3. Check for the presence of battery voltage between ground and terminal 17, 18. Is the voltage equal to the specified value? Value 11 - 14 V Yes Go to Step 3 System OK Go to Step 4 No Go to Step 2 Go to Step 8
4 5
Go to Step 5 -
Go to Step 7
Go to Step 26
System OK
11 - 14 V -
Go to Step 10 System OK Go to Step 14
9 10 11
Go to Step 12 -
12
13
Go to Step 14
Go to Step 13
14
System OK
15
11 - 14 V
Go to Step 10
Go to Step 9
SSANGYONG Y200
4E-34 ABS AND TCS Power Supply to Control Module, No DTCs Stored (Contd)
Step Action 1. Turn the ignition switch to OFF. 2. Trace the RW wires between terminal 15 of the EBCM connector to fuse F7 of the I/P fuse block. 3. Repair the open in this circuit. Is the repair complete? Check the voltage between ground and terminal 20 of the EBCM connector. Is the voltage equal to the specified value? 1. Turn the ignition switch to OFF. 2. Check the resistance between ground and terminals 16 of the EBCM connector. Is the resistance equal to the specified value? 1. Turn the ignition to OFF 2. Check the resistance between ground and terminals 16 of the EBCM connector. Is the resistance equal to the specified value? Examine terminals 15, 20, 16 of the EBCM connector. Is there a defective terminal? Repair the defective terminal or replace the connector or wiring harness, as required. Is the repair complete? Replace the ABS unit. Is the repair complete? Repair the defective ground connection. Is the repair complete? Value Yes No
16
System OK
17
11 - 14 V
Go to Step 19
Go to Step 18
18
System OK
19
0 -
20 21
System OK System OK System OK
22 23
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ABS AND TCS 4E-35
BLANK
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4E-36 ABS AND TCS
YAD4E150
ABS INDICATOR LAMP ILLUMINATED CONTINUOUSLY, NO DTCS STORED

Circuit Description Battery voltage is supplied to the ABS warning lamp with the ignition in ON or START. The warning lamp should be activated only by the ABS control module internally supplying ground to terminal 20. Diagnosis This procedure checks for a short to ground in the wiring or a defective electronic brake control module (EBCM). Cause There is a short to ground in the circuit between the cluster terminal D7 and the EBCM terminal 31. The EBCM is faulty.
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ABS AND TCS 4E-37 ABS Indicator Lamp Illuminated Continuously, No DTCs Stored
Step 1 2 Action Check the EBCM connector. Is it connected properly? Connect the EBCM connector. Is the repair complete? 1. Disconnect the EBCM connector. 2. Turn the ignition to ON. 3. Use an insulated tool to push the shorting bar in the connector away from terminal 20. Does the ABS indicator lamp go out? Replace the ABS unit Is the repair complete? Repair the short to ground in circuit Lg between I/P cluster connector B7 and terminal 20 EBCM. Is the repair complete? Value Yes Go to Step 3 System OK No Go to Step 2 -
Go to Step 5 -
System OK
SSANGYONG Y200
4E-38 ABS AND TCS
SELF-DIAGNOSTICS
Important: The electronic brake control module (EBCM) turns the valve relay off when a diagnostic trouble code (DTC) is set. The scan tool will indicate that the valve relay is off when it is used to monitor the data list. This is normal and should not be considered a malfunction. The EBCM performs system self-diagnostics and can detect and often isolate system malfunctions, When it detects a malfunction, the EBCM sets a DTC that represents the malfunction, turns on the ABS and/or the TCS indicators in most instances, and may disable the ABS and/or the TCS function, as necessary, for the duration of the ignition cycle. Once each ignition cycle, the EBCM performs an automatic test when the vehicle reaches 2.75 km/h (1.7 mph). In the course of this test, the system cycles each valve solenoid and the pump motor, along with the necessary relays, to check component operation. If the EBCM detects any malfunctions, it will set a DTC as described above.
Scan Tool Method

The scan tool can clear ABS/TCS system DTCs using the mess storage cartridge. 1. Install the scan tool and the mass storage cartridge. 2. Select Fault Memory. 3. Select Clear Fault Memory. Clearing the fault memory cannot reset a valve relay which was shut down when the fault was recognized. Changes are possible only after the fault has been eliminated and the next ignition cycle has begun.
Ignition Cycle Default

A DTC is erased from memory after 249 ignition cycles without any reappearance of that malfunction.
INTERMITTENT AND POOR CONNECTIONS

As with most electronic systems, intermittent malfunctions may be difficult to diagnose accurately, The following is a method to try to isolate an intermittent malfunction, especially in wheel speed circuitry. If an ABS malfunction occurs, the ABS indicator will illuminate during the ignition cycle in which the malfunction was detected. If it is an intermittent problem which seems to have corrected itself (ABS indicator OFF), a history DTC will be stored. Also stored will be the history data of the DTC at the time the malfunction occurred. Use the scan tool modular diagnostic system to read ABS history data. Most intermittents are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at fault.
DISPLAYING DTCs
Tools Required Scan Tool DTCs can be read through the use of the scan tool.
CLEARING DTCs
Tool Required Scan Tool The diagnostic trouble codes (DTCs) in the electronic brake control module (EBCM) memory are erased in one of two ways: Use the scan tool Clear DTCs selection. After 249 DTC-free ignition cycles. These two methods are detailed below. Be sure to verify the proper system operation and, the absence of DTCs when the clearing procedure is completed. The EBCM will not permit DTC clearing until all DTCs have been displayed. Also, ETC s cannot be cleared by disconnecting the EBCM, disconnecting the battery cables, or turning the ignition switch to LOCK.
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ABS AND TCS 4E-39
BLANK
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SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
General Description and Operation ..................... 5B-2 Shift Lever ........................................................... 5B-2 Transmission Assembly ....................................... 5B-2 Specifications ...................................................... 5B-3 Diagnostic Information and Procedures .............. 5B-4 Diagnosis Table ................................................... 5B-6 Component Locator ............................................ 5B-7 Cross-Sectional View ........................................... 5B-7 Power Flow .......................................................... 5B-8 Seni-Remote Kit Disassembly and Assembly ....... 5B-9 Transmission Assembly ..................................... 5B-10 Transmission Assembly Disassembled View ...... 5B-11 Maintenance and Repair ................................... 5B-14 On-Vehicle Service ............................................... 5B-14 Semi-Remote Kit ................................................ 5B-14 Transmission ..................................................... 5B-19 Unit Repair .......................................................... 5B-24 Major Unit .......................................................... 5B-24 Main Shaft ......................................................... 5B-34 Input Shaft ........................................................ 5B-38 Counter Shaft .................................................... 5B-40 Extension Housing ............................................. 5B-40 Shift Cover ........................................................ 5B-41 Inspection of Components ................................. 5B-45
5B-2 MANUAL TRANSMISSION

SHIFT LEVER
The shift lever is a type of linkage connected directly and lock shifting from 5th to reverse. This unit decreases the possibility of any blown, wear etc.
YAD5B010
YAD5B020
TRANSMISSION ASSEMBLY
YAD5B030
SSANGYONG Y200
MANUAL TRANSMISSION 5B-3
SPECIFICATIONS
Application Model Type Gear Ratio 1st 2nd 3rd 4th 5th Reverse Oil Specification Capacity(litre) Change Interval Weight (Dry) Notice: Add LUBRIZOL (280cc) in oil after overhauling. Description T5WC Floor Change 3.969 : 1 2.341 : 1 1.457 : 1 1.000 : 1 0.851 :1 3.710 : 1 ATF DEXRON II / III 3.4 L Check : Every 15,000 km, Replace : Every 50,000 km 33kg
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Applicatio Will not shift (control lever moves) Check Control lever assembly broken or damaged. Damaged offset lever, shift fork, selector place or selector arm. Hard shift or control lever will not move into gear Clutch not releasing. Improper or low transmission oil. Shift or shift rail binding. Binding of sliding synchronizers or gears. Action Replace control lever and housing assembly. Remove extension, adapter or case cover. Check or replace damaged parts. Adjust or replace clutch. Add or replace with specified oil. Remove extension, adapter or case cover. Check or replace damaged parts. Remove extension, adapter or case cover. Check synchronizers and gears and replace damaged parts. If reverse only, faulty backup switch. Worn or damaged flywheel pilot bushing. Gears crash when shifting Engine idle speed too high. Damaged or faulty clutch. Pilot bearing between input shaft and output shaft binding. Damaged synchronizer. Bell housing misaligned. Damaged gear(s). Worn or damaged flywheel pilot bushing. Transmission jumps out Loosened transmission or flywheel housing bolts, improper alignment. Synchronizer damaged or excessively worn. Blocking ring damaged, worn index slots or friction surfaces worn or damaged. Excessive countershaft end play. Check worn or damaged parts. Adjust shim thickness using roller bearings if necessary. Worn or damaged fork due to loosened shaft, rail or shifting fork. Transmission locked in one gear Worn or damaged forks, offset lever, shaft or rail. Fork or offset lever loose on shaft or rail. Check for wear or damaged. Replace worn or damaged parts. Replace extension, adapter or case cover. Check or replace loose parts on shaft or rail. Replace roll pin(s). Remove extension, adapter or case cover. Check for wear or damaged. Replace damaged parts. Check or replace blocking ring. Check or replace synchronizer parts. Align bell housing and bore. Check or replace gear(s). Replace pilot bushing. Tighten bolts to specified value. Realign if necessary. Check or replace synchronizer parts. Check or replace backup switch. Replace pilot bushing. Adjust idle speed to specified speed. Adjust or replace clutch. Replace or check roller bearings.
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Applicatio Transmission locked in one gear Worn or damaged gears. Transmission noise Improper or low transmission oil. Loose bolts or other attaching parts. Improper flywheel housing to engine crankshaft alignment. Noisy transmission bearing. Check bearings, bearing rollers and parts for wear or damage. Replace if necessary. Noisy gears. Check for worn or damaged gears(including speedometer gear). Replace if necessary. Transmission leakage Leakage from transmission. Vent or breather clogged. Too much oil. Loose bolts at sealing faces. Improperly applied sealant. Worn or damaged oil seal. Clean all exposed surfaces, then check for leaks. Clean or replace vent or breather. Check oil level. Tighten as specified. Clean leaking surfaces. Reapply sealant. Replace oil seal. Check Worn or damaged synchronizer. Action Check worn or damaged synchronizer parts and replace if necessary. Check worn or damaged gears and replace if necessary. Add or drain and replace with proper oil. Tighten as specified. Realign correctly.
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DIAGNOSIS TABLE
Applicatio 1 Shift Hop-out 2 Shift Gear Crash 3 Shift Block-out 4 Hard Shift 5 Noise in Reverse Gear 6 Noise in 5th Gear 7 Noise in 4th Gear 8 Noise in 3rd Gear 9 Noise in 2nd Gear 10 Noise in 1st Gear 11 Noise in All Speeds 12 Leak at Transmission Rear Part 13 Leak at Transmission Center Part 14 Leak at Transmission Front Possible Faulty Part Transmission Case Extension Housing Shift Cover / Shift Shaft Shift Control Lever Input Bearing Retainer Input Gear Set 3rd Speed Gear Set 2nd Speed Gear Set Reverse Speed Gear Set 1st Speed Gear Set 5th Speed Gear Set Clutch Housing and Release Derive Crankshaft Pilot Bushing and Release Bearing Input Bearing Main Shaft Input Bearing Main Shaft Thrust Bearing 3rd Speed Gear Bearing 2nd Speed Gear Bearing 1st Speed Gear Bearing Reverse Idler Gear Bushing Counter Shaft Front Bearing Counter Shaft Rear Bearing Counter Shaft Thrust Bearing 5th Speed Drive Gear Bearing Slip Yoke Bushing Slip Yoke Seal Speedometer Drive / Driven Gears Speedometer Driven Gear Housing Input Shaft Seal 1 - 2 Synchronizer Assembly 3 - 4 Synchronizer Assembly 5th Synchronizer Assembly
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COMPONENT LOCATOR
YAD5B040
1 2 3 4 5 6
4th Gear 3rd-4th Synchronizer 3rd Gear 2nd Gear 1st-2nd Synchronizer Reverse Gear
7 8 9 10 11
1st Gear 5th Gear 5th Synchronizer Counter Shaft Reverse Idler
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POWER FLOW
1st 2nd
YAD5B050
YAD5B060
3rd
4th
YAD5B070
YAD5B080
5th
Reverse
YAD5B090
YAD5B100
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SEMI-REMOTE KIT DISASSEMBLY AND ASSEMBLY
YAD5B110
1 2 3 4 5 6 7 8 9 10 11 12 13
Remote Shift Shift Lever Shift Inner Boot Lining Shift Socket Control Housing Arm Insulator Control Housing Arm Bushing Shift Rod Link Washer Clip Shift Rod Pin Cover Assembly Shift Tower Cover
14 15 16 17 18 19 20 21 22 23 24 25
Bolt Breather Hose Bar Control Shift Spring Offset Control Lever Retainer Ring Pin Shift Rail Grove Pin Pin & Clip Joint Assembly Joint Housing Bushing
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TRANSMISSION ASSEMBLY
YAD5B270
1 2 3 4 5 6 7 8 9 10 11
Clutch Housing Oil Filler Plug .......................................... 25 Nm Transmission Assembly Back-up Switch Washer Bolt ..................................................... 77-87 Nm Oil Drain Plug .......................................... 25 Nm Bolt ..................................................... 81-89 Nm Washer Front Propeller Shaft Transfer Case Assembly
12 13 14 15 16 17 18 19 20 21
Speedometer Cable Rear Propeller Shaft Washer Bolt ..................................................... 70-80 Nm Cross Member Washer Bolt ..................................................... 21-35 Nm Washer Bolt ..................................................... 62-93 Nm Breather Hose
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TRANSMISSION ASSEMBLY DISASSEMBLED VIEW
YAD5B460
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Remote Shift Shift Lever Shift Inner Boot Lining Shift Socket Control Housing Arm Insulator Control Housing Arm Bushing Shift Rod Link Washer Clip Shift Rod Pin Cover Assembly Shift Tower Cover Bolt Bleeder Hose Barb Control Shift Spring Offset Control Lever Retainer Ring Pin Shift Rail Groove Pin Pin and Clip Joint Assembly Joint Housing Bushing Bolt Bolt O-ring Shaft Rail Case Cover Cap Plug Insert Selecter Plate Selecter Arm Inlockter Plate Selecter Arm Pin Selecter Plate Insert Shift Fork Output Shaft Retainer Ring Washer Inner Corn Outer-Race 1-2nd Blocking-Ring Output Shaft Assembly Insert Ball Spring Reverse Sliding Gear 1-2nd Blocking-Ring Outer Corn Race Inner Corn Sleeve Bearing Sleeve Needle Bearing 1st Speed Driven Gear 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 Bearing Corn Bearing Cup Thrust Bearing Thrust Race Blocking-Ring Spring Insert Synchronizer Sleeve Spring Blocking-Ring Synchronizer 3rd Speed Gear Needle Bearing Spacer Snap Ring Washer 2nd Speed Gear Needle Bearing Spacer Synchronizer Sleeve Bearing O-Ring Bearing Corn Bearing Shaft Gear Counter Shaft Gear Corn Bearing Roll Pin Shift 5th Fork Insert Shift Rail Reverse Fork Spring Retainer Ring Shift Lever 5th Speed Driven Gear Snap Ring Bearing Cap Shim Rear Retainer Bolt 5th Speed Driven Gear Blocking 5th-Ring Hub Bearing Insert Sleeve Spring Spring Synchronizer 5th Synchronizer Retainer Snap Ring Oil Ring Funnel Roll Pin Reverse Idler Shaft Reverse Idler Gear O-Ring Cross member Mounting Hole
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115 116 117 118 119 120 121 122 Bolt Spacer Seal and O-ring Pivot Pin Back-up Switch Transmission Case Filler/Drain Plug Plug Bolt 123 124 125 126 127 128 129 Input Bearing Retainer Oil Seal Shim Bearing Cap Bearing Corn Input Drive Shaft Roller Bearing
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SEMI-REMOTE KIT
Removal Procedure
1. Remove the control housing arm insulator from the semi-remote kit.
YAD5B120
2. Remove two snap rings and two screws using the snap ring plier. Notice: Do not reuse the damaged snap ring.
YAD5B130
3. Disconnect the shift rod pin using the punch.
YAD5B140
SSANGYONG Y200

4. Remove the shift rod link from the semi-remote kit. 5. Remove four metal bushing from the shift rod.
YAD5B150
6. Push down the socket linings wing from the control housing arm and disconnect the socket lining and shift lever from the semi-remote kit.
YAD5B160
7. Remove the control housing arm by rotating the clip pin.
YAD5B170
8. Remove the retainer-ring from the U-joint assembly using the snap ring plier.
YAD5B180
SSANGYONG Y200

9. Remove the pin from the U-joint assembly using the punch. 10. Remove the U-joint assembly from the cover assembly.
YAD5B190
11. Remove the shift rail from the cover assembly using the punch. 12. Pull out the shift rail from the cover assembly. 13. Inspect and clean all of the disassembled parts and replace as needed.
YAD5B200
1. Insert the shift rail to the cover.
YAD5B210
2. Pull the shift rail to the offset lever using the punch and assemble them.
YAD5B220
SSANGYONG Y200

3. Insert the rail to U-joint assembly and assemble the retainer ring using the snap ring plier.
YAD5B230
4. Push down the shift lever and the lining shift socket from the control housing arm.
YAD5B160
5. Insert the clip pin to fix the cover assembly and the control housing arm.
YAD5B170
6. Insert the metal bushing to the shift rod.
YAD5B240
SSANGYONG Y200

7. Assemble the shift rod, the shift rail and U-joint using the pin.
YAD5B250
8. Insert the washer and assemble the snap ring.
YAD5B130
9. Insert the control housing arm insulator to the semiremote kit.
YAD5B260
SSANGYONG Y200
TRANSMISSION
Removal Procedure
1. Disconnect the negative terminal from the battery. 2. Lift up the vehicle and fix it safely.
YAD5B280
3. Remove the drain plug from the transmission housing and drain the oil. Reinstall the drain plug. 4. Disconnect the back-up switch connector.
YAD5B290
5. Remove the breather hose.
YAD5B300
6. Remove the speedometer connector and other wiring harnesses and connectors.
YAD5B310
SSANGYONG Y200

7. Remove the front and rear propeller shafts from the transfercase.
YAD5B320
8. Support the transmission on an suitable jack. Unscrew the center mounting nuts and each sides mounting bolts and remove the cross member.
YAD5B330
9. Remove the transmission mounting bolts. Notice: For removing the transmission, there may be any damage in the clutch housing inside CSC. Thus remove the transmission with the clutch housing.
YAD5B340
10. Move the transmission jack backward careful and disengage the transmission input shaft from the engine. Remove the transmission.
YAD5B020
SSANGYONG Y200
Pre-Installation Checks Checking Procedure

1. Separate the clutch release fork from the pivot and remove the pivot from the clutch housing. 2. Check the pivot. Fork and release bearing. 3. Check the pressure plate spring.
YAD5B350
Notice: Inspect each parts and replace the excessively worn parts. 4. Check the clutch housing alignment as follows :
YAD5B360
Place the magnetic base on the pressure plate spring. Check the housing bore alignment.
YAD5B370
- Place the dial indicator on the bore. - By rotating the crankshaft one revolution, record the dial indicator reading.
YAD5B380
SSANGYONG Y200
Check the housing face alignment. - Place the dial indicator on the housing face. - By rotating the crankshaft one revolution, record the dial indicator reading.
Notice: If the reading is greater than 0.010 inch, insert the shim between the engine and clutch housing and adjust the alignment.
YAD5B390
5. Check the following parts :
Pressure plate spring assembly Disc Flywheel Input shaft pilot bearing
Notice: Replace the excessively worn parts. 6. Lubricate the clutch release bearing bore, fork pivot head during assembly.
YAD5B400
1. Install the transmission to the vehicle. At this time, seat correctly the input shaft of the transmission on the pilot bearing of the flywheel. 2. Tighten the transmission mounting bolts as the specified torque on the vehicle. Installation Notice Tightening Torque
YAD5B410
77 - 87 N m (57 - 64 lb-ft)
3. Install the cross member and tighten as the specified torque by supporting the suitable jack. Installation Notice Left/Right Tightening Torque Center 62 - 93 N m (45 - 69 lb-ft) 21 - 35 N m (15 - 26 lb-ft)
YAD5B420
SSANGYONG Y200

4. Install the front and rear propeller shafts to the transmission. Installation Notice Front Tightening Torque Rear 81 - 89 Nm (60 - 66 lb-ft) 70 - 90 Nm (52 - 66 lb-ft)
YAD5B430
5. Connect the cable, the harness and the bleeder. 6. Install the back lamp switch.
YAD5B440
7. Install the speedometer cable.
YAD5B310
8. Charge the approved oil in the transmission housing and tighten the drain plug and the filler plug. Installation Notice Tightening Torque Filler Plug Drain Plug 25 Nm (18 lb-ft) 25 Nm (18 lb-ft)
Oil Spec. Capacity 4WD 2WD ATF Dexron II 3.4L 2.0L
YAD5B450
SSANGYONG Y200
UNIT REPAIR
MAJOR UNIT
1. Remove the shift lever from the extension housing.
YAD5B470
2. Install the removed transmission into a fixture. 3. Remove the drain plug and drain the oil. Using a 10 mm wrench, remove the clamp bolt and position the offset lever in the 3-4 position of neutral. Notice: Removal of the offset lever in a position other than 3-4 of neutral will be difficult.
YAD5B480
4. Using a pin punch and a hammer, remove the roll pin to remove the shift lever from the offset lever. 5. Using a 15 mm wrench, remove the 8 bolts from the extension housing.
YAD5B490
6. Separate the extension housing from the case and shift cover. Separate the offset lever from the shift. Notice: Do not remove the offset lever while the extension housing is still assembled to the case.
YAD5B500
SSANGYONG Y200

7. Remove the offset lever from the extension housing with the detent ball and spring. 8. Remove the roll pin from either the offset lever or extension housing.
YAD5B510
9. Remove the counter shaft thrust race and bearing.
YAD5B520
10. Carefully remove the oiling funnel from the end of the counter shaft.
YAD5B530
11. Using a 10 mm wrench, remove the 10 bolts from the shift cover. Notice: For assembly, note the location of the two bolts. 12. Lift up the shift cover after sliding it toward the drain plug about 3 cm. At this time remove sealer bond.
YAD5B540
SSANGYONG Y200

13. Using a needle nose pliers, remove the 5th-R lever clip.
YAD5B550
14. Using a 21 mm wrench or a T-50 bit, remove the 5th-R lever pivot bolt. Notice: Apply sealer bond to this bolt during assembly.
YAD5B560
15. Using a 22 mm wrench, remove the back-up lamp switch from the 5-R lever side. Notice: Apply sealer to the threads. 16. Pull out the 5th-R lever out of the transmission.
YAD5B570
17. Using a snap ring pliers, remove the 5th synchronizer snap ring from the end of the counter shaft.
YAD5B580
SSANGYONG Y200

18. Remove the 5th synchronizer assembly with its fork and rail assembly from the counter shaft.
YAD5B590
19. Remove the slip yoke snap ring from the main shaft.
YAD5B600
20. Remove the 5th speed drive gear snap ring from the main shaft.
YAD5B610
21. Make alignment marks on the case and input bearing retainer and remove the 4 input shaft bearing retainer bolts, using a 13 mm wrench. Remove the input bearing retainer with the bearing outer race and shim. Notice: Apply sealer on these bolts during assembly.
YAD5B620
SSANGYONG Y200

22. Remove the input shaft from the case by rotating it until the flat surface appears. 23. Remove the following parts from the input shaft.
4th speed gear blocking ring. Main shaft thrust race and bearing. Main shaft pilot bearing rollers (15 rollers).
Notice: Be careful not to dissipate the pilot bearing rollers.
YAD5B630
24. Remove the main shaft in 2 steps.
To remove the rear bearing outer race, push the main shaft rearward.
YAD5B640
Tilt and lift the main shaft from the case.
YAD5B650
25. Remove the reverse fork and spring from the case.
YAD5B660
SSANGYONG Y200

26. Remove the counter shaft as follows: Using a punch and hammer, pry up the lock tabs.
Using a 13 mm wrench or T-40 bit, remove the 4 bolts. Remove the retainer and shim from the case. Push the counter shaft rearward to remove the rear bearing outer race.
YAD5B670
27. Using a pin punch and a hammer, remove the roll pin fixed on the reverse idler shaft.
YAD5B680
28. By pushing the reverse idler shaft rearward and out of the case, remove the reverse idler gear and O-ring.
YAD5B690
29. Using a puller, remove the rear bearing assembly from the counter shaft.
YAD5B700
SSANGYONG Y200
5B-30 MANUAL TRANSMISSION Assembly Procedure

1. Using a hydraulic press and a supporting tool, press the counter shaft rear bearing into the case. Be sure that the supporting tool inside of the case should support the counter shaft.
YAD5B710
2. Without the shim, install the retainer and counter shaft rear bearing outer race. Tighten the 4 retainer bolts. Installation Notice Tightening Torque 20 N m (15 lb-ft)
YAD5B720
3. Place a dial indicator on the case and measure counter shaft end play by moving up and down.
YAD5B730
4. Select a shim which is the same thickness as the indicator rearing (up to 0.004 inch) and assemble it. 5. When the end play is correctly adjusted, remove the counter shaft rear bearing retainer and outer race. 6. Using a pin punch and rubber hammer, install the reverse idler shaft, gear and O-ring.
YAD5B740
SSANGYONG Y200

7. Install the counter shaft rear bearing outer race, shim and retainer. Installation Notice Tightening Torque 20 N m (15 lb-ft)
Notice: Using a punch and hammer, bend the lock tabs on the retainer.
YAD5B750
8. Install the following parts : Install the main shaft into case. Install the main shaft rear bearing outer race into the rear of the case.

YAD5B760
Install the 4th speed blocking ring onto the front of the main shaft. Install the input shaft onto the front of the main shaft. Install the input bearing retainer without shim onto the front of the case. Using a torque wrench, tighten the 4 bolts.
Installation Notice Tightening Torque 20 N m (15 lb-ft)
9. Install the 5th speed drive gear and blocking ring on the counter shaft. 10. Install the 5th synchronizer and rail/fork. 11. Install the 5th synchronizer snap ring and oiling funnel.
YAD5B770
SSANGYONG Y200

12. Align the slots of the lever with the rollers of the reverse fork and 5th shift rail. Apply sealer on the 5-R lever pivot bolt and install it into the case. Installation Notice Tightening Torque 28 N m (21 lb-ft)
13. Using a needle nose pliers, install the 5-R lever clip.
YAD5B780
14. Using a needle nose pliers, install the reverse fork spring to its pin inside the case. Check the operation of the 5-R shift mechanism at this time.
YAD5B790
15. Using a snap ring piers, install the slip yoke snap ring onto the end of the main shaft. 16. Make sure that the 1-2 and 3-4 synchronizer sleeves and 5-R shift lever are in neutral position.
YAD5B800
17. Align the holes the case and cover with alignmenttype bolts. Tighten the 10 bolts. Installation Notice Tightening Torque 15 N m (11 lb-ft)
18. Apply RTV sealant on the sealing surface of the extension housing. 19. Apply grease on the detent/guide plate in the extension housing. Install the detent ball in the 34 position.
YAD5B810
SSANGYONG Y200

20. Place the detent spring and offset lever in the extension housing and push the extension against the case and shift cover.
YAD5B820
YAD5B830
21. Completely compress the detent spring. 22. To install the extension housing to the case, apply sealer to the top two bolts and tighten them and tighten the 6 bolts. 23. Apply sealer to the back-up lamp switch and drain plug and tighten them. 24. Using a hammer, install the offset lever-to-shift roll pin. 25. Turn the transmission case reversely and place a dial indicator on the extension housing. Move the input and main shift up and down and measure end play. Select a shim which is the same thickness as the measurement ( 0.001 inch). After shim installation, the end play should be 0 .
YAD5B840
26. Remove the input bearing retainer and do the following : Install the adjusting shim behind the input bearing outer race in the retainer and if 2 shims are used, install the thinner one in first. Install the retainer to the case and tighten the bolts. If end play is not 0change the shim again. Apply RTV sealant to the sealing surface of the retainer. Apply sealer to the 4 retainer bolts and tighten them.
SSANGYONG Y200

27. Remove the fill plug. 28. Remove the transmission from the holding fixture and install it to the vehicle. 29. Clean the sealing surface of the shift control lever. 30. Install the control cables to the shift lever.
MAIN SHAFT
1. For correct reassemble, place an alignment mark on the 3-4 Synchronizer hub and sleeve. 2. Using a hydraulic press and puller plate, remove the 3-4 Synchronizer assembly and the 3rd speed gear.
YAD5B850
3. Remove the 3rd speed gear bearing and spacer.
YAD5B860
4. Using a snap ring pliers, remove the 2nd speed gear snap ring. 5. Remove the 2nd speed gear thrust washer.
YAD5B870
SSANGYONG Y200

6. Remove the 2nd speed gear, bearing and spacer.
YAD5B880
7. Using a screwdriver, remove the spiral retaining ring.
YAD5B890
8. Remove the thrust washer and three-piece 2nd speed blocking ring assembly.
YAD5B900
9. For correct reassembly, place an alignment mark on the 1-2 synchronizer hub and sleeve. 10. Remove the 1-2 synchronizer sleeve from the hub with following parts : The anti-rattle ball and spring. The three keys. One of the 3 springs.
YAD5B910
SSANGYONG Y200

11. Using a hydraulic press and puller plate, remove the 5th speed driven gear from the main shaft.
YAD5B920
12. Remove the main shaft rear bearing assembly from the shaft.
YAD5B930
13. Remove the 1st speed gear and bearing.
YAD5B940
14. Remove the inner race.
YAD5B950
SSANGYONG Y200

15. Remove the tree-piece 1st speed blocking ring assembly and remaining synchronizer spring. 16. Check and clean all removed parts and replace if necessary.
YAD5B960
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubs and sleeves are matched and the 3 keys are installed properly. Also align blocking rings with keys during installation. Notice: Before assembly, coat all parts with lubricant. In case of the paper-lined blocking rings, soak them in DexronII/III before installation.
YAD5B970
2. Assemble the following parts : 1st speed blocking ring. Alignment pin and 1st speed gear bearing race. 1st speed gear and its bearing. 3. Install the rear bearing assembly to the main shaft.
YAD5B980
4. Using a hydraulic press and installer, press the 5th driven gear onto the main shaft. While the main shaft is still on the press bed, install the 5th driven gear snap ring. If the snap ring does not fit completely, continue pressing the 5th driven gear.
YAD5B990
SSANGYONG Y200

5. Install the following parts : 2nd speed blocking ring assembly. Thrust washer for the blocking ring inner cone. Spiral retaining ring (Use special tools).
2nd speed gear spacer, bearing and gear. 2nd gear thrust washer and snap ring. 3rd speed gear spacer, bearing and gear. 3rd speed blocking ring.
YAD5B0A0
6. Using a hydraulic press and installer, install the 3-4 synchronizer hub onto the main shaft. Notice: Align the blocking ring with the synchronizer keys while installing the hub.
YAD5B0B0
INPUT SHAFT
1. Remove the following parts from the input shaft : Main shaft thrust race and bearing. Main shaft pilot bearing rollers (15 rollers).
YAD5B0C0
2. Using a hydraulic press and puller plate, remove the input shaft bearing assembly from the shaft.
YAD5B0D0
SSANGYONG Y200

3. Remove the input bearing.
YAD5B0E0
4. Remove the input shaft seal. 5. Check and clean all removed parts and replace if necessary.
YAD5B0F0
Assembly Procedure
1. Using a hydraulic press and installer, press the input shaft bearing onto the input shaft. 2. Apply grease to the thrust bearing inner roller (15 rollers) and install the main shaft thrust bearing and its race in the rear of the input shaft.
YAD5B0G0
3. Using a rubber hammer and installer, install the input bearing retainer and input shaft seal after applying grease. 4. Install the bearing outer race to the retainer without end play adjusting shim.
YAD5B0H0
SSANGYONG Y200
COUNTER SHAFT
1. Using a hydraulic press and special tool, remove the front bearing assembly from the counter shaft. 2. Check and clean all removed parts and replace if necessary.
YAD5B0J0
Assembly Procedure
1. Using a hydraulic press and installer, press the front bearing assembly onto the counter shaft.
YAD5B0K0
2. Install is as follows : Install a new O-ring on the counter shaft outer race and lubricate it. Using a installer, lightly tap the race into its bore until the O-ring is compressed. Install the race to be fully seated on the inside of the case.
YAD5B0L0
EXTENSION HOUSING
1. Remove the vent from the extension housing. 2. Remove the O-ring and steel ring from the rear of the extension housing. 3. Check and clean all removed parts and replace if necessary.
YAD5B0M0
SSANGYONG Y200

Assembly Procedure
1. Install the O-ring and steel ring to the rear of the extension housing. 2. Install the vent to the extension housing.
SHIFT COVER
1. Using a hammer and a pin punch (3/16) remove the selector arm roll pin.
YAD5B0N0
2. Before removal, note the correct position of the interlock plate and selector arm and remove the shift shaft. 3. Check and clean all removed parts and replace if necessary.
YAD5B0P0
Assembly Procedure
1. If the shaft cup plug was removed, apply plug outer surface with sealer and install it into the cover. 2. Install the fork pads and selector plates onto the 1-2 and 3-4 shift forks. 3. Assemble the sift cover parts as follows : Push the shift shaft into the cover until the front of the shaft is at the inside of the cover.
YAD5B0Q0
SSANGYONG Y200
Install the 1-2 shift fork and its selector plate.
YAD5B0R0
Push the shift shaft through the 1-2 shift fork.
YAD5B0S0
Place the selector arm and interlock plate in the cover. Note the position of the interlock plate and selector arm.
YAD5B0T0
YAD5B0U0
SSANGYONG Y200
Install the 3-4 shift fork and its selector plate.
YAD5B0V0
YAD5B0W0
Install the roll pin that fixes the selector arm to the shift shaft.
YAD5B0X0
4. Check the shift cover parts for proper assembly as follows : Insert a pin punch (3/16) into the offset lever hole of the shift shaft. Place the shift cover to the flat ground and rotate the shift shaft so that the punch is vertical.
YAD5B0Y0
SSANGYONG Y200
Selector arm should be aligned with the 3/4 shift fork selector plate.
YAD5B0Z0
5. Lubricate and install the O-ring on the rear of the shift cover.
YAD5B1A0
SSANGYONG Y200
INSPECTION OF COMPONENTS
1. Clean all parts with solvent and dry them with compressed air. Check the following parts for cracks and damaged sealing surfaces. Case Extension housing Shift Cover Input bearing retainer Counter shaft rear bearing retainer 2. Check the parts which support bearings and shafts for excessive wear and replace them if necessary.
YAD5B1B0
3. Check the bearing surfaces of the following parts ; Input shaft Main shaft and its gears Counter shaft and 5th drive gear 4. Check the reverse idler shaft and its gears.
YAD5B1C0
Notice: Replace excessive wear parts and do not file on the hardened surface and precision ground.
YAD5B1D0
SSANGYONG Y200

5. Check the shift mechanism parts as follows : Wear of the shift shaft. Wear of the detent/guide plate and offset lever.
YAD5B1E0
6. Check worn edges on the following parts : Selector arm. Interlock plate.
Selector plates for the 1-2 and 3-4 shift forks.
YAD5B1F0
5-R shift lever and the rollers on the reverse fork and the 5th shift rail/fork.
YAD5B1G0
7. Check worn mating surfaces on the following parts :
1-2 shift fork, pads and synchronizer sleeve. 3-4 shift fork, pads and synchronizer sleeve. 5th shift rail/fork pads and synchronizer sleeve. Reverse fork and reverse idler gear sleeve.
YAD5B1H0
SSANGYONG Y200

8. Check the following Bearing for excessive war: Crankshaft pilot bushing for the front of the input shaft. Clutch release bearing. Input shaft bearing. Main shaft pilot bearing rollers. Main shaft thrust Bearing and its surfaces.
YAD5B1J0
Speed gear roller bearing on the main shaft. Main shaft rear bearing. Counter shaft front and rear bearings.
YAD5B1K0
9. Check the gear tooth surfaces of all gear sets.
YAD5B1L0
10. Check the reverse gear set surfaces. Check the surfaces of gear teeth for excessive wear, pitting, scoring and spalling and replace if necessary.
YAD5B1M0
SSANGYONG Y200

11. Take apart the three synchronizer assemblies and check : The 1-2 synchronizer.
YAD5B1N0
The 5th blocking ring.
YAD5B1P0
12. Check the fit between the hub and sleeve of each synchronizer Excessively tight or loose hub-to-sleeve fit.
Wear of the cone clutch surfaces of brass blocking rings and gears.
YAD5B1Q0
13. Measure the clearance between the blocking ring and the speed gear New 1-2 blocking ring : 0.87 - 1.4mm New 3-4 blocking ring : 0.88 - 1.5mm Notice: Excessive wear of the blocking ring or the speed gear cone surface will cause shift blockout gear clash.
YAD5B1R0
SSANGYONG Y200

14. Check for gear clash on the synchronizer sleeve teeth or the clutch teeth on the speed gear. 15. Check the synchronizer sleeve and gear clutch tooth for hop-out.
YAD5B1S0
SSANGYONG Y200
SECTION 5C
CLUTCH
TABLE OF CONTENTS
General Description and Operation ..................... 5C-2 General Description ............................................. 5C-2 Bleeding of Clutch System ................................... 5C-3 Specifications ...................................................... 5C-4 Diagnostic Information and Procedures .............. 5C-5 Component Locator ............................................. 5C-6 Cross Sectional View ........................................... 5C-6 Clutch Hydraulic Lines ......................................... 5C-7 Clutch Disc Assembly ......................................... 5C-8 Clutch Pedal Assembly ....................................... 5C-9 Maintenance and Repair ................................... 5C-10 On-Vehicle Service ............................................... 5C-10 Clutch Disc ........................................................ 5C-10 Master Cylinder ................................................. 5C-12 Clutch Pedal ...................................................... 5C-13 Clutch Pedal Box ............................................... 5C-14 Inspecton Procedure .......................................... 5C-15 Clutch Disc ........................................................ 5C-15 Clutch Pedal ...................................................... 5C-16 Special Tools and Equipment ............................ 5C-17 Special Tools Table ............................................ 5C-17
5C-2 CLUTCH

GENERAL DESCRIPTION
Driving members
The driving members consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel and the other is the pressure plate. The pressure plate is fitted into a steel cover, which is bolted to the flywheel.
Driven members
The driven member is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft, but which drives the input shaft through these same splines. The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly.
Operating members
The clutch release system consists of the clutch pedal, the clutch release shaft, the clutch cable, the release arm and the release bearing. When pressure is applied to the clutch pedal, the clutch release shaft pushes against the release bearing by rotating. The bearing then pushes against the diaphragm spring in the pressure plate assembly, thereby releasing the clutch.
YAD5C010
A. Clutch Release Cylinder Pipe (W/ transmission case) B. Clutch Release Cylinder Pipe (W/ transmission case) C. Concentric Slave Cylinder
SSANGYONG Y200
CLUTCH 5C-3
BLEEDING OF CLUTCH SYSTEM

Notice: Keep the fluid level over MAX in reservoir during bleeding operation. Do not let fluid contact a painted surface. 1. Remove the air bolt cap of the release cylinder. Connect a vinyl tube to the bolt. 2. Insert the other end of the tube in a vacant container. 3. Slowly depress the clutch pedal several times. 4. With clutch pedal fully depressed, open the air bolt and release air rind fluid in the fluid line, 5. Repeat this procedure until there are no more air bubbles in the fluid flows.
YAD5C030
YAD5C040
SSANGYONG Y200
5C-4 CLUTCH
SPECIFICATIONS
Type Clutch Pedal Type Max. Pedal Stroke Pedal Free Play Clutch Disc Type Facing O.D. I.D. Thickness Facing and Quantity Thickness of Disc Clutch Cover Assembly Setting Weight Clutch Master Cylinder Clutch Fluid Stroke Inner Diameter Free With Load 610 kg 28.4 mm 15.87 mm DOT3 or DOT4 DSL GSL 5 - 10 mm Single Dry Diaphragm 240 155 mm 22 cm2 1 9.85 - 10.2 mm 9.2 mm Hydraulic Suspended 148 mm 150 mm
SSANGYONG Y200
CLUTCH 5C-5

Check Clutch slips Possible Cause Excessive Wear of Facing Hard or Oily Facing Damaged Pressure Plate or Flywheel Damaged or Burnt Diaphragm Spring Clutch Pedal Free play Insufficient Faulty Operation of Clutch Pedal Worn or Damaged Clutch Disc Poor disengagement Vibration or Excessive Run-out of Disc Rust or Wear of Disc Spline Oily Facing Damaged Diaphragm Spring Excessive Clutch Pedal Free play Hard to shift or will not shift Excessive Clutch Pedal Free play Faulty Clutch Release Cylinder Worn Disc, Excessive Run-out, Damaged Lining Dirty or Burred Splines on Input Shaft or Clutch Disc Damaged Clutch Pressure Plate Clutch chatters when starting Oily Facing Hard or Faulty Facing Burnt Torsion Spring Faulty Pressure Plate Bent Clutch Diaphragm Spring Hard or Bent Flywheel Engine Mounts Loose or Burnt Lever Difficult pedal operation Poor Lubrication on Clutch Cable Poor Lubrication on Pedal Shaft Poor Lubrication on Clutch Pedal Not Using the Clutch After Disengagement Clutch Noisy When Disengaging Clutch Pedal is Partially Depressed and Vehicle Speed is Reduced Insufficient Clutch Pedal Free play Excessive Wear of Facing Worn or Damaged Release Bearing Poor Lubrication Contact Surface of Bearing Faulty Installation of Clutch Assembly or Bearing Damaged Pilot Bushing Replace Repair Replace Repair or Replace Replace Replace Replace Replace Repair or Replace Tighten or Replace Lubricate or Replace Lubricate or Replace Repair Adjust Replace Replace Replace Repair as Necessary Action Replace Repair or Replace Replace Replace Adjust Repair or Replace Replace Replace Repair or Replace Repair or Replace Replace Adjust Adjust Pedal Freeplay Repair Release Cylinder Repair or Replace
SSANGYONG Y200
5C-6 CLUTCH
COMPONENT LOCATOR
;;;;; ;;;;; ; ;;;;; ;; ;;; ; ;;;; ;;; ;; ;; ;;; ;; ;; ;;; ;; ;;; ;; ;;; ;;;; ;; ; ;;; ;;;; ;; ;;;;;;; ;; ;;; ;; ;;;; ;;;;;;; ;; ; ;; ;;;;;;; ;; ; ;; ;;;;;;; ;; ; ;; ;;;;;;; ; ;; ;;;;;;; ;;;;;;;
1 2 3 4 5 6 Clutch Disc Clutch Cover Clutch Housing Concentric Slave Cylinder Adapter Bolt 7 8 9 10 11 12 Bolt Hose Spring Lock Washer Transmission Input Spline Bolt Gasket
YAD5C050
SSANGYONG Y200
CLUTCH 5C-7
CLUTCH HYDRAULIC LINES
YAD5C020
1 Clutch Pedal 2 Clutch Master Cylinder 3 Clutch Hydraulic Line
4 Clutch Oil Chamber 5 Clutch Hydraulic Hose
SSANGYONG Y200
5C-8 CLUTCH
CLUTCH DISC ASSEMBLY
YAD5C060
1 2 3 4
Clutch Disc Clutch Cover Concentric Slave Cylinder Clutch Housing
5 6 7 8
Bolt and Washer ...................... 35 Nm (26 lb-ft) Bolt and Washer ...................... 47 Nm (35 lb-ft) Bolt and Washer ...................... 47 Nm (35 lb-ft) Adapter
SSANGYONG Y200
CLUTCH 5C-9
CLUTCH PEDAL ASSEMBLY
YAD5C180
1 2 3 4 5 6 7 8
Snap Pin................................................. Replace Clevis Pin ...................................... Apply Grease Master Cylinder Push Rod Gasket Nut ................................. 16-22 Nm (12-16 lb-ft) Spring washer Nut ....................................................... 8-18 Nm Fulcrum Pin
9 10 11 12 13 14 15 16
Turn Over Spring .......................... Apply Grease Bushing ......................... Replace, Apply Grease Full Stroke Stopper Contact Pad Interlock Switch Stopper Pad Clutch Pedal Pedal Pad Pedal Mounting Bracket Stopper Bolt ................... 16-22 Nm (12-16 lb-ft)
Notice: Assembly should follow the disassembly procedure in the reverse order. Grease specification : Long - term grease (T/Mn DBL6611.00)
SSANGYONG Y200
5C-10 CLUTCH

CLUTCH DISC
1. Remove the starter motor. Install the special tool to the flywheel through the starter motor mounting holes.
YAD5C070
2. Unscrew the release cylinder mounting bolts and remove the release cylinder. Installation Notice Tightening Torque 30 - 40 Nm (22 - 30 lb-ft)
Notice: When the clutch housing and the transmission is removed, it may be possible any damage in the concentric slave cylinder.
YAD5C080
3. Unscrew the clutch housing bolts and remove the clutch housing, release fork and release bearing. Insert the centering pin into the clutch spline. Loosen the clutch cover bolts 1/2 turn in crisscross sequence until the spring tension is released. Notice: Do not remove the bolts at a time, or clutch cover can be damaged or deformed.
YAD5C090
SSANGYONG Y200
CLUTCH 5C-11
4. Unscrew the bolts and remove the clutch cover, pressure plate and clutch disc. Notice: Be careful not to drop the pressure plate and clutch disc. Installation Notice Tightening Torque 21 - 27 N m (15 - 20 lb-ft)
YAD5C100
5. Remove the oil pipe and the adapter from the clutch housing.
YAD5C110
6. Remove the oil pipe nut at the clutch housing inside.
YAD5C120
7. Remove the concentric slave cylinder mounting bolt and remove the concentric slave cylinder from the input shaft. 8. Remove the spacer from the input shaft.
YAD5C130
SSANGYONG Y200
5C-12 CLUTCH
9. Installation should follow the removal procedure in the reverse order. Notice:
Before installation, clean oil and grease on the flywheel surface. Do not clean the clutch disc and release bearing in solvent.
YAD5C140
10. Tighten the pipe nut and the cylinder mounting bolt as the specified torque. Hose Nut Pipe Nut Cylinder mounting bolt Adapter Nut A: 1.5 ~ 1.8 kgf.m B: 1.5 ~ 1.8 kgf.m C: 1.5 ~ 1.8 kgf.m D: 1.5 ~ 1.8 kgf.m
YAD5C150
MASTER CYLINDER
1. Draw out the fluid. 2. Pull out the snap pin and clevis pin from the clutch pedal connection. 3. Remove the clutch tube. Installation Notice Tightening Torque
YAD5C160
15 - 18 N m (11 - 13 lb-ft)
Notice: Be careful not the fluid contact a painted surface. 4. Remove the master cylinder mounting nuts and pull off the master cylinder. Installation Notice Tightening Torque 15 - 18 N m (11 - 13 lb-ft)
5. Check the clutch pedal operation. 6. Bleed the clutch system. 7. Installation should follow the removal procedure in the reverse order.
YAD5C170
SSANGYONG Y200
CLUTCH 5C-13
CLUTCH PEDAL
1. Remove the turn over spring from the clutch pedal.
YAD5C190
2. Remove the snap pin and the clevis pin from the clutch master cylinder push rod and separate the push rod and the clutch pedal.
YAD5C200
3. Remove the pedal mounting and nut from the clutch pedal bracket and remove the pedal from the bracket.
YAD5C210
4. Installation should follow the removal procedure in the reverse order. Perform the following procedure for installation. Apply the grease to the clutch pedal clevis pin and pedal bushing.
YAD5C220
SSANGYONG Y200
5C-14 CLUTCH
Apply the grease to the connecting portion between the clevis pin and the turnover spring.
YAD5C230
Check the clutch pedal height after connecting the pedal and the push rod. Align the height according to the A free play of the push rod.
YAD5C240
CLUTCH PEDAL BOX

1. Remove the clutch master cylinder. 2. Remove the upper bolt from the clutch pedal box and remove the clutch pedal assembly.
YAD5C250
3. Installation should follow the removal procedure in the reverse order. Notice: Charge the clutch oil as specified and then bleed the system.
YAD5C260
SSANGYONG Y200
CLUTCH 5C-15
INSPECTION PROCEDURE
CLUTCH DISC
1. Clutch Cover Check the diaphragm spring tip for wear and height unevenness. Unevenness Limit 0.8 mm

YAD5C270
Check the pressure plate surface for wear, crack and discoloration. Check the strap plate rivet for looseness and replace the clutch cover if loosened.
2. Clutch Disc Check the facing for rivet looseness, excessive runout, sticks, oil and grease. Measure the rivet head depth. If out limit, replace the disc. Wear Limit 0.3 mm
YAD5C280
3. Clutch Disc Plane Rate Measure the clutch disc plane rate and replace the disc as needed. Limit Value 0.7 mm
YAD5C290
SSANGYONG Y200
5C-16 CLUTCH
4. Concentric Slave Cylinder Check any heat damage, abnormal noise, poor rotation and wear of the concentric slave cylinder bearing.
YAD5C300
CLUTCH PEDAL
1. Pedal Stroke (A). Max. Stroke GSL 158 mm DSL 148 mm Notice: To adjust the pedal stroke, loosen the lock nut (H) of the interlock switch (G) and turn the two lock auto until the stroke is correct. 2. Pedal Height (B). Height (From the Floor Carpet) 182 5 mm
Notice: To adjust the pedal height, loosen the lock nut (C) of the stopper bolt(D) and turn the stopper bolt until the height is correct. 3. Pedal Free Play (E). Free Play 5 - 10 N m
yyyyy ;;;;;
YAD5C310
Notice: To adjust the pedal free play, loosen the lock nut (F) of the master cylinder and turn the push rod until the free play is correct.
4. Check the fulcrum pin and the bushing for wear, the pedal for bending and the spring for damage.
SSANGYONG Y200
CLUTCH 5C-17

SPECIAL TOOLS TABLE
602 589 00 40 00 Engine Lock
661 589 00 15 00 Centering Pin
YAD5C320
YAD5C330
SSANGYONG Y200
SECTION 5D1
PART TIME - T/C

TABLE OF CONTENTS
General Infromation and Operation .................. 5D1-2 4WD Operation Overview ................................... 5D1-2 System Structure ............................................... 5D1-3 2H Mode (Rear Wheel Drive) .............................. 5D1-5 4H Mode (4WD Drive - High Speed) ................... 5D1-6 4H Mode (4WD Drive - Low Speed) .................... 5D1-7 System Description ........................................... 5D1-8 Specifications .................................................... 5D1-9 Diagnostic Infromation and Procedures .......... 5D1-10 General Diagnosis ........................................... 5D1-10 Self-Diagnosis Test .......................................... 5D1-11 Diagnostic Diagram ......................................... 5D1-15 Component Locator ......................................... 5D1-16 Cross Sectional View ....................................... 5D1-16 Transfer Case Assembly .................................. 5D1-17 Disassembly and Assembly ............................ 5D1-18 Maintenance and Repair ................................. 5D1-20 On-Vehicle Service ............................................. 5D1-20 Maintenance of Transfer Case Lubricant ........... 5D1-20 4H and 4L Indicator ......................................... 5D1-21 TCCU Inspection ............................................. 5D1-21 Transfer Case Assembly .................................. 5D1-22 TCCU .............................................................. 5D1-24 Unit Repair ........................................................ 5D1-25 Disassembly Procedure ................................... 5D1-25 Assembly Procedure ....................................... 5D1-35
5D1-2 PART TIME - T/C
GENERAL INFORMATION AND OPERATION

4WD OPERATION OVERVIEW
Application Driving Type 2H 4H 4L Mode Position 2WD Drive(Rear Wheel Drive) 4WD Drive(High Speed) 4WD Drive(Low Speed) Operation Condition Normal Driving on the normal road or highway, or high speed driving Slipped road such as snow, rainy, sand, mud etc. Max driving force requiring condition such as towing, rough road. When a vehicle is driven in turning at low speed on the paved road, a vibration and a noise may be occurred by tight corner braking. Transferring 2H 4H 2H, 4H 4L 2WD Drive 4WD Drive(High Speed) 2WD Drive, 4WD Drive(High Speed)
2WD 4WD transfer is possible below 70 km without operating the clutch. Manual Transmission Transfer starts after the vehicle stops and the clutch is applied
4WD Drive(Low
Speed)
Automatic Transmission Transfer starts after the vehicle stops and the shift lever is shifted [N] position. Notice: After the vehicle stops and the mode switch is selected with applying the brake pedal, shifting [N-R-N] makes the mode transfer easier.
SSANGYONG Y200
PART TIME - T/C 5D1-3
SYSTEM STRUCTURE
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YAD5D010
SSANGYONG Y200
5D1-4 PART TIME - T/C Power Flow
Switch Transfer 2H, 4H4L
TCCU
Locking Hub Solenoid
Vacuum System Operation
Locking Hub Operation
Transfer
Front Propeller Shaft
Front Axle
Rear Axle
Front Wheel
Rear Wheel
SSANGYONG Y200
2H MODE(REAR WHEEL DRIVE)
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Power Flow
Transmission Output Shaft
YAD5D020
T/C Input Shaft
Rear Wheel
Output Shaft
Rear Axle
Rear Wheel
SSANGYONG Y200
4H MODE(4WD DRIVE - HIGH SPEED)
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Power Flow
TCCU Motor Transmission Input Shaft
YAD5D030
Shift Cam, Rail, Fork Magnetic Clutch
Hub
Output Shaft
Chain
SSANGYONG Y200
4L MODE(4WD DRIVE - LOW SPEED)
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Power Flow
TCCU Motor Transmission Input Shaft
YAD5D040
Shift Cam, Rail, Fork
Hub
Planetary Gear (2.483)
Chain
Output Shaft
SSANGYONG Y200
SYSTEM DESCRIPTION
Transfer Case Control Unit (TCCU)
TCCU is located under the front left handed seat and permits the vehicle to shift from two-wheel drive to four-wheel drive (and back shift) according to drivers switch operation during driving (For the shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
YAD5D050
1. Shifting from 2H to 4H Position the transfer case switch from 2H to 4H. Shifting is possible during driving.
4WD Hl indicator light will turn on.
2. Shifting from 4H to 2H Position the transfer case switch from 4H to 2H. Shifting is possible during driving. 4WD Hl indicator light will turn off.
YAD5D060
YAD5D070
3. Shifting between 4H and 4L Shifting is possible when the vehicle is almost stopped (below approx. 2 km/h), so it would be better stop the vehicle. In case of manual transmission equipped vehicle, apply clutch pedal. In case of auto transmission equipped vehicle, put the lever position into N . Position the transfer case switch 4H to 4L or 4L to 4H . According to the shifted position, indicator light will turn on. Notice: If there are malfunctions during shifting, 4H or 4L indicator light will blink.
SSANGYONG Y200
SPECIFICATIONS
Model Type Gear Ratio Oil High Low Specification Capacity Lubrication Manufacturer Weight Part-Time 4408 (E) E.S.O.F. Type 1:1 2.48 : 1 ATF S-3, S-4 or DEXRON II, III 1.2 L Check : Every 15,000 km Replace : Every 50,000 km Borg Warner 30 kg
SSANGYONG Y200

GENERAL DIAGNOSIS
Symptoms Electric shift problems Check Faulty or damaged TCCU, speed sensor, motor, clutch or internal wirings Damaged or worn shift cam, hub, fork and rail shift Cannot front wheel drive when shifted 4H,4L Noise in 4WD operation Binding shift fork, hub collar or gear Broken drive chain Action Overhaul and check, replace if necessary. Overhaul and check for wear and damage. Replace if necessary. Check sliding parts, replace if necessary.
Improper or low oil Loosened bolts or mounted parts Noisy T/C bearing
Drain and replace with specified oil. Retighten as specified. Disassemble bearings and parts and check for wear or damage. Replace if necessary.
Gear abnormal noise
Check for wear and damage including speedometer gear, replace if necessary.
Noise in 4H or 4L
Worn or damaged sprockets or drive chain Incorrect tire pressure Cracked transfer case Leakage from other parts Breather clogging Improper or too much oil Loosened sealing bolts Improperly applied sealant Worn or damaged oil seal
Disassemble and check for wear and damage, replace if necessary. Adjust tire pressure. Replace the case. Clean case and parts and check for leakage. Remove breather hose and clean, replace if necessary. Use specified oil and adjust oil level. Retighten Use specified sealant and retighten. Replace
Transfer case oil leakage
SSANGYONG Y200
SELF-DIAGNOSIS TEST
System Description
1. TCCU detects transfer case system malfunctions and indicates malfunctioning part(s) through flashing 4H,4L indicator lights. Using a service connector, connect it to the diagnosis box in the engine room and read the flashing of the 4WD CHECK indicator light. The flashing indicator light will show you defective code(s). 2. Identify 7 defective codes after reading the flashing indicator light. TCCU Shift motor Magnetic synchronizer clutch Speed sensor
YAD5D080
Hub solenoid Selector switch Motor position sensor
YAD5D090
3. Transfer case system is malfunctioning when:
4H, 4L indicator lights are remain on after 0.6 second when turning the ignition switch ON 4H, 4L indicator lights are continuously come on during driving.
YAD5D100
4. If only 1 part is malfunctioning, 4WD CHECK indicator light will display defective code 3 times continuously. 5. If more then 2 part is malfunctioning, the first malfunctioning part will be displayed 3 times and following malfunctioning parts will be displayed . 6. To read defective code, connect the service connector and turn the ignition switch ON . 7. After repairing, eliminate the defective code stored in the TCCU. Notice: Before replacing the malfunction parts with defective code, check the wires and connectors for proper condition.
YAD5D110
SSANGYONG Y200

Defective Code Reading
1. Position the ignition switch to OFF 2. Using a service connector, connect the No.2 pin (lgnition) and No.13 pin (TCCU) of the diagnosis socket in the engine room. 3. Position the ignition switch to ON. 4. Read the flashing 4WD CHECK indicator light and identify the malfunctioning part(See Diagnosis Table).
YAD5D120
How to Clear the Fault Code

1. Position the ignition switch to OFF. 2. Using a service connector, connect the No.2 pin (GND) and No.13 pin (TCCU) of the diagnosis socket in the engine room. 3. Position the ignition switch to ON over 5 seconds. 4. Do defective code reading and make sure that all defective codes are eliminated.
YAD5D130
SSANGYONG Y200
PART TIME - T/C 5D1-13 Diagnostic Table

Connect a service connector. If turn the ignition switch ON 4WD CHECK indicator light will come on for 0.6 second and turn off for 3 seconds and then display a defective code 3 times continuously. No. Defective Code Malfunctioning Part
4WD CHECK 1 Light ON OFF

YAD5D140
TCCU

YAD5D150
Shift Motor

YAD5D160
Synchronizer Clutch

YAD5D170
Speed Sensor

YAD5D180
Locking Hub Solenoid
SSANGYONG Y200

No. Defective Code Malfunctioning Part

YAD5D190
Selector Switch

YAD5D200
Motor Position Sensor
SSANGYONG Y200
DIAGNOSTIC DIAGRAM
YAD5D210
SSANGYONG Y200
COMTONENT LOCATOR
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YAD5D250
SSANGYONG Y200
TRANSFER CASE ASSEMBLY
YAD5D260
1 2 3 4 5 6 7
Rear Companion Flange Case Cover Front Companion Flange Breather Plug Transfer Case Input Shaft Mounting Bolt
8 9 10 11 12 13 14
Transmission Extension Housing Bolt Washer Front Propeller Shaft Bolt Washer Rear Propeller Shaft
SSANGYONG Y200
DISASSEMBLY AND ASSEMBLY
YAD5D370
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 Transfer Case Spring Washer Oil Seal Companion Flange Shift shaft Oil Seal Pipe Plug Screw Bolt Speed Sensor and Harness Bracket Speed Sensor Assembly Speed Sensor O-Ring Locking Clip Connector Motor Assembly Oil Seal Bearing Bolt Pump Assembly Output Shaft Assembly Bearing Ring Gear Cover Assembly Nut Snap Ring Bearing Needle Bearing Clutch Coil Assembly Speed Gear Oil Seal Return Spring Magnet Clutch Housing Snap Ring Snap Ring Lock-up Hub Sleeve Return Spring Lock-up Collar 41 42 43 44 45 46 47 48 49 53 54 55 56 58 59 60 61 66 67 68 71 72 73 74 75 76 80 81 82 83 84 86 87 88 89 90 97 99 Rail Shaft Lock-up Fork Snap ring Spacer Driven Sprocket Driving Sprocket Drive Chain Nut Gasket Spring Pin Hose Clamp Hose Coupling Oil Strainer Reduction Hub Shift Fork Assembly Shift Fork Facing Roller and Retainer Nut Plane Washer Oil Seal Spacer Front Output Assembly Breather Bolt Front Adapter Assembly Snap Ring Snap Ring Bearing Input Shaft Assembly Sleeve Assembly Needle Bearing Thrust Washer Retaining Ring Thrust Plate Sun Gear Gear Carrier Assembly Electric Shift Cam Spacer
SSANGYONG Y200

MAINTENANCE OF TRANSFER CASE LUBRICANT
1. Oil Level Check Clean the oil level plug and surrounding area. Remove the oil level plug and check whether oil is drip out or not.
YAD5D220
Tighten the oil level plug.
Installation Notice Tightening Torque 20 - 30 N m (15 - 22 lb-ft)
2. Oil Change
;;;;;;
YAD5D230
Clean the oil level plug and surrounding area Place a suitable container under the transfer case. Remove the oil and tighten the drain plug. Fill the oil through the oil level plug until oil begins to drip out. Tighten the oil level plug.
3. Cautions for oil level check and plugs tightening Do not use an impact wrench to remove or tighten the oil level plug or drain plug since this will damage the threads in the transfer case.
SSANGYONG Y200
4H AND 4L INDICATOR
When the ignition switch turns on, 4H and 4L indicators turn on for 0.6 seconds and turn off.
Notice: If 4H and 4L indicators do not turn on, check the related bulb, the wiring harness and TCCU.
YAD5D240
TCCU INSPECTION
Pin No. J1 - 7 J1 - 8 J1 - 13 J1 - 14 J1 - 15 J1 - 16 J1 - 17 J1 - 23 Operation Condition 4H or 4L 2H 4H indicator light ON 4H indicator light OFF 2H or 4H 4L Clutch pedal applied Clutch pedal released 4L indicator light ON 4L indicator light OFF Motor OFF Motor ON Motor OFF Motor ON Auto locking hub ON Auto locking hub OFF Voltage(V) 4.75 - 5.35 0 - 0.50 < 1.00 > 11.00 4.75 - 5.35 0 - 0.50 < 0.50 > 11.00 < 1.00 > 11.00 < 1.00 > 11.00 < 1.00 > 11.00 > 11.00 < 1.00
Notice: DC 12V for the TCCU operation should be maintained. In case of J1-8 and J1-15, indicator light will turn on for 0.6 second when turn the ignition switch ON. If 4H and 4L indicator lights remain turned on when turn the ignition switch on or during driving, perform the TCCU diagnosis.
SSANGYONG Y200

1. 2. 3. 4. Disconnect the negative terminal from the battery. Lift up the vehicle and fix it safely. Remove the damper mounting bolt. Remove the drain plug and drain the oil. Reinstall the drain plug. Installation Notice Tightening Torque 19 - 30 N m (14 - 22 lb-ft)
YAD5D270
5. Remove the breather hose.
YAD5D280
6. Disconnect the speedometer cable connector and other cable connectors and wiring harnesses.
YAD5D290
7. Support the transfer case with jack and remove the front and rear propeller shafts from the transfer case. Installation Notice 81 - 89 Nm Tightening Torque Front Rear (60 - 66 lb-ft) 70 - 90 Nm (52 - 66 lb-ft)
YAD5D300
SSANGYONG Y200

8. Remove the center mounting nuts and end sides mounting bolts of the cross member and then remove the cross member. Installation Notice 12 - 23 Nm Tightening Torque(1) Tightening Torque(2) (9 - 17 lb-ft) 6 - 8 Nm (53 - 71 lb-in)
YAD5D310
9. Remove the transfer case by removing the bolts attaching the transfer case to the transmission. Installation Notice Tightening Torque 35 - 60 N m (26 - 44 lb-ft)
Notice: Apply long-term grease to the inner spline of the transfer case input shaft. 10. Installation should follow the removal procedure in the reverse order.
YAD5D320
SSANGYONG Y200
TCCU
1. Disconnect the negative terminal from the battery.
YAD5D330
yyyy ;;;; ;;;; yyyy ;;;; yyyy ;;;; yyyy ;;;; yyyy ;;;; yyyy
YAD5D340 YAD5D350 YAD5D360
2. Remove the TCCU connector.
3. Remove the TCCU mounting bolt and remove the TCCU. TCCU installation position : Under the drivers seat
4. Installation should follow the removal procedure in the reverse order. Notice: Be careful not to give any impact to the TCCU body. Installation Notice Tightening Torque 10 N m (89 lb-ft)
SSANGYONG Y200
UNIT REPAIR
DISASSEMBLY PROCEDURE
Shift Motor Assembly
1. Separate the harness bracket. 2. Remove the shift motor mounting bolt and remove the shift motor assembly.
YAD5D380
Companion Flange
1. Holding the companion flange, remove the nut and washer and then remove the companion flange. 2. Remove the oil seal. 3. Remove the companion flange from the case cover.
YAD5D390
Case Cover Assembly

1. Remove the cover mounting bolts(9), and the case mounting bolts(5). Notice: Identification tag has information required for ordering replacement parts, so be careful not to lose it. 2. Using a driver, pry and disconnect the sealant bond of the cover and required case.
YAD5D400
YAD5D410
SSANGYONG Y200

3. Remove the clutch coil wiring from the connector. 4. Remove the clutch coil assembly mounting nut.
YAD5D420
5. Remove the snap ring and pull out the ball bearing from the cover to remove the speed gear.
YAD5D430
6. Remove the clutch coil assembly and the oil seal from the cover.
YAD5D440
7. Remove the speed sensor and the O-ring from the case cover.
YAD5D450
SSANGYONG Y200
PART TIME - T/C 5D1-27 Transfer Case Assembly

1. Separate the shift motor shaft cam assembly and the spring(1).
YAD5D460
2. Remove the clutch housing assembly from the output shaft. Clutch Housing Component (1) Retaining Ring (2) Shift collar Hub (3) Clutch Housing
YAD5D470
Remove the shift cam from the shaft. Fix the shaft at the vise with the cam removed and remove the torsion bar using a driver.
YAD5D480
3. Remove the 2WD/4WD lock up assembly, the lock up fork and rail shaft from the output shaft.
YAD5D490
SSANGYONG Y200
2WD/4WD Lock Up Assembly Component (37) Snap Ring (38) Lock up Hub (39) Return Spring (40) Lock up Collar
YAD5D500
4. Remove the snap ring from the front output driven sprocket and separate the snap ring and the spacer.
YAD5D510
5. Remove the driving sprocket, the driven sprocket and the driving chain from the front/rear output shaft.
YAD5D520
6. Remove the oil pump assembly and the magnetic from the output shaft.
YAD5D530
SSANGYONG Y200
Remove the bolt and the retainer. Separate the output shaft and rear pump cover. Remove the hose clamp and remove the hose coupling cover from the pump housing. Remove the hose clamp, the hose coupling and the strainer. Remove two pump pins and the spring from the output shaft. Separate the front pump and remove the output shaft.
YAD5D540
Reduction Shift Parts

1. Remove the reduction hub and reduction shift fork assembly from the case. 2. Remove the 2 shill fork facings from the shift fork assembly. 3. To remove the roller cam and pin, cut elf the plastic retainer when disassembling the fork assembly.
YAD5D550
Front Output Assembly

1. Holding the companion flange, remove the nut and washer and then remove the companion flange and oil seal. 2. Remove the output shaft.
YAD5D560
SSANGYONG Y200
5D1-30 PART TIME - T/C Adapter, Input Shaft and Carrier Gear
1. Remove the breather. 2. After removing 6 bolts, remove the front adopter by separating the adapter sealer bond from the case using a screw driver. Notice: Be careful not to damage the contacting surface of the case and adapter. 3. Remove the adapter assembly, input shaft assembly and carrier gear assembly. 4. Remove the snap ring and oil seal from the front adapter. 5. After removing snap ring, pull out the bearing and thrust washer from the input shaft assembly and separate the input shaft assembly from the carrier gear assembly. 6. Remove the needle bearing and sleeve bearing from the input shaft assembly. 7. Remove the retaining ring, thrust plate rind sun gear from the planet carrier assembly. Notice: Do not disassemble the planet carrier assembly.
YAD5D570
Transfer Case Assembly(Front)

1. Remove the oil seal. 2. Remove the retaining ring and the ball bearing. 3. Remove the pin from the transfer case. Notice: Be careful not to give any damage to the case for removing the pin. 4. Remove the ring gear from the case using the press. Notice: Replace new part for installation.
YAD5D580
SSANGYONG Y200
PART TIME - T/C 5D1-31 Cleaning Procedure

Notice: Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case.
1. Using cleaning solvent, clean the residual oil and dirt deposits. Notice: During cleaning, be careful not to damage the metal surfaces. 2. After cleaning, dry the parts with low pressure(Max. 20 psi) compressed air. 3. Lubricate the ball bearings and needle bearings with transfer case oil after cleaning. Notice: Protect the lubricated bearings from dust.
1. Visually check the all removed parts. Notice: Always replace the hose coupling, O-ring and oil seal with new parts. 2. Inspection Terms Burr : Local rise of material forming protruding sharp edge Chip : An area from which a small fragment has been broken off or cut Crack : Surface break of line nature indicating partial or complete separation of material. Excessive wear : Heavy or obvious wear beyond expectations considering conditions of operation. Indentation : Displacement of material caused by localized heavy contact. Galling : Breakdown of metal surface due to excessive friction between parts. Particles of the softer material are torn loose and welded to the harder material. Nick : Local break or notch, usually displacement of material rather than loss. Scoring : Tear or break in metal surface from contact under abnormal pressure.
SSANGYONG Y200
Step wear : Heavy wear that produces a step that can be seen or felt between adjacent contact and non-contact surfaces. Uneven wear : Condition of localized, unevenly distributed wear Includes hollows, shiny spots, uneven polish and other visual indications.
3. Specific Inspection
Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary.
YAD5D590
SSANGYONG Y200

4. Inspection of contact patterns Description Normal Wear Normal Abnormal
YAD5D600
End Face Wear
YAD5D610
YAD5D620
Traveling Face Wear
YAD5D630
YAD5D640
Upper Face Wear
YAD5D650
YAD5D660
Lower Face Wear
YAD5D670
YAD5D680
SSANGYONG Y200

5. Chip pattern of the gear face Description Corner chip at drive face Patterns Action Repair
YAD5D690
Edge chip at drive face
Repair
YAD5D700
Corner chip at coast face
Repair
YAD5D710
Chip within contact pattern
Replace
YAD5D720
Chip completely through tooth
Replace
YAD5D730
Side edge chip at drive face
Replace
YAD5D740
SSANGYONG Y200
ASSEMBLY PROCEDURE

Use special tools during assembly of oil seals and bearings. Lubricate bearings, oil seals and bushings before assembly.
Transfer Case Assembly

1. If the ring gear was removed, align the outer diameter of the new replaced ring gear with transfer case and assemble it. 2. Insert the pin. 3. Insert the ball bearing to the case and install the retaining ring. 4. Install the new oil seal by pressing into the case.
YAD5D750
5. Make sure that all parts are correctly and firmly installed into the case.
YAD5D760
Electric Shift Cam Parts

1. Insert the spacer into torsion spring. 2. Insert the end of the shift shaft into the spacer smoothly.
YAD5D770
SSANGYONG Y200

3. Slide the torsion spring and spacer to the left of the shift shaft and position the end of the first spring to fix on the drive tang.
YAD5D780
4. Push the end of the second spring to right and fix it on the drive tang.
YAD5D790
5. Push the torsion spring and spacer together back them completely. 6. Slide the electric shift cam onto the shift shaft. 7. Install the electric shift cam assembly into the transfer case after installation of the shift fork.
YAD5D800
SSANGYONG Y200
PART TIME - T/C 5D1-37 Adapter, Input Shaft and Carrier

1. Place the planet carrier assembly on work bench to be the retaining ring mounting groove upward. 2. Install the sun gear with the hub end up into the planet carrier assembly and rotate the sun gear to make sure that gears are fully engaged. 3. Align the tabs and install the thrust plate into the planet carrier assembly. 4. Install the retaining ring to the planet carrier assembly. 5. Press the needle bearing into the input shaft and press the new sleeve bearing into the input shaft assembly. 6. Install the planet carrier assembly onto the input shaft and install the thrust washer. Press the bearing over input shaft. 7. After pressing the bearing, install the retaining ring. 8. Press the pin into the front adapter. 9. Slowly press the oil seal into the front adapter. 10. Install the front adapter assembly. Notice: After installation, make sure that snap ring is correctly installed into the groove.
YAD5D810
11. Position the input shaft assembly over front cover and engage into the bearing groove by expanding the ends of snap ring. 12. Apply 1.6mm bead of sealant on the mounting face for the transfer case and tighten the 6 bolts. 13. Install the breather. Installation Notice Item 6 Bolts Breather Tightening Torque 28 - 48 Nm (21 - 35 lb-ft) 8 - 15 Nm
Front Output Shaft

Cross Sectional View
YAD5D820
SSANGYONG Y200
5D1-38 PART TIME - T/C Input Shaft Cross Sectional View
YAD5D830
Front Output Shaft

1. Install the deflector on the yoke. 2. Position the output shaft in transfer case and install the companion flange assembly, oil seal, washer and nut. 3. Holding the companion flange, tighten the nut. Installation Notice Tightening Torque 346 - 380 N m
YAD5D840
Reduction Shift Parts

1. Install the new pin, roller and retainer into the reduction shift fork. 2. Press the pin, roller and retainer into the reduction spilt fork bore completely. Notice: Make sure that the cam roller turns freely. 3. Install the 2 fork facing on the reduction shift fork assembly. 4. Install the reduction shift fork onto the previously installed reduction hub in the transfer case. 5. Install the output shaft spline into the reduction hub and engage the output shaft end with input shaft bearing. Notice: For installation of the output shaft, assemble the oil pump temporarily.
YAD5D850
SSANGYONG Y200
PART TIME - T/C 5D1-39 Oil Pump

1. Install the pump front cover to be the TOP mark down and turn the cover to be the TOP mark up when installed in vehicle. 2. Install the 2 pump pins and spring to the output shaft. Notice: Flat surface of the pins must point out and align the center line of pins and spring. 3. Connect the hose coupling to the strainer coupling and install the strainer foot into the transfer case slot.
YAD5D860
Notice: The hose coupling must face the pump assembly. 4. Install the pump housing to be the REAR mark up and seat the 2 pump pins inside of the pump housing by moving pump pins inward and compressing the spring. 5. Tighten the hose to pump housing by hose clamp. 6. Position the pump rear cover to be the TOP REAR mark up and located at the top of transfer case when installed in vehicle. Position the pump retainer on the cover so that tab on the retainer is in notch in the transfer case. Apply Loctite to the bolts and tighten the bolts with turning the output shaft by hand to make the pump pins move freely. Installation Notice Tightening Torque 4 - 8.5 N m (35 - 75.5 lb-in)
Drive Chain
1. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. 2. Install the drive chain onto the sprocket. 3. Holding each sprocket to be the drive chain tight and parallel with transfer case, install the drive chain assembly to the output shafts. 4. Rotate the driven sprocket slightly to engage splines on the front output shaft. 5. Install the spacer to the front output shaft and insert the snap ring into the shaft groove over spacer.
YAD5D870
SSANGYONG Y200
5D1-40 PART TIME - T/C Lockup Shift

1. Install the lockup hub and return spring to the lockup collar and insert the snap ring. 2. Install the rail shaft through reduction shift fork assembly previously installed and into the blind hole in case. 3. Engage the lockup fork into the 2WD/4WD groove and check operation. 4. Install the shift collar hub to the output shaft spline.
YAD5D880
YAD5D890
5. Install the previously assembled electric shift cam and assemble the clutch housing as follows. Rotate the shift cam assembly to right so that the end of the torsion spring contacts with reduction shift fork side. Holding the rail shaft, lift up the fork assembly slightly. Adjust electric shift cam assembly so that the roller on reduction shift fork assembly is in groove in shift cam and button on lockup fork is on cam end. Install the clutch housing over shift collar hub and insert the retaining ring into the clutch collar hub groove.
SSANGYONG Y200
PART TIME - T/C 5D1-41 Cover

1. Position the cover to be the open end up on the work table. 2. Position the end of needle bearing to be identification mark up and press into the cover until upper end of bearing is 40.47 - 40.97 mm below cover face that contacts with transfer case. 3. Press the ball bearing into the cover and install the snap ring . 4. Install remaining parts as follows. Install the 4 O-rings on the stud bolts of the clutch coil assembly. Install the clutch coil assembly inside the cover and tighten 3 nuts. Installation Notice Tightening Torque 8 - 11 N m (71 - 97 lb-in)
YAD5D900
Install the bearing and motor bearing into the cover.
Cover Assembly
1. Install the return spring over rail shaft in the transfer case. 2. Insert the magnet into the transfer case slot. 3. Apply 1.6mm bead of Loctite RTV 598 to the transfer case mounting surface. Notice: For installation of cover, align the transfer case with cover not to use excessive force. 4. Install the cover onto the transfer case as follows: Align the cover bores with transfer case pins. Align the cover bearings with output shafts. Align the cover blind hole with rail shaft and make sure that return spring is not cocked.
YAD5D910
SSANGYONG Y200

5. Tighten 9 bolts positioning identification tag and wiring clip. Installation Notice Tightening Torque 28 - 48 N m (21 - 35 lb-ft)
6. Install the speed gear over output shaft spline in the cover assembly. 7. Press the new oil seal into the cover assembly.
YAD5D920
External Electric Shift

1. Align the motor with shift shaft and position the motor assembly onto the cover. 2. Install the motor to the shift shaft and contact cover and rotate the motor clockwise direction to check correct engagement.
YAD5D930
3. Insert the 0-ring on the speed sensor assembly to the cover. 4. Install the bracket to the motor assembly and tighten 3 bolts. Installation Notice Tightening Torque 8 - 11 N m (71 - 97 lb-in)
YAD5D940
SSANGYONG Y200
PART TIME - T/C 5D1-43 Companion Flange

1. Install the 2 plugs to the cover. 2. Install the companion flange, oil seal and washer. 3. Holding the companion flange, tighten the nut. Installation Notice Tightening Torque 346 - 380 N m
Notice: Apply Loctite #262 to nut before installation.
SSANGYONG Y200
SECTION 5D2
TRANSFER CASE - TOD

TABLE OF CONTENTS
General Operation and Description ................... 5D2-2 TOD System Function ........................................ 5D2-2 4WD Operation Overview ................................... 5D2-3 System Structure ............................................... 5D2-4 4H Mode (4WD Drive - High Speed) ................... 5D2-5 4L Mode (4WD Drive - Low Speed) ..................... 5D2-7 Specifications .................................................... 5D2-9 Tightening Specifications ................................. 5D2-10 Component Locator ......................................... 5D2-11 Transfer Case Cross Sectional View ................. 5D2-11 Transfer Case Assembly .................................. 5D2-13 Function Description ........................................ 5D2-14 TOD System Select Mode ................................ 5D2-14 Component Function ........................................ 5D2-14 Definition fo Terminology .................................. 5D2-16 Control Unit ..................................................... 5D2-18 System Operation ............................................ 5D2-20 Diagnosis .......................................................... 5D2-30 Diagnostic Tests .............................................. 5D2-24 Coding on TOD ................................................ 5D2-25 Schmatic Wiring Diagram ................................. 5D2-27 TOD Control Unit Diagnostic System Check ..... 5D2-28 Diagnostic Trouble Codes (DTCs) ................... 5D2-29 4WD Check Indicator Stays on with Ignition Switch on ...................................................... 5D2-30 4WD Low Indicator Stays on with Ignition Switch on ...................................................... 5D2-31 No 4WD Check or 4WD Low Indicator with Ignition Switch on ......................................... 5D2-32 4WD Low Indicator Blink Steadily ..................... 5D2-33 Diagnostic Trouble Code (DTC) 1714 ................ 5D2-34 Diagnostic Trouble Code (DTC) 1715 ................ 5D2-36 Diagnostic Trouble Code (DTC) 1716 ................ 5D2-38 Diagnostic Trouble Code (DTC) 1721 ................ 5D2-40 Diagnostic Trouble Code (DTC) 1722 ................ 5D2-42 Diagnostic Trouble Code (DTC) 1731 ................ 5D2-44 Diagnostic Trouble Code (DTC) 1732 ................ 5D2-46 Diagnostic Trouble Code (DTC) 1733 ................ 5D2-48 Diagnostic Trouble Code (DTC) 1734 ................ 5D2-50 Diagnostic Trouble Code (DTC) 1735 ................ 5D2-52 Diagnostic Trouble Code (DTC) 1736 ................ 5D2-54 Diagnostic Trouble Code (DTC) 1741 ................ 5D2-56 Diagnostic Trouble Code (DTC) 1742 ................ 5D2-58 Diagnostic Trouble Code (DTC) 1743 ................ 5D2-60 Diagnostic Trouble Code (DTC) 1750 ................ 5D2-61 Diagnostic Trouble Code (DTC) 1751 ................ 5D2-63 Diagnostic Trouble Code (DTC) 1752 ................ 5D2-64 Diagnostic Trouble Code (DTC) 1753 ................ 5D2-65 Diagnostic Trouble Code (DTC) 1754 ................ 5D2-66 Maintenance and Repair ................................. 5D2-67 On-Vehicle Service ............................................. 5D2-67 Transfer Case (TOD) Component Locator ......... 5D2-67 Transfer Case Assembly .................................. 5D2-68 TOD Control Unit .............................................. 5D2-70 Shift Motor ....................................................... 5D2-70 Speed Sensor in Front and Rear Propeller Shaft 5D2-71 Unit Repair ........................................................ 5D2-74 Transfer Case Assembly .................................. 5D2-76 Special Tools and Equipment .......................... 5D2-89 Special Tools Table ......................................... 5D2-89
5D2-2 TRANSFER CASE - TOD
GENERAL INFORMATION AND OPERATION

TOD system means the full time 4WD system and the registered trade mark of Borg Warner. TOD is an abbreviation of Torque On Demand. TOD control unit automatically tailors torque distribution to road, offering full time four wheel drive. TOD distributes electronically-controlled power into front and rear wheels whose ratio change from 0 : 100 to 50 : 50 complying with wheel speed differences. Also TOD control unit analyzes data from wheel speed sensor and engine output then changes pressure of electromagnetic clutch. This pressure controls front propeller shaft and power to front wheel. Power to front wheel depends on degree of pressure corresponding clutch slip. TOD is designed to distribute the power to front and rear axle by operation of 4H/4L switch and shift motor. Shifting 4WD high (4H) to 4WD low (4L) is performed towards reducing high-low collar by means for connection high-low shift fork with output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary gear. Front planetary gear joins with output shaft and drives at low position. The TOD system has 2 selectable mode, 4H and 4L. 4H is the normal operating mode when drive of which gear ratio is 1:1 and 4L mode distributes power to front and rear wheels 50 : 50 of which gear ratio is 2.48:1.
TOD SYSTEM FUNCTION

4H Mode
The TOD system transfer case controls the clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference exceeds the permissible range, corresponding power is distributed into front wheel through electromagnetic clutch (EMC). Hall effect speed sensors are located front and rear propeller shafts, send signals to TOD transfer case control unit (TCCU). The EMC coil is activated by variable current on exceeding difference of speed in front and rear propeller shafts.
4L Mode
When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetary gear set.
Transfer Case Control Unit (TCCU)

Transfer case control unit (TCCU) receives, front and rear propeller shaft speed, shift motor position and 4H/4L switch signals and controls electromagnetic clutch (EMC), shift motor. TCCU communicates with scan tool with K-line for diagnosis. It located under the front LH seat.
SSANGYONG Y200
TRANSFER CASE - TOD 5D2-3
4WD OPERATION OVERVIEW

Application Driving Type 4H Mode Position 4WD Drive(High Speed) 4L 4WD Drive(Low Speed) Transferring 4H 4L 4WD Drive High Speed Low Speed Operation Condition Normal Driving on the normal road or highway, or high speed driving Slipped road such as snow, rainy, sand, mud etc. Max driving force requiring condition such as towing, rough road. Same function as part time transfer case 4L. A vehicle should stop for transfer. Manual Transmission
Transfer starts after the vehicle stops and the clutch is applied
Automatic Transmission
Notice: After the vehicle stops and the mode switch is selected with applying the brake pedal, shifting [NR-N] makes the mode transfer easier.
Transfer starts after the vehicle stops and the shift lever is shifted [N] position.
SSANGYONG Y200
SYSTEM STRUCTURE
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YAD5D010
SSANGYONG Y200
;;;;;; yyyyy ;;;;; ;;; @@@ ;; ;;; ;;; @@@ ;; @@ @@@ ;;;; QQQQ ;;;;;; ;;;;; yyyyy ;; yy ;;; yyy ; y y ; ;;;; yyyy ;;;; QQQQ ; @ ;;; ;;; @@@ ;; @@ ;; @@ @@@ ;; ;;;;;;;;;; QQ QQ ;; ;; QQ Q ; Q ; ; Q ;;;; QQQQ ; @ ;;; ;; @@ @@@ ;;;;;; ;;;;; yyyyy y ; ;; yy ;;; yyy ; y ; yy ;; y ;;;; yyyy ;;;;;;;;;; ;; QQ ; Q ;;;;;; ;;;; QQQQ @@@ ;;; ; @ ;; @@ ;;;; yyyy ;; yy ;;; yyy yy ;; ; y ;;;; yyyy ;;;;;;;;;; QQ ;; QQ ;; QQ ;; ; Q Q ; ;;;; QQQQ @@@ ; @ ;;; ;;; @@@ ;; @@ ;;;;;; ;; ;;;; yyyy ;; yy ;;; yyy y ; ;;;; yyyy @@@ ;;; ;;; @@@ ;; ; Q ;;;;;; ;; ;; ;;;; yyyy ;;;; @@@@ ;;;; @@ ;; @@@@ ;;;;;; ;; ;; QQQQQ ;;;;; ;;;; yyyy ;;;; @@@@ ;;;;; yyyyy ;;;;;; ;; ;;;; yyyy y ; ;; yy ;;;;; yyyyy Q ; QQ ;; ;;;;;; ;; ;; yy ;;;;; yyyyy ; Q ; QQ ; ;;;;;; ;; ;;;;; yyyyy ;;; yyy ; yy ; ; Q Q Q ;;;;;; ;; ; ;;; yyy ;;;;;; ;
4H MODE (4WD DRIVE - HIGH SPEED)
YAD5D020
SSANGYONG Y200
5D2-6 TRANSFER CASE - TOD Power Flow
Front Speed Sensor
Rear Speed Sensor
TOD Control Unit
Transmission Input Shaft
Throttle Open Rate (TPS Value)
Magnetic Clutch MAX DUTY
Force Distribution Unit BALL RAMP
Multi-Plate Clutch
Driving Sprocket
Output Shaft
Chain
SSANGYONG Y200
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4L MODE (4WD DRIVE - LOW SPEED)
YAD5D030
SSANGYONG Y200
5D2-8 TRANSFER CASE - TOD Power Flow
Front Speed Sensor
Transmission Input Shaft
Rear Speed Sensor
TOD Control Unit
Throttle Open Rate (TPS Value)
Magnetic Clutch MAX DUTY
Planetary Gear (2.483)
Force Distribution Unit BALL RAMP
Multi-Plate Clutch
Driving Sprocket
Output Shaft
Chain
SSANGYONG Y200
SPECIFICATIONS
Check TOD Model Length Weight (w/oil) Shift Mode Gear Ratio Oil High Low Specification Capacity Interval Max. Torque TOD Control Unit Current(Below Max. Operation Voltage) Max. Operation Current Voltage Normal Range CAN Comm. Ignition Switch OFF Ignition Switch ON Motor OFF Motor ON Action TOD (Torque On Demand) Transfer Case (4423E) 343.0 mm 37.9 kg 4H and 4L 1:1 2.48 : 1 ATF S-3, S-4 or Dexron II, III 1.4 L Inspect Every 15,000km, Replace Every 50,000km 550 lb ft (76kg cm) 9-16 V 6-16 V 2 mA 1A 7A 20 A
SSANGYONG Y200
TIGHTENING SPECIFICATIONS
Application Clutch Coil Retaining Bolt Drain Plug Filter Plug Front Case - Rear Case Mounting Bolt Front Propeller Shaft - Front Output Shaft/Flange Mounting Bolt Planner Damper - Transfer Case Mounting Bolt Rear Output Shaft Flange Mounting Nut Rear Propeller Shaft - Rear Output Shaft/Flange Mounting Bolt Shift Motor Adjusting Nut Shift Motor Bracket Bolt Shift Motor Mounting Bolt Speed Sensor Retaining Bolt Transfer Case Control Unit (TCCU) Retaining Bolts Transfer Case - Transmission Adapter Housing Mounting Bolt Nm 10 25 25 31 85 35 167 85 5 10 10 5 10 48 Kgf.m 1.0 2.5 2.5 3.1 8.6 3.6 17.0 8.7 0.5 1.0 1.0 0.5 1.0 4.9
SSANGYONG Y200
COMPONENT LOCATOR
TRANSFER CASE CROSS SECTIONAL VIEW
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;;;;;;; yyyyyyy ;;; yyy ;; yy ;; yy ;;; yyy ;;; yyy
YAD5D040
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Case Bearing Ring Gear Oil Seal Retaining Ring Input Shaft Carrier Pinion Gear Pinion Shaft Thrust Washer Needle Roller Spacer Bearing Bushing Sun Gear Thrust Plate Hub Bearing Snap Ring Snap Ring Snap Ring Hub Reduction Shift Fork Spacer Shaft Shift Spring Cam Breather Hose Breather Plug Shift Rail Intermediate Shaft Thrust Washer Pump Clamp Hose Upper Sprocket Thrust Washer 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 Chain Cover Bearing Oil Seal Dowel Pin Bearing Sleeve Seal Snap Ring Center Bearing Support Ball Bearing Dowel Pin Viscous Coupling Pinion Gear Thrust Washer Pinion Shaft Thrust Washer Thrust Washer Bushing Output Shaft Ring Gear Retaining Ring Needle Bearing Ball Bearing Speed Gear Flange Oil Seal Washer Nut Flange Dust Deflector Tone Wheel Bolt Motor Bolt Cap Screw
SSANGYONG Y200
YAD5D050
1 2 3 4
Input Shaft Air Control Cap Front Companion Flange Rear Companion Flange
5 Drain Plug 6 Filler Plug 7 Shift Cam Driving Motor
SSANGYONG Y200
FUNCTION DESCRIPTION
TOD SYSTEM SELECT MODE
4H is the mode when drive normally of which gear ratio is 1 : 1 and 4L mode distributes power to front and rear wheels 50 : 50 of which gear ratio is 2.48 : 1.
COMPONENT FUNCTION
Shift Motor
It locates backside transfer case, which drives rotary helical cam. When mode select switch changes to 4L, shift fork is on position for 2.48:1 by rotation of helical cam.
Transfer Case
TOD transfer case distributes power into front and rear axle by operation of 4H/4L switch and shift motor. Shifting 4H to 4L, is performed towards reducing HILO collar by means for connection HI-LO shift fork with output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary gear. Front planetary gear join with output shaft and drives LO position.
YAD5D060
TOD Control Unit

TOD control unit is located on the floor under the driver seat.
TOD system controls clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference exceeds the permissible range, corresponding power is distributed into front wheel through EMC (Electro-Magnetic Clutch). Hall effect sensor signals speed on front and rear propeller shafts going through with TOD control unit. Transfer case clutch coil is activated by variable current on exceeding difference of speed in front and rear propeller shafts.
Select 4L Mode
When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 : 1 to 2.48 : 1 by planetary gear set.
YAD5D070
Shape and function of TOD Control Unit Deselect 4L Mode

When select 4H mode, the 4WD mode is deselected and returns the 4WD - high speed mode.
4H switch : Slef-return Type 4L switch : Push Lock Type
YAD5D080
SSANGYONG Y200

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Function Motor HI-LO Motor LO-HI EMC Battery (+) Ignition Position Return Diagnosis Display HI / LO Switch Position 2 Front Speed TPS Supply (Diesel) Speed/TPS Return Motor HI-LO Motor LO-HI Pin 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Function Speed Reference Ground Ground Battery (+) K-LINE 4L Illumination CAN-H CAN-L Auto T/M, Neutral ABS Input Brake Switch Position 1 Position 3 Rear Speed Position 4 Pin A B C D E Speed Sensor, Clutch Coil and Motor Connector are located at the upper & rear side of the transfer case (upper shift motor) as shown. Shift Motor Connector : Black (upper arrow as shown) Speed Sensor and Clutch Coil Connector : White (lower arrow as shown) F G Function Motor HI-LO (clockwise) Motor HI-LO (counter-clockwise) Position Return Position 1 Position 2 Position 3 Position 4
YAD5D100
Shift Motor Connector
Speed Sensor, Clutch Coil, Motor Connector
Speed sensor, clutch coil connector
YAD5D110 YAD5D090
Pin H I J K L M N
Function Clutch Coil Front Speed Return Front Speed Front Speed Sensor Voltage Supply Rear Speed Sensor Voltage Supply Rear Speed Rear Speed Return
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DEFINITION OF TERMINOLOGY
Definitions Rear Speed Sensor Description A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in response to a rotating 30 tooth wheel coupled to the rear propeller shaft inside the Transfer Case. Each rotation of the rear propeller shaft will result in 30 speed sensor pulse.
YAD5D120
Front Speed Sensor
A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in response to a rotating 30 tooth wheel coupled to the front propeller shaft inside the Transfer Case.
EMC (Electromagnetic Clutch) TOD TPS (Throttle Position Sensor) PWM Duty Cycle Touch-off Front Overrun Rear Overrun High Range Low Range
Each rotation of the front propeller shaft will result in 30 speed sensor pulse. An Electromagnetic clutch used to control the amount of torque applied to the front propeller shaft. TOD is an abbreviation of Torque On Demand and means that the torque is transferred according to the operating condition. TPS is an abbreviation of Throttle Position Sensor. For MSE engine, the potentiometer in the throttle actuator acts as TPS. PWM is an abbreviation of Pulse Width Modulation and is a type of output value control by adjusting pulse width. Duty Cycle is the time the EMC is on divided by the period in which it is being modulated. A minimum amount of duty cycle applied to the EMC. A condition where the front propeller shaft is turning at a rate which is faster than the rear propeller shaft. A condition where the rear propeller shaft is turning at a rate which is faster than the front propeller shaft. The highest (numerically lowest = 1 : 1) gear ratio between the input and outputs of the Transfer Case. The lowest (numerically highest = 2.48 : 1) gear ratio between the input and outputs of the Transfer Case.
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Definitions 4H/4L Switch Shift Motor Position Encoder Neutral Safety Switch Shift Inhibit Speed Description A switch which selects the desired gear ratio. Electric motor which changes the Transfer Case range. A set of 4 Gray code switches which provide feedback to the TOD indicating the position of the Shift Motor. A switch on vehicles equipped with a manual transmission which indicates that the clutch pedal is depressed. A switch on vehicles equipped with an automatic transmission which indicates that the transmission is in neutral. The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speed is indicated by propeller shaft speed measurement.
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CONTROL UNIT
Input/Output diagram
TOD control unit and main wiring harness is linked by 30 pin connector. Each pin joins with switch and actuator whose details refer to the below diagram.
YAD5D130
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Classification Power Supply Signal Input Pin No. 17,18 4,19 5 27 10 28 30 9 24 12, 16 11 29 25 26 22 23 20 Signal Output Pin Name Ground Input Ignition Position 1 Position 2 Position 3 Position 4 4H/4L Switch Auto T/M Neutral Speed Voltage Supply Front Speed Rear Speed ABS Operation Brake Switch CAN-L CAN-H K-LINE (1) Motor LO-HI Description TOD control unit ground TOD control unit battery supply : (Fuse No 13,20A) Ignition ON / OFF Position encoder 1 : check of shift motor position Position encoder 2 : check of shift motor position Position encoder 3 : check of shift motor position Position encoder 4 : check of shift motor position Transfer case mode input Check of neutral gear position in Auto T/M 5V supply (TPS / speed sensor) Front speed sensor signal input Rear speed sensor signal input ABS ON / OFF Brake Switch ON/OFF Signal Input CAN bus low line CAN bus high line Connect to Diagnostic Connector No. 15 Motor output port Motor HI-LO 3 21 6 7 13 EMC 4L Illumination Position Return Self Diagnosis Display Speed LO to HI : join with battery HI to LO (or motor brake) : join with ground HI to LO : join with battery LO to HI (or motor brake) : join with ground
Motor output port
TOD Output When the transfer case is in 4L mode, illuminates 4L indicator. Position encoder ground Illuminates 4L indicator 4WD check lamp turns ON Upon defect ; Ground circuit Ground for speed sensor / TPS
(1) K-LINE : It means that Communication line for coding and diagnosis with diagnostic scanning tool.
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5D2-20 TRANSFER CASE - TOD SYSTEM OPERATION

Initial Operation of TOD Control Unit When ignition ON, 4L and 4WD check lamps illuminates for 0.6 second to check bulb in instrument panel, then perform diagnosis of system (See 3F-19 Self-Diagnosis Condition). Position Encoder The Position Encoder is used by the TOD to determine the position of the Shift Motor. Each motor position is identified by a position code below. Notice: All other position codes are invalid Position Input Open Circuit (> 4.5V) = 1 Position Input shorted to Speed/Position Return (< 0.5V) = 0
Position Code 1/2/3/4 1110 1010 0010 0000 1110
Motor Position Left Stop Left of High High Right of High Zone 1
Position Code 1/2/3/4 1001 0001 0101 0100 -
Motor Position Neutral Zone 2 Low Right Stop -
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Position Sensor Interpretation When the module powers up, it will read the position sensor and the 4H/4L switch input and respond to the possible codes as follows. 4H/4L Switch Input 4H 4H 4H 4H Motor Position Left Stop Left of High High Right of High System Response (Action) No action required. 4L bulb off. No action required. 4L bulb off. No action required. 4L bulb off. Blink 4L bulb. After the shift conditions are met, attempt a shift to 4H under conditions of below 87 rpm in front and rear propeller shaft and Neutral position. After successfully shifting into 4H, stop blinking 4L bulb. 4H 4H 4H 4H Zone 1 Neutral Zone 2 Low Same as above Same as above Same as above Blink 4L bulb. After the shift conditions are met, attempt a shift to 4L. After successfully shifting into 4L, stop blinking 4L bulb. 4H 4L Right Stop Left Stop Same as above Blink 4L bulb. After the shift conditions are met, attempt a shift to 4L. After successfully shifting into 4L, stop blinking 4L bulb. 4L 4L 4L 4L 4L 4L 4L 4L Left of High High Right of High Zone 1 Neutral Zone 2 Low Right Stop Same as above Same as above Same as above Same as above Same as above Same as above No action required. 4L bulb on. No action required. 4L bulb on.
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A command to shift will only be acted upon if the TOD is reading a valid code at the time the command to shift is made. After a shift has started, the TOD will power the shift motor until the code for the requested position is read. If an invalid code is read, the TOD will go into a default mode. During a shift attempt, the shift motor will be energized for a maximum of 5 seconds. Indicator function on shifting Once a range change has been initiated the 4L Indicator will begin to blink at a rate of 0.3 seconds on, 0.3 seconds off until the shift is completed or canceled.
Electric Shift System Operation

The Electric Shift System is responsible for changing the Transfer Case gear ratio by controlling the electric shift motor. The TOD monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch. A range change is initiated when ; 1. The 4H/4L Switch is changed from 4H to 4L or from 4L to 4H. 2. The motor position (as indicated by the position encoder) does not match the 4H/4L Switch immediately after the ignition is turned on. Shift criteria When a range change is initiated a Diagnostic Test will be completed on the motor, speed sensors, and position encoder. If the Diagnostic Test fails, the shift will not be attempted. If all components are operating properly, the TOD will attempt a range change after the following shift criteria are met: 1. The transmission is in neutral for 2 seconds after the shift is requested. 2. Both propeller shaft speeds are below 87 rpm (2580 pulses/minute). If the transmission is taken out of neutral before 2 seconds has elapsed, or either propeller shaft speed increases above the limit, the shift will be suspended and the 4L Indicator will continue to blink until the criteria are met again or the 4H/4L Switch is returned to the original position. Range change When the shift criteria are met, the motor is rotated in the appropriate direction (as determined by the selector switch) until one of the following occurs: 1. The motor reaches its destination. 2. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TOD will respond as default mode. 3. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement. When the motor is energized, the Ignition, 4H/4L Switch, propeller shaft speeds, and transmission neutral inputs are ignored.
YAD5D140
If a successful shift has been completed, the 4L Indicator will be illuminated if the motor is in Low and it will be turned off if the motor is in High. 4L Indicator illuminates as below figure. Electric shift default mode If the motor fails to reach its destination, the TOD will attempt the following (in order): 1. The TOD will wait 3 seconds then attempt the shift again. 2. If the second attempt to reach the destination fails the TOD will wait 3 seconds then attempt to rotate the motor back to the original position. If successful, all future shifts will be inhibited until the Ignition is cycled. 3. If the attempt to return to the original position fails, the TOD will wait 3 seconds then attempt to rotate the motor to the original position again. If the second attempt to return to the original position is successful, the 4WD CHECK lamp will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
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4. If the second attempt to return to the original position fails the motor will be turned off, the 4WD CHECK lamp will be illuminated, and all future shifts will be inhibited until the Ignition is cycled. TOD TM System operation The TODTM System is responsible for distributing torque between the front and rear axles. The TOD monitors the propeller shaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to the front axle by Pulse Width Modulating the current applied to the EMC. 1. Touch-off Torque The minimum EMC Duty Cycle is based on the vehicle speed and throttle position. The TOD receives the TPS signal from the following sources: On vehicles equipped with CAN, the TOD receives the TPS signal from the CAN bus. 2. When Slip Detection The TOD continuously monitors the front and rear propeller shaft speeds to detect wheel slip. 3. Wheel Slip Control When wheel slip is detected the TOD controls the EMC duty cycle as necessary until the wheel slip is reduced below the allowable limit. The EMC Duty Cycle will then be reduced to the Touch-Off value. 4. Brake/ABS Strategy When the ABS System is active, the EMC Duty Cycle is set to a fixed duty cycle (30 %) to aid in braking without counteracting the ABS System. 5. 4L Strategy When the system is operating in 4L, the TOD continues TODTM (operation provided that the propeller shaft speed is below 175 rpm (5220 pulses/minute)). When the speed increases above 175 rpm, the EMC Duty Cycle is set to the maximum value (88 %) which applies the maximum available torque to the front axle.
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DIAGNOSIS
While the TOD is active it periodically monitors its inputs and outputs. If a fault is detected the 4WD CHECK lamp is illuminated and a fault code is stored in the TOD memory. When requested, fault codes are downloaded to a diagnostic connector (K-line) serial communications using SCAN-100. 5. If a shift command has been received, but not acted upon when a failure occurs the TOD will cancel the command and not respond to any subsequent shift commands. 6. If a shift command is in progress when an invalid position code is confirmed it will be halted and the TOD will turn the motor toward the high position. Afterwards the TOD will not respond to any shift commands. 7. If the shift motor/position encoder assembly failure (other than a motor failure which occurs when the motor is energized) recovers continuously for one second the TOD will function normally. The 4WD CHECK lamp is turned off but the fault code will remain in memory. 8. A motor failure (i.e. open or short circuit) which occurs when the motor is energized can only be cleared by cycling the ignition off-on.
DIAGNOSTIC TESTS
TOD Internal Function
When the Ignition is turned on the TOD tests its ROM and RAM. If there is a fault, the TOD immediately resets itself and re-tests the ROM and RAM. If the fault persists the TOD continues to reset and re-test until the fault is corrected or the ignition is turned off. All TOD functions are inhibited until the fault is corrected. The 4WD CHECK lamp is not illuminated if there is a ROM or RAM fault. If the ROM/RAM passes the EEPROM memory is tested. If there is a fault the 4WD CHECK lamp is illuminated and the TOD continues to operate using the default calibration data stored in ROM. Fault codes are not stored when there is an EEPROM fault. An EEPROM fault can only be cleared by cycling ignition off-on.
Front Speed Sensor Test

If a Front Speed Sensor fault is detected continuously for 0.5 second the 4WD CHECK lamp is illuminated. The TOD then responds as follows: 1. If the system is in High Range the TOD uses the Rear Speed Sensor to determine the EMC Touch Off level and wheel slip control is suspended. 2. If the system is in Low Range, the EMC Duty Cycle is set to maximum (independent of vehicle speed) until the system is shifted out of 4L. 3. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. If the Front Speed Sensor recovers continuously for O.5 second the TOD will function normally. The 4WD CHECK lamp is turned off but the fault code will remain in memory.
Shift Motor Assembly Test

If the TOD detects a shift motor or position encoder fault continuously for one second the 4WD CHECK lamp is turned on and the appropriate fault code is stored in memory. 1. A shift motor fault when the motor is off is defined as follows: Motor H-L shorted to Ground Motor L-H shorted to Ground Motor open circuit 2. A shift motor fault when the motor is energized is defined as follows: Motor H-L shorted to Ground Motor L-H shorted to Ground Motor H-L shorted to Motor L-H Motor open circuit 3. A position encoder fault is defined as follows: Any position code which does not correspond to the valid 9 codes. A short to ground on any of the encoder lines. 4. If no shifts are in progress when a failure occurs the TOD will not respond to any shift commands.
Rear Speed Sensor Test

If a Rear Speed Sensor fault is detected continuously for 0.5 second the 4WD CHECK lamp is illuminated. The TOD then responds as follows: 1. If the system is in High Range the TOD uses the Front Speed Sensor to determine the EMC Touch Off level and wheel slip control is suspended. 2. If the system is in Low Range, the EMC Duty Cycle is set to maximum (independent of vehicle speed) until the system is shifted out of 4L. 3. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. If the Rear Speed Sensor recovers continuously for 0.5 second the TOD will function normally. The 4WD CHECK lamp is turned off but the fault code will remain in memory.
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Both Speed Sensor Faulty

If both the Front and Rear Speed Sensors are faulty continuously for 0.5 seconds the 4WD CHECK lamp is illuminated. The TOD then responds as follows: 1. If the system is in High Range the TOD sets the EMC Touch off level based on a vehicle speed of 0 and wheel slip control is suspended. 2. If the system is in Low Range, the EMC Duty Cycle is set to maximum until the system is shifted out of 4L. 3. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. If both Speed Sensors recover continuously for 0.5 second the TOD will function normally. The 4WD CHECK lamp is turned off but the fault code will remain in memory.
EMC Test
The EMC is tested for open circuit or short circuit to ground. If a fault is detected continuously for 0.8 second the 4WD CHECK lamp is turned on and all TODTM activity is halted. If the EMC recovers continuously for 0.8 second the TOD will function normally. The 4WD CHECK lamp is turned off but the fault code will remain in memory.
CODING ON TOD
Connection of Coding Tool
Construct SCANNER into diagnosis connector (20 pins) near fuse box in engine room as below figure. 1. Diagnosis Connector 2. SCANNER Notice: Coding ; An input activity of data for the proper performance by matching specification, devices and system with control unit. Coding required 1. Replacement of TOD control unit. 2. Adjustment by input error. 3. Change of tire specification. Coding method 1. Check and record engine type, axle ratio and tire size. 2. Ignition OFF. 3. Connect SCANNER with diagnosis connector in engine room. 4. Ignition ON. 5. Read the current memorized specification in TOD control unit.
YAD5D150
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6. Compare memorized specification with the checked record. If not matched, perform a coding. 7. Read again memorized coding specification in TOD control unit for confirmation of coding. 8. Check coding specification whether it matches with vehicle or not. If not, perform a coding again.
Eliminate the Memorized Fault Code

When diagnose by SCANNER, it is required that you make adequate service on defects against all fault codes. And then you should delete the memorized fault codes in TOD control unit using SCANNER as follows; 1. Connect SCANNER with diagnosis connector. 2. Ignition turns ON. 3. Select Vehicle Type and press ENTER key. 4. Select Model Type and press ENTER key. 5. Select Control System and then select 06 Transfer Case (TOD). Press ENTER key.
YAD5D160
6. When system confirmation screen displays, press ENTER key. 7. If there is any fault in the system, it displays as shown.
YAD5D170
8. Press the function key F2. 9. Press Yes. 10. If the memorized fault code is cleared successfully, it appears on the screen as following; Self Diagnosis Result is Normal.
YAD5D180
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SCHEMATIC WIRING DIAGRAM
YAD5D190
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TOD CONTROL UNIT DIAGNOSTIC SYSTEM CHECK

Circuit Description
The diagnostic system check is an organized approach to identifying a problem created by a transfer case control unit (TOD) malfunction. It must be starting point for any derivability complaint diagnosis because it directs the technician to the next logical step in diagnosing the complaint. Understanding the table and using it correctly will reduce diagnostic time and prevent the unnecessary replacement of parts. Step 1 2 3 Action Verify the customers complaint. Does it verify the customers complaint? Turn the ignition ON. Does 4WD CHECK lamp turns on continuously? Jump between the terminal A2 of the TOD and ground. Does 4WD CHECK lamp turns on? 1. Turn the ignition OFF. 2. Connect the data diagnosis connector to scan tool and follow the manual instruction. 3. Turn the ignition ON. Does the scan tool communicate with TOD? Check whether the scan tool communicates with other control units. Does the scan tool communicate with other control units? Repair the diagnostic line between the TOD terminal A12 and DLC connector 13. Is the repair complete? Change the scan tool. Does the scan tool communicate with other control units? 1. Replace the TOD. 2. Connect the data diagnosis connector to scan tool. 3. Request the DTC. Does any DTC display? Request the DTC with the scan tool. Does any DTC display? 1. Perform the road test. 2. Recheck any DTC. Does any DTC display? Refer to applicable DTC table. Start the lowest DTC and move another DTC. Does the DTC identify as a valid DTC? Value Yes Go To Step 2 Go To Step 4 NO Go To Step 3 Repair the bulb and circuit
Go To Step 4
Go To Step 9
Go To Step 5
Go To Step 6
Go To Step 7
Go To Step 4
Go To Step 4
Go To Step 8
Go To Step 11 Go To Step 10 Go To Step 11 Go To Step 10
10
Go To Step 11 Go To the applicable DTC table
System OK
11
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DIAGNOSTIC TROUBLE CODES (DTCs)

Diagnostic Trouble Code Retention
The first time a fault is detected a DTC is stored in the TODs Non-Volatile memory. This DTC will remain in memory until the TOD is instructed to erase DTCs by SCAN-100. DTCs will not be erased by disconnecting power to the TOD.
Diagnostic Trouble Code Assignments

Classification TOD Fault Code 1714 1715 1716 EMC Speed Sensor 1721 1722 1731 1732 1733 1734 1735 1736 Shift Motor 1741 1742 1743 Position Encoder 1750 1751 1752 1753 1754 Description EEPROM Checksum Fault TPS Loss of Signal TPS Out of Range EMC Open / Short to Battery EMC Short to ground Front Speed Sensor Voltage Low Front Speed Sensor Voltage High Rear Speed Sensor Voltage Low Rear Speed Sensor Voltage High Speed Sensor Reference Voltage Low Speed Sensor Reference Voltage High Motor Open / Shorted to Battery Motor Output Shorted to Ground Shift System Timeout General Position Encoder Fault (Invalid Code) Position 1 Shorted to Ground Position 2 Shorted to Ground Position 3 Shorted to Ground Position 4 Shorted to Ground
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4WD CHECK INDICATOR STAYS ON WITH IGNITION SWITCH ON

Circuit Description When the ignition switch turns to ON the transfer case control unit (TOD) illuminates 4WD CHECK and 4WD LOW indicator to check bulb operation and turns off after 0.6 seconds. Then TOD starts self-diagnosis and illuminate 4WD CHECK indicator when TOD detects any fault. Diagnostic Aids If the 4WD CHECK indicator illuminates steadily the TOD may detect some fault. TOD should be checked by scan tool to solve the problem. The 4WD CHECK indicator also illuminates steadily if the terminal B2 of TOD connector is shorted to ground. The shorted wire or terminals should be repaired. Step 1 Action 1. Turn the ignition switch to OFF. 2. Connect the scan tool to the data link connector (DLC). 3. Turn the ignition switch to ON and request the DTC. Does the scan tool display any DTC? 1. Turn the ignition switch to OFF. 2. Disconnect the 18-pin connector from transfer case control unit (TOD). 3. Turn the ignition switch to ON and check the 4WD CHECK bulb operation. Does the 4WD CHECK indicator come on steadily? Repair any short to ground circuit between terminal A2 of TOD connector and terminal 31 of cluster. Is the repair complete? 1. Turn the ignition OFF. 2. Check the pin or terminals for damage or improper connection. 3. Reconnect all the connectors. 4. Turn the ignition ON. Does the 4WD CHECK indicator come on steadily? Replace the TOD. Is the repair complete? Value Yes Go to the specific DTC diagnostic table No Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step, along with step 4, checks the short to ground condition of the wire or terminals.
Go to Step 2
Go to Step 3
Go to Step 4
System OK
System OK -
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4WD LOW INDICATOR STAYS ON WITH IGNITION SWITCH ON

Circuit Description When the ignition switch turns to ON the transfer case control unit (TOD) illuminates 4WD CHECK and 4WD LOW indicator to check bulb operation and turns off after 0.6 seconds. Then TOD starts self-diagnosis and illuminate 4WD CHECK indicator when TOD detects any fault. Diagnostic Aids If the 4WD LOW indicator illuminates steadily the transfer case in 4WD low range and 4H/4L switch set to 4L. It is normal condition. The 4WD LOW indicator also illuminates steadily if the terminal B9 of TOD connector is shorted to ground. The shorted wire or terminals should be repaired. Step 1 Action Check the position of 4H/4L switch. Does the 4H/4L switch set on 4L? 1. Turn the ignition switch to ON. 2. Set the shift lever to N (neutral). 3. Turn the 4H/4L switch to 4H. Does the 4WD LOW indicator go off? 1. Turn the ignition switch to ON. 2. Set the shift lever to N (neutral). 3. Turn the 4H/4L switch to 4L. Does the 4WD LOW indicator go off? The wiring of 4H/4L switch is reversed. Repair the wiring. Is the repair complete? 1. Turn the ignition OFF. 2. Check the pin or terminals for damage or improper connection. 3. Reconnect all the connectors. 4. Turn the ignition ON. Does the 4WD LOW indicator come on steadily? Repair any short to ground circuit between terminal B9 of TOD connector and terminal A13 of cluster. Is the repair complete? Replace the TOD. Is the repair complete? Value Yes Go to Step 2 No Go to Step 3 Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks for the normal bulb operation.
System OK
3 4
Go to Step 5 -
Go to Step 6
System OK
6 7
System OK System OK
Go to Step 7 -
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NO 4WD CHECK OR 4WD LOW INDICATOR WITH IGNITION SWITCH ON

Circuit Description When the ignition switch turns to ON the transfer case control unit (TOD) illuminates 4WD CHECK and 4WD LOW indicator to check bulb operation and turns off after 0.6 seconds. Then TOD starts self-diagnosis and illuminate 4WD CHECK indicator when TOD detects any fault. Diagnostic Aids If the both of the 4WD CHECK and 4WD LOW indicator were not illuminating there would be some problems with fuse, power supply line, improper connection of connector or transfer case control unit (TOD). If one of the indicators illuminates, the fuse and power supply line is good and the connector or TOD may be the cause of problems. Step 1 Action Check the bulb operation when the ignition switch turns to ON. Does the only 4WD LOW indicator come on and goes after 0.6 seconds? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connector from the transfer case control unit (TOD). 3. Using test lamp check the continuity between terminal B2 of TOD and ground. Does the test lamp come on? 1. Turn the ignition OFF. 2. Check the pin or terminals for damage or improper connection. 3. Reconnect all the connectors. 4. Turn the ignition ON. Do the two indicators come on go after 0.6 seconds? Repair or replace of following components: 4WD CHECK indicator bulb. Open circuit between terminal A12 of cluster and terminal B2 of TOD connector. Is the repair complete? 1. Check the fuse F2 and indicator bulbs. 2. Check the continuity for following terminals: Fuse F2 to B2 (TOD) A2 (Cluster) to B2 (TOD) B15 (Cluster) to B9 (TOD) Are there any problems? Repair open circuit or replace damaged parts. Is the repair complete? Replace the TOD. Is the repair complete? Value Yes No Test Description The number(s) below refer to step(s) on the diagnostic table. 1. This step checks for the normal bulb operation. 5. This step checks voltage supply condition.
Go to Step 2
Go to Step 5
Go to Step 3
Go to Step 4
System OK
Go to Step 7
System OK
Go to Step 7
Go to Step 6 System OK System OK
Go to Step 7 Go to Step 7 -
6 7
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4WD LOW INDICATOR BLINK STEADILY

Circuit Description When the 4H/4L switch turned from 4H (4L) to 4L (4H) electric shift starts and 4WD LOW indicator begin to blink until the shifting is completed or canceled. If 4H to 4L shifting is completed the 4WD LOW indicator will illuminated and 4L to 4H shifting is completed it will be turned off. If shifting fails the 4WD LOW indicator will blink steadily until the shifting is completed or canceled. Step 1 Action 1. Stop the vehicle. 2. Turn the 4H/4L switch to original position. Does the 4WD LOW indicator stop blinking? 1. Make sure the vehicle stopped completely. 2. Set the shift lever to N (neutral) and wait more than 2 seconds. 3. Turn the 4H/4L switch. Does the 4WD LOW indicator blink and stop after complete shifting? 4H > 4L: 4WD LOW indicator illuminates. 4L > 4H: 4WD LOW Indicator turns off. 1. Starts TOD Diagnostic System Check. 2. If there were no trouble code, replace TOD. Is the repair complete? Diagnostic Aids The 4WD LOW indicator shows that the transfer case is operating in low range. And the indicator will blink while shifting from low to high range or high to low range. If the indicator blinks steadily it warns the shifting command and real position of the shift motor or position encoder are not matched.
Value
Yes
No
Go to Step 2
Go to Step 3
System OK
Go to Step 3
System OK
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DIAGNOSTIC TROUBLE CODE (DTC) 1714

EEPROM Checksum Fault
Circuit Description When the ignition is turned on the transfer case control unit (TOD) receives battery voltage and ignition voltage and illuminates the 4WD CHECK and 4WD LOW indicators for 0.6 seconds. Then it starts self diagnosis to check itself. Conditions for Setting the DTC DTC 1714 is an indication of a potential internal transfer case control unit (TOD) malfunction. It will set if any of following conditions is detected. The calculated checksum for internal memory does not match the stored value. The permanent memory storage area is malfunctioning. Step 1 1. Turn the ignition switch OFF. 2. Disconnect the 12-pin connector from transfer case control unit (TOD). 3. Turn the ignition switch to ON. 4. Connect a digital voltmeter between each of the following TOD connector terminal and ground. A4 (Battery supply) A11 (Battery supply) A5 (Battery supply) Does the voltage of the all circuits measure within the value specified? 1. Check the fuse EF9 and voltage supply circuit. 2. Repair or replace any open or damaged circuit or fuse. Is the repair complete? Connect a digital ohmmeter between each of the following TOD connector terminal and ground. B9 (Ground). B2 (Ground). Does the resistance of the all circuits measure within the value specified? Repair or replace any open or damaged circuit. Is the repair complete? Go to Step 2 Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. Diagnostic Aids Check for poor connections, fuse and power supply wiring. Check for ground condition. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks the battery supply voltage. 4. This step checks the ground condition. 6. This step checks the connection status.
Action Was the TOD Diagnostic System Check performed?
Value
Yes
No Go To TOD Control Unit Diagnostic System Check
11 ~ 14 V
Go to Step 4
Go to Step 3
Go to Step 4
0 -
Go to Step 5 -
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Step Action 1. Check the terminals for damages and loose connection. 2. Replace or repair the faulty connector, wire, or terminals. 3. Connect the TOD connector. 4. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 5. Turn the ignition switch to ON. 6. Delete and request DTC with scan tool. Is DTC 1714 still present? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete DTC with scan tool. Is the repair complete? Value Yes No
Go to Step 7
System OK
System OK
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TP Sensor Loss of Signal
Circuit Description The transfer case control unit (TOD) receives throttle position (TP) sensor signals from engine control module (ECM) through CAN bus line. Conditions for Setting the DTC The transfer case control unit (TOD) can not receive throttle position (TP) sensor signal from engine control module (ECM). There is a bad communication between TOD and ECM. TOD is malfunction. ECM is malfunction. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. Diagnostic Aids Check for poor connections of CAN bus line. Check for ECM and TP sensor. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step decides the causal parts of the problem. 4. This step checks the ground condition. 6. This step checks the connection status.
Step 1
Value
Yes
1. Turn the ignition switch to OFF. 2. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON and request engine DTC. Are there any engine DTC related throttle position (TP) sensor? 1. Turn the ignition switch to OFF. 2. Disconnect the 18-pin connector from the transfer case control unit (TOD). 3. Disconnect the gray connector from engine control module (ECM). 4. Connect a digital ohmmeter between the following TOD connector terminal and gray ECM connector terminal. B11 (TOD) and 37 (ECM) B10 (TOD) and 38 (ECM) B11 (TOD) and 24 (ECM) B10 (TOD) and 23 (ECM) Does the resistance of the all circuits measure within the value specified? Repair or replace any open wires, faulty connector, or terminal. Is the repair complete?
Go to Step 2 Go to TOD Diagnostic System Check Refer to Section Engine
No Go to TOD Diagnostic System Check
Go to Step 3
Go to Step 5
Go to Step 4
System OK
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Step 5 Action 1. Replace the TOD. 2. Connect all connectors. 3. Request DTC with scan tool. Is the repair complete? Replace the ECU. Is the repair complete? Value Yes No
System OK System OK
Go to Step 6 -
SSANGYONG Y200

TP Sensor Out of Range
Circuit Description The transfer case control unit (TOD) receives throttle position (TP) sensor signals from engine control module (ECM) through CAN bus line. Conditions for Setting the DTC D The transfer case control unit (TOD) receives throttle position (TP) sensor signal from engine control module (ECM), but the signal is out of the range. There is a bad communication between TOD and ECU. TOD is malfunction. ECU is malfunction. Action taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. Diagnostic Aids Check for poor connections of CAN bus line. Check for ECU and TP sensor. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step decides the causal parts of the problem. 4. This step checks the ground condition. 6. This step checks the connection status.
Step 1
Value
Yes
1. Turn the ignition switch to OFF. 2. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON and request engine DTC. Are there any engine DTC related throttle position (TP) sensor? 1. Turn the ignition switch to OFF. 2. Disconnect the 18-pin connector from the transfer case control unit (TOD). 3. Disconnect the gray connector from engine control module (ECU). 4. Connect a digital ohmmeter between the following TOD connector terminal and gray ECU connector terminal. B11 (TOD) and 38 (ECU) B10 (TOD) and 37 (ECU) B11 (TOD) and A24 B10 (TOD) and A23 B11 (TOD) and ground B10 (TOD) and ground Does the resistance of the all circuits measure within the value specified? Repair or replace any short wires, faulty connector, or terminal. Is the repair complete? Go to Step 2 Go to TOD Diagnostic System Check Go to specific engine DTC diagnosis.
Go to Step 2
Go to Step 4
Go to Step 5
System OK
SSANGYONG Y200

Step 5 Action 1. Replace the TOD. 2. Connect all connectors. 3. Request DTC with scan tool. Is the repair complete? Replace the ECU. Is the repair complete? Value Yes No
System OK System OK
Go to Step 6 -
SSANGYONG Y200

Electromagnetic Clutch Open / Short to Battery
Circuit Description To control the distribution of the torque to front propeller shaft, the transfer case control unit (TOD) sends a signal to the electromagnetic clutch (EMC). Then the clutch disc is compressed or released by the EMC. Conditions for Setting the DTC Even the TOD send signal for controlling the EMC, it receives uncontrolled propeller shaft speed signal. The wiring circuit to EMC opened. The wiring circuit is shorted to battery. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. Step 1 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? 1. Turn the ignition switch to OFF. 2. Disconnect the 12-pin connector from transfer case control unit (TOD). 3. Turn the ignition switch to ON. 4. Connect a digital voltmeter between each of the following TOD connector terminal and ground. A4 (Battery supply). A11 (Battery supply). Does the voltage of the all circuits measure within the value specified? Go to Step 2 Action Was the TOD Diagnostic System Check performed? Value Yes No Go to TOD Diagnostic System Check Diagnostic Aids Check for poor connections of the circuit. Check for EMC. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks poor connection or damage on the pin. 3. This step, along with step 4, checks the voltage supply condition. 5. This step checks the ground condition. 7. This step checks the continuity of the wire and short to battery condition.
Go to Step 3
System OK
11 ~ 14 V
Go to Step 5
Go to Step 4
SSANGYONG Y200

Step 4 Action 1. Check the fuse EF9, F10 and voltage supply circuit. 2. Repair or replace any open or damaged circuit or fuse. Is the repair complete? Connect a digital ohmmeter between each of the following TOD connector terminal and ground. A9 (Ground) A10 (Ground) Does the resistance of the all circuits measure within the value specified? Repair or replace any open or damaged circuit. Is the repair complete? 1. Disconnect the 7-pin connector under the body. 2. Measure the voltage between terminal 4 and ground. Is the resistance within the value specified? Repair open or short to battery circuit. Is the repair complete? Measure the resistance between the clutch coil terminal H and ground. Is the measurement within the value specified? 1. Replace EMC (Electronic Magnetic Clutch). 2. Connect all the connectors. 3. Connect a scan tool to the DLC. 4. Turn the ignition switch to ON. 5. Delete and request DTC. Is the repair complete? Replace TOD. Is the repair complete? Value Yes No
Go to Step 5
0 -
Go to Step 6 -
12 -
Go to Step 8 -
8 9
2.2 ~ 2.8
10
System OK System OK
11
SSANGYONG Y200

Electromagnetic Clutch Short to Ground
Circuit Description To control the distribution of the torque to front propeller shaft, the transfer case control unit (TOD) sends a signal to the electromagnetic clutch (EMC). Then the clutch disc is compressed or released by the EMC. Conditions for Setting the DTC Even the TOD send signal for controlling the EMC, it receives uncontrolled propeller shaft speed signal. The wiring circuit to EMC is shorted to ground. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. Step 1 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? 1. Turn the ignition switch to OFF. 2. Disconnect the 12-pin connector from transfer case control unit (TOD). 3. Turn the ignition switch to ON. 4. Connect a digital voltmeter between each of the following TOD connector terminal and ground. A4 (Battery supply). A11 (Battery supply). Does the voltage of the all circuits measure within the value specified? 1. Check the fuse EF9, F10 and voltage supply circuit. 2. Repair or replace any open or damaged circuit or fuse. Is the repair complete? Go to Step 2 Diagnostic Aids Check for poor connections of the circuit. Check for EMC. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks poor connection or damage on the pin. 3. This step, along with step 4, checks the voltage supply condition. 5. This step checks the ground condition. 7. This step checks the continuity of the wire and short to battery condition.
Value
Yes
Go to Step 3
System OK
11 ~ 14 V
Go to Step 5
Go to Step 4
Go to Step 5
SSANGYONG Y200

Step Action Connect a digital ohmmeter between each of the following TOD connector terminal and ground. A9 (Ground) A10 (Ground) Does the resistance of the all circuits measure within the value specified? Repair or replace any open or damaged circuit. Is the repair complete? 1. Disconnect the 7-pin connector under the body. 2. Measure the voltage between terminal 4 and ground. Is the resistance within the value specified? Repair open or short to battery circuit. Is the repair complete? Measure the resistance between the clutch coil terminal H and ground. Is the measurement within the value specified? 1. Replace EMC (Electronic Magnetic Clutch). 2. Connect all the connectors. 3. Connect a scan tool to the DLC. 4. Turn the ignition switch to ON. 5. Delete and request DTC. Is the repair complete? Replace TOD. Is the repair complete? Value Yes No
0 -
Go to Step 6 -
7 8
0 -
Go to Step 8 -
2.2 ~ 2.8
10
System OK System OK
11
SSANGYONG Y200

Front Speed Sensor Voltage Low
Circuit Description The transfer case control unit (TOD) supplies 5 volts reference voltage to the front speed sensor and receives speed signals generated by Hall effect speed sensor. Conditions for Setting the DTC The wiring circuit for speed sensor shorted to ground or opened. The reference voltage circuit is shorted to ground or opened. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. The TOD then responds as follows: If the system is in high range the TOD uses the rear speed sensor to determine the EMC touch off level and wheel slip control is suspended. If the system is in low range, the EMC duty cycle is set to maximum, independent of vehicle speed, until the system is shifted out of low range. All electric shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. Step 1 1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1735 also shown? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connectors of the transfer case control unit (TOD) and white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 3. Measure the resistance between terminals B6 and terminals of the 7-pin connector. 4. Measure the resistance between terminals B6 and ground. Is measured value equal to specified range? Go to Step 2 Action Was the TOD Diagnostic System Check performed? Value Yes No Go to TOD Diagnostic System Check Diagnostic Aids Check for short to ground or open circuit. Check for front propeller speed sensor. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the continuity. 5. This step checks the speed sensor.
Go to DTC 1735 Speed Sensor Reference Voltage Low
Go to Step 3
Go to Step 5
Go to Step 4
SSANGYONG Y200

Step Action 1. Repair any damaged pins, terminals, open or short to ground circuit. 2. Reconnect the connectors and make sure it is seated properly. 3. Connect a scan tool to the data link connector (DLC). 4. Turn the ignition ON. 5. Request the DTC with scan tool. Is the DTC still current? Measure the resistance between terminals of the male white 7-pin connector. Is the measurement within specified range? Terminal 6 and terminal 3 Terminal 6 and terminal 2 Terminal 3 and terminal 2 Replace front propeller shaft speed sensor. Is the repair complete? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete and request DTC with scan tool. Is the repair complete? Value Yes No
Go to Step 5
System OK
5 ~ 6 M 5 ~ 6 M 9 ~ 10 M -
Go to Step 6 -
System OK
SSANGYONG Y200

Front Speed Sensor Voltage High
Circuit Description The transfer case control unit (TOD) supplies 5 volts reference voltage to the front speed sensor and receives speed signals generated by Hall effect speed sensor. Conditions for Setting the DTC The wiring circuit for speed sensor shorted to voltage. The reference voltage circuit is shorted to voltage. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. The TOD then responds as follows: If the system is in high range the TOD uses the rear speed sensor to determine the EMC touch off level and wheel slip control is suspended. If the system is in low range, the EMC duty cycle is set to maximum, independent of vehicle speed, until the system is shifted out of low range. All electric shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. Step 1 1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1736 also shown? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connectors of the transfer case control unit (TOD) and white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 3. Measure the voltage between terminals B6 and ground. Is measured value below the specified value? Go to Step 2 Action Was the TOD Diagnostic System Check performed? Value Yes No Go to TOD Diagnostic System Check Diagnostic Aids Check for short to ground or open circuit. Check for front propeller speed sensor. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the continuity. 5. This step checks the speed sensor.
Go to DTC 1736 Speed Sensor Reference Voltage High
Go to Step 3
Go to Step 5
Go to Step 4
SSANGYONG Y200

Step Action 1. Repair any damaged pins, terminals, short to battery circuit. 2. Reconnect the connectors and make sure it is seated properly. 3. Connect a scan tool to the data link connector (DLC). 4. Turn the ignition ON. 5. Request the DTC with scan tool. Is the DTC still current? Measure the resistance between terminals of the male white 7-pin connector. Is the measurement within specified range? Terminal B and terminal C Terminal B and terminal D Terminal C and terminal D Replace front propeller shaft speed sensor. Is the repair complete? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete and request DTC with scan tool. Is the repair complete? Value Yes No
Go to Step 5
System OK
5 ~ 6 M 5 ~ 6 M 9 ~ 10 k -
Go to Step 6 -
System OK
SSANGYONG Y200

Rear Speed Sensor Voltage Low
Circuit Description The transfer case control unit (TOD) supplies 5 volts reference voltage to the front and rear speed sensor and receives speed signals generated by Hall effect speed sensor. Conditions for Setting the DTC The wiring circuit for speed sensor shorted to ground or opened. The reference voltage circuit is shorted to ground or opened. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. The TOD then responds as follows: If the system is in high range the TOD uses the front speed sensor to determine the EMC touch off level and wheel slip control is suspended. If the system is in low range, the EMC duty cycle is set to maximum independent of vehicle speed until the system is shifted out of low range. All electric shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. Step 1 1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1736 also shown? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connectors of the transfer case control unit (TOD) and white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 3. Measure the resistance between terminals 17 of TOD and terminals in female white 7-pin connector. Is measured value equal to specified range? 4. Measure the resistance between terminals B17 of TOD and ground. Is measured value equal to specified range? Go to Step 2 Action Was the TOD Diagnostic System Check performed? Value Yes No Go to TOD Diagnostic System Check Diagnostic Aids Check for short to ground or open circuit. Check for front propeller speed sensor. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the continuity. 5. This step checks the speed sensor.
Go to DTC 1735 Speed Sensor Reference Voltage Low
Go to Step 3
Go to Step 5
Go to Step 4
SSANGYONG Y200

Step Action 1. Repair any damaged pins, terminals, open or short to ground circuit. 2. Reconnect the connectors and make sure it is seated properly. 3. Connect a scan tool to the data link connector (DLC). 4. Turn the ignition ON. 5. Request the DTC with scan tool. Is the DTC still current? Measure the resistance between terminals of the male white 7-pin connector. Is the measurement within specified range? Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Replace rear propeller shaft speed sensor. Is the repair complete? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete and request DTC with scan tool. Is the repair complete? Value Yes No
Go to Step 5
System OK
5 ~ 6 M 5 ~ 6 M 9 ~ 10 k -
Go to Step 6 -
System OK
SSANGYONG Y200

Rear Speed Sensor Voltage High
Circuit Description The transfer case control unit (TOD) supplies 5 volts reference voltage to the front speed sensor and receives speed signals generated by Hall effect speed sensor. Conditions for Setting the DTC The wiring circuit for speed sensor shorted to voltage. The reference voltage circuit is shorted to voltage. Action Taken When the DTC Sets The TOD will illuminates 4WD CHECK indicator and DTC is stored in TOD. The TOD then responds as follows: If the system is in high range the TOD uses the front speed sensor to determine the EMC touch off level and wheel slip control is suspended. If the system is in low range, the EMC duty cycle is set to maximum independent of vehicle speed until the system is shifted out of low range. All electric shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed. Step 1 1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1736 also shown? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connectors of the transfer case control unit (TOD) and white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 3. Measure the voltage between terminals B17 of TOD and ground. Is measured value below the specified value? Go to Step 2 Action Was the TOD Diagnostic System Check performed? Value Yes No Go to TOD Diagnostic System Check Diagnostic Aids Check for short to ground or open circuit. Check for front propeller speed sensor. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the continuity. 5. This step checks the speed sensor.
Go to DTC 1736 - Speed Sensor Reference Voltage High
Go to Step 3
Go to Step 5
Go to Step 4
SSANGYONG Y200

Step Action 1. Repair any damaged pins, terminals, open or short to ground circuit. 2. Reconnect the connectors and make sure it is seated properly. 3. Connect a scan tool to the data link connector (DLC). 4. Turn the ignition ON. 5. Request the DTC with scan tool. Is the DTC still current? Measure the resistance between terminals of the male white 7-pin connector. Is the measurement within specified range? Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Replace rear propeller shaft speed sensor. Is the repair complete? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete and request DTC with scan tool. Is the repair complete? Value Yes No
Go to Step 5
System OK
5 ~ 6 M 5 ~ 6 M 9 ~ 10 k -
Go to Step 6
System OK
SSANGYONG Y200

Speed Sensor Referance Voltage Low
Circuit Description The transfer case control unit (TOD) provides reference voltage to front and rear propeller-shaft speed sensor. Conditions for Setting the DTC If the system is in high range the TOD sets the EMC touch off level based on a vehicle speed of 0 and wheel slip control is suspended. If the system is in low range, the EMC duty cycle is set to maximum until the system is shifted out of low range. Step 1 1. Disconnect white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 2. Turn the ignition switch to ON. 3. Measure the voltage between following terminals of male white 7-pin connector: Terminal D/E and terminal B/G Is measured value within the specified range? Measure the resistance between terminal A8 and terminals B8 of transfer case control unit (TOD). Is measured value within the specified range? 1. Turn the ignition switch to OFF. 2. Check two connectors of the TOD and white 7-pin connector. 3. Repair any damaged pins, connector or wires. 4. Reconnect all the connectors and make sure it is seated properly. 5. Connect a scan tool to the data link connector (DLC). 6. Turn the ignition switch to ON. 7. Request DTC Is the DTC still current? 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the TOD and white 7-pin connector under the body. 3. Measure the resistance between following terminals: A8 (TOD) and 1/2 (7-pin connector) B8 (TOD) and 6/7 (7-pin connector) Is the resistance equal to specified value? 4. Measure the resistance between A8 and B8 of TOD connector and ground Is the resistance equal to specified value? Repair any open or short to ground circuit. Is the repair complete? Go to Step 2 Diagnostic Aids Check for short to ground or open circuit. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step, along with step 3, checks the voltage supply condition. 5. This step checks the continuity of ground line. 7. This step checks the speed sensors.
Value
Yes
4.5 ~ 5.5 V
Go to Step 7
Go to Step 3
4.5 ~ 5.5 V
Go to Step 5
Go to Step 4
Go to Step 5
System OK
SSANGYONG Y200

Step Action Measure the resistance between terminals of the male white 7-pin connector. Terminal 6 and terminal 3 Terminal 6 and terminal 2 Terminal 3 and terminal 2 Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Is the measurement within specified range? Replace front or rear propeller shaft speed sensor. Is the repair complete? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete and request DTC with scan tool. Is the repair complete? Value Yes No
5 ~ 6 M 5 ~ 6 M 9 ~ 10 k 5 ~ 6 M 5 ~ 6 M 9 ~ 10 k Go to Step 9 System OK Go to Step 8 -
System OK
SSANGYONG Y200

Speed Sensor Reference Voltage High
Circuit Description The transfer case control unit (TOD) provides reference voltage to front and rear propeller-shaft speed sensor. Conditions for Setting the DTC If the reference voltage supply line is shorted to battery, then the 4WD CHECK indicator will illuminated and the diagnostic trouble code (DTC) will stored to the TOD. If the system is in high range the TOD sets the EMC touch off level based on a vehicle speed of 0 and wheel slip control is suspended. If the system is in low range, the EMC duty cycle is set to maximum until the system is shifted out of low range. Step 1 1. Disconnect white 7-pin connector, for propeller shaft speed sensor and clutch coil, located under the body. 2. Turn the ignition switch to ON. 3. Measure the voltage between following terminals of male white 7-pin connector: Terminal D/E and terminal B/G Is measured value within the specified range? Measure the resistance between terminal A8 and terminals B8 of transfer case control unit (TOD). Is measured value within the specified range? 1. Turn the ignition switch to OFF. 2. Check two connectors of the TOD and white 7-pin connector. 3. Repair any damaged pins, connector or wires. 4. Reconnect all the connectors and make sure it is seated properly. 5. Connect a scan tool to the data link connector (DLC). 6. Turn the ignition switch to ON. 7. Request DTC. Is the DTC still current? Go to Step 2 Diagnostic Aids Check for short to ground or open circuit. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step, along with step 3, checks the voltage supply condition. 5. This step checks the continuity of ground line. 7. This step checks the speed sensors.
Value
Yes
4.5 ~ 5.5 V
Go to Step 7
Go to Step 3
4.5 ~ 5.5 V
Go to Step 5
Go to Step 4
Go to Step 5
System OK
SSANGYONG Y200

Step Action 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the TOD and 7-pin connector under the body. 3. Measure the resistance between following terminals: A8 (TOD) and 1/2 (7-pin connector) B8 (TOD) and 6/7 (7-pin connector) Is the resistance equal to specified value? 4. Measure the voltage between A8 and B8 of TOD connector and ground. Is the resistance below the specified value? Repair any short to circuit. Is the repair complete? Measure the resistance between terminals of the male white 7-pin connector. Terminal 6 and terminal 3 Terminal 6 and terminal 2 Terminal 3 and terminal 2 Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Is the measurement within specified range? Replace front or rear propeller shaft speed sensor. Is the repair complete? 1. Replace the TOD. 2. Turn the ignition switch to OFF. 3. Connect the scan tool to data link connector (DLC) and follow the directions given in the scan tool manual. 4. Turn the ignition switch to ON. 5. Delete and request DTC with scan tool. Is the repair complete? Value Yes No
5 ~ 6 M 5 ~ 6 M 9 ~ 10 k 5 ~ 6 M 5 ~ 6 M 9 ~ 10 k Go to Step 9 System OK Go to Step 8 -
System OK
SSANGYONG Y200

Motor Output Open / Shorted to Battery
Circuit Description The transfer case control unit (TOD) sends current to move the shift motor upon the position of the 4H/4L switch. Conditions for Setting the DTC If the TOD detects a shift motor fault continuously for one seconds, the 4WD CHECK indicator will illuminated and the diagnostic trouble code (DTC) will stored to the TOD. Motor HI-LO circuits are shorted to battery. Motor LO-HI circuits are shorted to battery. Motor HI-LO circuits are shorted to motor LO-HI circuits. Diagnostic Aids Check for short to battery or open circuit. Check for the shift motor. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks the connector and connection status. 3. This step, along with step 3, checks the voltage supply condition. 5. This step checks the continuity of ground line. 7. This step checks the shift motor.
Motor circuits are open. Action Was the TOD Diagnostic System Check performed? Value Yes No Go to TOD Diagnostic System Check
Step 1
1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and 7-pin connector under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? 1. Disconnect the black 7-pin connector for shift motor under the body. 2. Turn the ignition switch to ON. 3. Position shift lever to N (neutral). 4. Connect the voltmeter between terminal 7 of female 7-pin connector and ground. 5. Measure the voltage while switching the 4L/4H switch from 4H to 4L. Is the voltage within the specified value? 6. Connect the voltmeter between terminal 6 of female 7-pin connector and ground. 7. Measure the voltage while switching the 4L/4H switch from 4L to 4H. Is the voltage within the specified value?
Go to Step 2
Go to Step 3
System OK
11 ~ 14 V
11 ~ 14 V
Go to Step 7
Go to Step 4
SSANGYONG Y200

Step Action 1. Connect terminal A1/A6 and terminal A9/A10 with digital voltmeter. 2. Measure the voltage while switching the 4L/4H switch from 4H to 4L. Is the voltage within the specified value? 3. Connect terminal A2/A7 between terminals A9/A10 with digital voltmeter. 4. Measure the voltage while switching the 4L/4H switch from 4L to 4H. Is the voltage within specified range? 1. Disconnect 12-pin connector from transfer case control unit (TOD) and black 7-pin connector. 2. Measure the resistance between following terminals. A2 (TOD) and 6 (7-pin connector) A7 (TOD) and 6 (7-pin connector) A1 (TOD) and 7 (7-pin connector) A6 (TOD) and 7 (7-pin connector) Is the resistance equal to specified value? 3. Measure the voltage between following terminals: A2/A7 (TOD) and ground A1/A6 (TOD) and ground Is the voltage below specified value? Repair any open or short to battery circuit. Is the repair complete? 1. Turn the ignition switch to OFF. 2. Disconnect the black 7-pin connector, for shift motor, under the body. 3. Measure the resistance between terminal G and terminal B. Is the resistance within the specified value? Replace the shift motor. Is the repair complete? Replace the TOD. Is the repair complete? Value Yes No
11 ~ 14 V
11 ~ 14 V
Go to Step 5
Go to Step 9
1V -
7
.
1 ~ 250 -
8 9
SSANGYONG Y200

Motor Output Shorted to Ground
Circuit Description The transfer case control unit (TOD) sends current to move the shift motor upon the position of the 4H/4L switch. Conditions for Setting the DTC If the TOD detects a shift motor fault continuously for one second, the 4WD CHECK indicator will illuminated and the diagnostic trouble code (DTC) will stored to the TOD. Motor HI-LO circuits are shorted to ground. Motor LO-HI circuits are shorted to ground. Motor HI-LO circuits are shorted to motor LO-HI circuits. Step 1 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and black 7-pin connector under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? 1. Disconnect the black 7-pin connector for shift motor under the body. 2. Turn the ignition switch to ON. 3. Position shift lever to N (neutral). 4. Connect the voltmeter between terminal 7 of female 7-pin connector and ground. 5. Measure the voltage while switching the 4L/4H switch from 4H to 4L. Is the voltage within the specified value? 6. Connect the voltmeter between terminal 6 of female 7-pin connector and ground. 7. Measure the voltage while switching the 4L/4H switch from 4L to 4H. Is the voltage within the specified value? Go to Step 2 Diagnostic Aids Check for short to ground circuit. Check for the shift motor. Test Description The number(s) below refer to step(s) on the diagnostic table. 2. This step checks the connector and connection status. 3. This step, along with step 3, checks the voltage supply condition. 5. This step checks the continuity of ground line. 7. This step checks the shift motor.
Value
Yes
Go to Step 3
System OK
11 ~ 14 V
11 ~ 14 V
Go to Step 7
Go to Step 4
SSANGYONG Y200

Step Action 1. Connect terminal A1/A6 and terminal A9/A10 with digital voltmeter. 2. Measure the voltage while switching the 4L/4H switch from 4H to 4L. Is the voltage within the specified value? 3. Connect terminal A2/A7 between terminals A9/A10 with digital voltmeter. 4. Measure the voltage while switching the 4L/4H switch from 4L to 4H. Is the voltage within specified range? 1. Disconnect 12-pin connector from transfer case control unit (TOD) and 7-pin connector. 2. Measure the resistance between following terminals. A2/A7 (TOD) and 6 (7-pin connector) A1/A6 (TOD) and 7 (7-pin connector) A1/A6 (TOD) and ground. A2/A7 (TOD) and ground. Is the resistance equal to specified value? Repair any short to ground or short between circuit. Is the repair complete? 1. Turn the ignition switch to OFF. 2. Disconnect the black 7-pin connector, for shift motor, under the body. 3. Measure the resistance between terminal G and terminal B. Is the resistance within the specified value? Replace the shift motor. Is the repair complete? Replace the TOD. Is the repair complete? Value Yes No
11 ~ 4 V
11 ~ 4 V
Go to Step 5
Go to Step 9
0 -
7
.
1 ~ 205 -
Go to Step 8 -
8 9
SSANGYONG Y200

Shift System Timeout
Circuit Description The transfer case control unit (TOD) sends current to move the shift motor upon the position of the 4H/4L switch. Conditions for Setting the DTC Shifting to other drive range is failed within specified range. Diagnostic Aids Check for short to ground circuit. Check for the shift motor. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the connector and connection status. 4. This step checks the shift motor. Value Yes No Go to TOD Diagnostic System Check
Step 1
1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1741 or 1742 also shown? 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and black 7-pin connector under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? 1. Remove the shift motor. 2. Connect the black 7-pin connector to shift motor. 3. Check the motor operation by turning the 4H/4L switch. Is the motor run? Replace the TOD. Is the repair complete? Repair any problems in transfer case assembly. Is the repair complete?
Go to Step 2
Go to Applicable DTC Table
Go to Step 3
Go to Step 4
System OK
Replace shift motor and Go to Step 3 Go to Step 6 -
5 6
SSANGYONG Y200

General Position Encoder Fault (Invalid Code)
Circuit Description The transfer case control unit (TOD) receives position encoder signals from position encoder. Conditions for Setting the DTC If the TOD detects a shift motor fault continuously for one second, the 4WD CHECK indicator will illuminated and the diagnostic trouble code (DTC) will stored to the TOD. Any position code which does not correspond to the valid 9 codes. A short to ground on any of the encoder lines. Step 1 1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1751, 1752, 1753, or 1754 also shown? 1. Disconnect 18-pin connector from the transfer case control unit (TOD). 2. Measure the resistance between following terminals: B15 (TOD) and ground B5 (TOD) and ground B16 (TOD) and ground B18 (TOD) and ground Is any of the resistance equal to specified value? Repair all of the short to ground circuit. Is the repair complete? 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and 7-pin connector under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? Go to Step 2 Action Was the TOD Diagnostic System Check performed? Diagnostic Aids Check for short to ground circuit. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the continuity of the position encoder line. 5. This step checks the connector and connection status.
Value
Yes
Go to Step 3
Go to Step 5
0 -
Go to Step 5 -
Go to Step 6
System OK
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Step 6 7 Action Replace the shift motor with position encoder. Is the repair complete? Replace the TOD. Is the repair complete? Value Yes System OK System OK No Go to Step 7 -
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Position 1 Shorted to Ground
Circuit Description The transfer case control unit (TOD) receives position encoder signals from position encoder. Conditions for Setting the DTC Position 2 code does not correspond to the specific codes. A short to ground on any of the encoder lines. Diagnostic Aids Check for short to ground circuit. Test Description The number(s) below refer to step(s) on the diagnostic table. 3. This step checks the continuity of the position encoder line. 5. This step checks the connector and connection status. Value Yes No Go to TOD Diagnostic System Check
Step 1
1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1751 only current trouble code? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connector from the transfer case control unit (TOD). 3. Measure the resistance between terminal A15 of TOD connector and ground. Is the resistance equal to specified value? Repair short to ground circuit. Is the repair complete? 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the transfer case control unit (TOD) and 7-pin connector under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? Replace the shift motor. Is the repair complete? Replace the TOD. Is the repair complete?
Go to Step 2
Go to Step 3
Go to DTC 1750 General Position Encoder Fault (Invalid Code)
0 -
Go to Step 5 -
System OK Go to Step 7 -
6 7
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Step 1
1. Turn the ignition switch to OFF. 2. Connect a scan tool to the data link connector (DLC) and follow the directions given in the scan tool manual. 3. Turn the ignition switch to ON. 4. Request DTC with scan tool. Is the DTC 1752 only current trouble code? 1. Turn the ignition switch to OFF. 2. Disconnect 18-pin connector from the transfer case control unit (TOD). 3. Measure the resistance between terminal A10 of TOD connector and ground. Is the resistance equal to specified value? Repair short to ground circuit. Is the repair complete? 1. Turn the ignition switch to OFF. 2. Disconnect two connectors of the TOD and black 7-pin connector under the body. 3. Inspect the terminals for damage or improper connection. 4. Repair any damaged pins or terminals on the wiring harness and TOD. 5. Reconnect the connectors and make sure it is seated properly. 6. Connect a scan tool to the data link connector (DLC). 7. Turn the ignition ON. 8. Request the DTC with scan tool. Is the DTC still current? Replace the shift motor. Is the repair complete? Replace the TOD. Is the repair complete?
Go to Step 2
Go to Step 3
Go to DTC 1750 General Position Encoder Fault (Invalid Code)
0 -
Go to Step 5 -
6 7
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Step 1
Go to Step 2
Go to Step 3
Go to DTC 1750 General Position Encoder Fault(Invalid Code)
0 -
Go to Step 5 -
6 7
SSANGYONG Y200

Step 1
Go to Step 2
Go to Step 3
Go to DTC 1750 General Position Encoder Fault(Invalid Code)
0 -
Go to Step 5 -
6 7
SSANGYONG Y200

TRANSFER CASE (TOD) COMPONENT LOCATOR
YAD5D200
1 2 3 4
Transmission (A/T) TOD Transfer Case Extension Housing Bolt ................................................... 35 - 60 Nm
5 6 7 8
Front Propeller Shaft Bolt (M14, 4) .................................... 81 - 89 Nm Rear Propeller Shaft Bolt (M14, 4) .................................... 81 - 89 Nm
SSANGYONG Y200
5D2-68 TRANSFER CASE - TOD Removal & Installation Procedure

1. Disconnect (-) cable from battery. 2. Lift on vehicle and make sure on safety. Notice: Be careful for catalytic converter due to high temperature after driving or engine running. 3. Prepare a vessel to drain transfer case and manual transmission oil. 4. Release drain plug and drain transfer case and manual transmission oil. If planar damper is installed, unscrew 4 bolts and remove the planar damper.
YAD5D210
Notice: Oil drain should be along with whole transfer case disassembly and assembly.
5. Disconnect transmission extension wiring connector back side transfer case. Notice: When disconnect connector, make sure on direction of locking tab towards inside. 6. Disconnect shift motor/clutch coil connect (Black 7 pin) connector upper backside. 7. Disconnect front and rear speed sensor connector (white 7 pin).
03E-019 YAD5D220
8. Disconnect speedometer sensor connector right upper side.
03E-019 YAD5D230
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9. Disconnect breather tube front upper side transfer case (Upper connecting point of transfer case and front propeller). 10. Prepare hydraulic jack and support transfer case assembly.
03E-019
YAD5D240
11. Unscrew 4 units of M12 bolts from case flange then disconnect front propeller shaft from transfer case. Installation Notice Tightening Torque 81 - 89 Nm (60 - 66 lb-ft)
YAD5D250
12. Unscrew 4 units of M12 bolts from case flange then disconnect rear propeller shaft from transfer case. Installation Notice Tightening Torque 81 - 89 Nm (60 - 66 lb-ft)
YAD5D260
13. Unscrew 5 units of mounting bolt (M12) from extension housing in transmission. Installation Notice Tightening Torque 35 - 60 Nm (26 - 44 lb-ft)
Notice: Make sure the connecting surface is clean. Applying long-life grease spline inside transfer case input shaft. 14. Installation should follow the removal procedure in the reverse order.
03E-019 YAD5D270
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yyyy ;;;; ;;;; yyyy ;;;; yyyy ;;;; yyyy ;;;; yyyy ;;;; yyyy
YAD5D280 YAD5D290 YAD5D300 YAD5D310
TOD CONTROL UNIT

1. Disconnect (-) cable from battery. 2. Pull toward the driver seat and disconnect the 30 pin connector from TOD control unit.
3. Unscrew 2 bolts.
4. Installation should follow the removal procedure in the reverse order. Notice: When replace TOD control unit, it is required to make a coding correspondent with vehicle specification. Installation Notice Tightening Torque 10 Nm (89 lb-in)
SHIFT MOTOR
1. Disconnect (-) cable from battery. 2. Disconnect shift motor/magnetic clutch coil connector (black pin7) upper backside. 3. Unscrew 3 shift motor mounting bolts (M10). 4. Unscrew a bracket mounting bolt (M10). Notice: When disconnecting shift motor and mounting bracket, it is required to unscrew 2 units of adjusting bolts (M10) form motor and bracket.
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5. Keep shift motor even then pull rearward. 6. Clean connection surface of transfer case and shift motor. 7. If necessary, make a test by SCANNER with shift motor assembly. Notice: Do not disassemble shift motor. If necessary, replace by shift motor assembly unit. 8. Applying sealant into connecting surface for new shift motor. 9. Installation should follow the removal procedure in the reverse order. Before installation, make sure that motor position match with mode of 4H/4L switch. Notice: When accord position of motor with 4H/ 4L switch and transfer case match position of the disconnected motor and new one.
YAD5D320
SPEED SENSOR IN FRONT AND REAR PROPELLER SHAFT

1. Disconnect (-) cable from battery. 2. Detach shift motor assembly. 3. Disconnect front and rear speed sensor connector (white 3 pin) upper backside transfer case. 4. Disconnect speed sensor connect from locking sleeve by pushing. 5. Disconnect wire stick cap from the detached connector. 6. Unscrew rear speed sensor mounting bolt (M10) from upper side of rear case flange.
03E-019 YAD5D330
SSANGYONG Y200

7. Detach sensor from transfer case by lifting up using tool. Notice: When disconnect sensor, make sure on adequate pressure due to sensitiveness with shock.
03E-019
YAD5D340
8. Disconnect taping from both protection tube ends that wrap 3 wires of speed sensor and 1 wire of clutch coil. 9. Disconnect tube.
10. Disconnect pin and wire from speed sensor connector by pulling sticking long-nose plier into L pin in connector. 11. On the same way, disconnect pin and wire M and N from connector. Notice: Do not touch the wires related with EMC.
03E-019 YAD5D350
12. Prepare new speed sensor. 13. Connect 3 pins with wires of speed sensor to coincide with each connection position. 14. Using long-nose plier, connect tightly by pulling pins. 15. Apply rubber cap into connector using long-nose plier not to detach. 16. Connect protection tube with wire. 17. Tape both ends of tube. 18. Putting rear speed sensor into hole, connect exactly pushing both ends. 19. Screw 1 unit of bolt (M10).
SSANGYONG Y200

Installation Notice Tightening Torque 3 - 6 Nm (27 - 53 lb-in)
20. Connect speed sensor connector, then locking sleeve. Notice: Front propeller shaft should be premised by removal of shift motor. After disconnecting shift motor, procedure of replacement on sensor assembly of accords with one of rear speed sensor.
SSANGYONG Y200
UNIT REPAIR
TRANSFER CASE, DISASSEMBLED VIEW
YAD5D360
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Bearing Bushing Carrier Assembly Sun Gear Thrust Plate Input Shaft Output Shaft Thrust Washer Bearing Snap Ring High-low Collar Rear Output Shaft Oil Strainer Coupling Hose Hose Clamp Pump Assembly Thrust Washer Sprocket, Drive (24T) Clutch Pack Assembly Insulator Washer Armature Snap Ring Wave Washer Apply Cam Ball Cam and Coil Assembly Nut (2) Output Shaft Yoke Washer Oil Seal Case Flange Bolt Upper Speed Sensor (Rear) Nut Washer Bolt (M10 X 105 X 30) Tag, Identification Thrust Bearing Clutch Coil Assembly Fork, Reduction Shift 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 Shift Rail Shaft, Shift Spacer Torsion Spring Electric Shift Cam Transfer Case Shift Motor Bolt J-clip Connector Retainer Bolt Support Stud Lower Speed Sensor (Front) Plug Identification Decal Cover Tone Wheel, Lower Chain, Drive Sprocket, Driven (24T) Magnet, Oil Pan Case Case Flange and Output Shaft Case Assembly Breather Bar Spiral Pin Oil Seal Pin, Dowel Ring Gear Retaining Ring Snap Ring Bearing Snap Ring Bearing Speedometer Drive Gear Facing, Shift Fork Upper Tone Wheel Oil Seal Bearing Sleeve Bearing
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1. Disconnect transfer case from vehicle 2. Using a 30 mm thin-wall socket, first remove the rear output nut, output shaft yoke washer, oil seal then the case flange. 3. Disconnect shift motor/clutch coil connector and speed sensor connector from upper bracket of transfer case. Notice: When disconnect connector, pull forwards grasping connector housing.
YAD5D370
4. Remove outer tube on speed sensor connector. 5. Remove wire supporting cape back side of speed sensor connector.
6. Disconnect pin of clutch coil wire (yellow) from speed sensor connector (7 pin) using long-nose plier.
03E-019 YAD5D380
7. Remove shift motor. Notice: When remove shift motor, pay attention to the location of triangular slot and shaft in transfer case inside motor.
YAD5D390
SSANGYONG Y200

8. Disconnect front and rear speed sensor as needed. 9. Remove the 17 bolts that retain the front case to the rear case.
YAD5D400
10. Make sure that the front case is facing downward so that the rear cover is facing upwards. 11. Remove the rear front case from the rear case. 12. Remove all traces of gasket sealant from the mating surfaces of the front case and rear case. 13. If the speedometer drive gear is to be replaced, first remove the flange seal by prying and pulling the curved-up lip of the flange seal. Notice: Be careful not to damage the bearing, bearing cage or case. Remove and discard the flange seal.
YAD5D410
14. Remove the speedometer drive gear and upper tone wheel. 15. If the rear output shaft bearing requires replacing, remove the internal snap ring that retains the bearing in the bore. 16. From the outside of the case, drive out the bearing using the driver.
17. Remove the three nuts and washers retaining the clutch coil assembly to the rear case. 18. Pull the assembly, along with the O-ring and wire, from the case.
YAD5D420
SSANGYONG Y200

19. Remove bearing assembly from output shaft. 20. Remove the clutch housing from the output shaft.
YAD5D430
21. Remove the balls and apply cam and wave washer from the output shaft. 22. Remove snap ring from output shaft. 23. Remove clutch pack assembly from output shaft.
YAD5D440
24. Remove the chain, driven sprocket and drive sprocket as an assembly. 25. Remove thrust washer from output shaft.
YAD5D450
26. Remove the magnet from the slot in the front of the case bottom. 27. Remove the output shaft and oil pump as an assembly. 28. If required, to remove the pump from the output shaft, rotate the pump to align. 29. Pull out the shift rail. 30. Remove the helical cam from the front case. 31. If required, remove the helical cam, torsion spring and sleeve from the shaft.
YAD5D460
SSANGYONG Y200

32. Remove the high-low range shift fork and collar as an assembly. 33. Expand the tangs of the large snap ring in the case. 34. With the input shaft against a bench, push the case down and slide the main drive gear bearing retainer off the bearing. 35. Lift the input shaft and front planet from the case. 36. If required, remove the oil seal from the case by prying and pulling on the curved-up lip of the oil seal.
YAD5D470
Notice: Be careful not to damage the bearing, bearing cage or case. 37. Remove the internal snap ring from the planetary carrier. 38. Separate the front planet from the input shaft. 39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing. 41. Remove the thrust washer, thrust plate and the sun gear off the input shaft.
YAD5D480
42. Inspect the bushing and needle bearing in the end of the input shaft for wear or damage. Notice: Under normal use, the needle bearing and bushing should not require replacement. If replacement is required, the bushing and needle bearing must be replaced as a set.
YAD5D490
SSANGYONG Y200

43. If replacement of the needle bearing and bushing is required, press the bearing and bushing is required, press the bearing and bushing out as follows: Position the input shaft on Axle Bearing/Seal plate, and using Pinion Bearing Cone Replacer as a spacer.

YAD5D500
Insert Input Shaft Bearing Remover into the input shaft so it is resting on top of the bearing cage. Tighten the actuator pin until it stops, then press the bearing and bushing out together.
44. If required, remove the front yoke to flange seal by prying and pulling on the curved-up lip of the yoke to flange seal. Notice: Be careful not to damage the bearing, bearing cage or case. 45. If required, remove the internal snap ring retaining the front output shaft ball bearing and remove the bearing.
YAD5D510
Assembly Procedure
1. Before assembly, lubricate all parts with Automatic Transmission Fluid or equivalent. 2. If removed, drive the bearing into the front output case bore.
Notice: Drive the bearing in straight, making sure it is not cocked in the bore. 3. Install the internal snap ring that retains the bearing to the front case. 4. If removed, install the front yoke to flange seal in the front case bore. 5. If removed, install the yoke to flange seal into the mounting adapter bore.
YAD5D520
SSANGYONG Y200

6. If the input shaft needle bearing and bushing were removed, install a new bearing and bushing as detailed in the following steps: Press a new needle bearing, then a new bushing in the input shaft as follows: Position the input shaft on Axle Bearing/Seal Plate or equivalent, and Pinion Bearing Cone Replacer as a spacer. Press a new needle bearing into the end of the input shaft until it seats in the input shaft.
YAD5D530
Press in a new bushing.
YAD5D540
7. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of the transfer case. 8. The stepped face of the thrust washer should face toward the bearing. 9. Slide the sun gear, thrust plate and thrust washer into position on the input shaft. 10. Press the bearing over the input shaft. 11. Install the external snap ring to the input shaft.
YAD5D550
12. Install the front planet to the sun gear and input shaft. 13. Install the internal snap ring to the planetary carrier.
YAD5D560
SSANGYONG Y200

14. Place the tangled snap ring in the case. Expand snap ring with snap ring pliers and install planetary carrier assembly. Check installation by holding the case and carefully tapping the face of the input shaft against a wooden block to make sure the snap ring is installed. 15. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces. Install a bead of gasket sealant on the surface of the front case.
YAD5D570
16. Install the high-low shift fork and high-low collar as an assembly into the front planet. 17. If new pump is used, align the flat of the output shaft and the flat of the pump. Slide the pump onto the output shaft.
YAD5D580
18. Inspect the outside surfaces and bore of the oil pump.
YAD5D590
19. Install the output shaft and oil pump in the input shaft. Make sure that the internal splines of the ouput shaft engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the front case.
YAD5D600
SSANGYONG Y200

20. Install the magnet in the slot in the front case just above the oil filter leg. 21. Install the front output shaft in the front case. 22. Install the thrust washer on the rear output shaft.
YAD5D610
23. Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft. Notice: The driven sprocket (on the front output shaft) must be installed with the marking REAR facing toward the rear case, if so marked. Drive sprocket has a bushing pressed into it.
YAD5D620
24. Install tone wheel onto the front output shaft. Make sure the spline on the tone wheel engages the spline on the front output shaft. 25. Install clutch pack assembly onto the rear output shaft. Make sure the spline of the clutch pack engages to the spline of the sprocket.
YAD5D630
26. Install snap ring onto the rear output shaft. Start the snap ring over the spline and use the wave spring to seat the snap ring in the snap ring groove. If the snap ring will not install, the thrust washer inside the clutch pack may not be seated properly. 27. Install wave spring, insulator washer and armature. (Three offset slots must align with housing to be installed) Notice: Three slots on the thrust washer must be aligned with the three tabs on the clutch pack housing.
YAD5D640
SSANGYONG Y200

28. Install apply cam onto the rear output shaft, 29. Install three balls into the apply cam. 30. Install cam and coil housing assembly onto rear output shaft. 31. Install thrust bearing assembly onto output shaft.
YAD5D650
32. If removed, drive the front output shaft ball bearing into the rear cover bore with Front Shaft Needle Bearing Replacer and Driver Handle.
YAD5D660
33. If removed, install the rear output bearing in the rear case bore. Drive the bearing into the rear case bore with Output Shaft Bearing Replacer and Driver Handle. Make sure that the bearing is not cocked in the bore. 34. Install the internal snap ring that retains the bearing to the rear case.
YAD5D670
35. Install the clutch coil from inside the rear case until the wire and studs extend through the cover. Notice: Do not kink or trap the wire while seating the clutch coil to the case. 36. Install the washers and nuts and tighten. Installation Notice Tightening Torque 8 - 11 Nm (71 - 97 lb-in)
YAD5D680
SSANGYONG Y200

37. Slide the spring spacer on the camshaft and position it beneath the drive tang. 38. Place the torsion spring on the camshaft. Position the first spring tang to the left of the camshaft drive tang.
YAD5D690
39. Rotate the second spring tang clockwise past the drive tang.
43a
YAD5D700
40. Push the torsion spring and sleeve in as far as it will go. 41. Install the helical cam and slide the drive tang between the torsion spring tangs as far as it will go.
YAD5D710
42. Install the pin on the tang end of the helical cam into the hole in the front case. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork. Notice: Do not bend the helical cam during installation to the front case because of possible damage to the pin at the tang end of the motor shaft. 43. Install the shift rail through the high-low shift fork and make sure that the reverse gear shift rail is seated in the front case bore.
YAD5D720
SSANGYONG Y200

44. Install upper and lower speed sensors into the cover. Feed the coil wire through the upper speed sensor wire shield.
YAD5D730
45. Install upper tone wheel, speedometer gear and rear output seal. Use Output Shaft Seal Replacer and Driver or equivalent to install seal.
YAD5D740
46. Coat the mating surface of the front case with a bead of Black Non-Acid Cure Silicone Rubber or equivalent. 47. The following procedure must be followed prior to installing the rear case onto the front case half: Align the output shaft with the rear case output shaft bore. Align the helical cam with the rear case motor bore. If difficulty is encountered with seating the rear case, tap the rear output shaft with a sharp blow using a rubber mallet in a direction away from the triangular shaft while pushing down on the rear case.
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48. Install the bolts retaining the case halves and tighten. Installation Notice Tightening Torque 25 - 37 N m (8 - 27 lb-ft)
YAD5D750
49. Install shift shaft oil seal if it is not installed.
YAD5D760
50. Using pliers equipped with soft jaws, rotate the triangular shaft so it is aligned with the triangular slot in the transfer case shift motor. Notice: If triangular shaft will not rotate, rotate the rear output shaft.
YAD5D770
51. Tighten manually the two nuts that attach the slotted support bracket to the end of the motor house. 52. Apply Black Non-Acid Cure Silicone Rubber or equivalent to motor housing base and install on transfer case. 53. Install the transfer case shift motor and three bolts along with speed sensor wire harness bracket and tighten. Installation Notice Tightening Torque 8 - 11 N m (71 - 97 lb-in)
SSANGYONG Y200

54. Holding the slotted support bracket tight against the motor housing end, secure the bracket to the transfer case, tightening the bolt with lock washer. Installation Notice Tightening Torque 8 - 11 N m (71 - 97 lb-in)
55. Retighten the two nuts that attach the slotted support bracket to the end of the motor. Installation Notice Tightening Torque 3 - 6 Nm (27 - 53 lb-in)
56. Install the clutch coil wire terminal(brown) and other shift motor wires to the 7-pin connector(black). 57. Install the connector retainer at the connector end. 58. Connect the front and rear speed sensors wiring to the 7-pin connector(white). 59. Install the rear case flange on the output shaft. 60. Install the rubber seal, output shaft yoke washer and nut. Tighten the nut. Installation Notice Tightening Torque 137 - 196 Nm
61. Install the drain plug and tighten. Tightening Torque 19 - 30 N m (14 - 22 lb-ft)
62. Fill the transfer case with 1.4 liters of Automatic Transmission Fluid or equivalent. 63. Install the fill plug and tighten. Installation Notice Tightening Torque 19 - 30 N m (14 - 22 lb-ft)
64. Install the transfer case as outlined in removal and Installation.
SSANGYONG Y200

SPECIAL TOOLS TABLE
Snap Ring Plier
Input Shaft Support
YAD5D780
YAD5D790
Bearing Installer
Bearing Removal/ Installer
YAD5D800
YAD5D810
Seal Installer
YAD5D820
SSANGYONG Y200
SECTION 5A
AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . BTRA M74 4WD Automatic Transmission . . . . . . Operators Interfaces . . . . . . . . . . . . . . . . . . . . . Control Systems . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control System . . . . . . . . . . . . . . . . . Hydraulic Control System . . . . . . . . . . . . . . . . . Hydraulic Control Circuit . . . . . . . . . . . . . . . . . . Power Train System . . . . . . . . . . . . . . . . . . . . . Power Flows . . . . . . . . . . . . . . . . . . . . . . . . . . Park and Neutral . . . . . . . . . . . . . . . . . . . . . . . Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive 2 and Manual 2 . . . . . . . . . . . . . . . . . . . . Drive 3 and Manual 3 . . . . . . . . . . . . . . . . . . . . Drive 3 Lock Up and Manual 3 Lock Up . . . . . . Drive 4 (Overdrive) . . . . . . . . . . . . . . . . . . . . . Drive 4 Lock Up . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 5A-2 5A-2 5A-3 5A-3 5A-10 5A-11 5A-15 5A-19 5A-20 5A-22 5A-24 5A-26 5A-28 5A-30 5A-32 5A-34 5A-36 Shift Quality Faults . . . . . . . . . . . . . . . . . . . . . . 5A-45 After Teardown Faults . . . . . . . . . . . . . . . . . . . 5A-47 Trouble Code Diagnosis - Gasoline Vehicle . . 5A-50 TCM Diagnostic System Overview . . . . . . . . . . 5A-50 Clearing Trouble Codes . . . . . . . . . . . . . . . . . . 5A-50 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A-50 Trouble Code Diagnosis - Disel Vehicle . . . . . . TCM Diagnostic System Overview . . . . . . . . . . Clearing Trouble Codes . . . . . . . . . . . . . . . . . . Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A-52 5A-52 5A-52 5A-52
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 5A-159 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 5A-159 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-159 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedure . . . . . . . . . . . . . . . . . . Assembly Procedure . . . . . . . . . . . . . . . . . . . . Front and Rear Band Adjustment . . . . . . . . . . . Gear Shift Control Lever . . . . . . . . . . . . . . . . . . Kickdown Switch . . . . . . . . . . . . . . . . . . . . . . . Transmission Control Module . . . . . . . . . . . . . . 5A-162 5A-162 5A-163 5A-173 5A-201 5A-204 5A-205 5A-205
Diagnostic Information and Procedures . . . . . 5A-38 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-38 Basic Knowledge Required . . . . . . . . . . . . . . . Functional Check Procedure . . . . . . . . . . . . . . . Transmission Fluid Level Service Procedure . . . Fluid Leak Diagnosis and Repair . . . . . . . . . . . Electrical / Garage Shift Test . . . . . . . . . . . . . . Road Test Procedure . . . . . . . . . . . . . . . . . . . . Electronic Adjustments . . . . . . . . . . . . . . . . . . 5A-38 5A-38 5A-38 5A-39 5A-40 5A-40 5A-41
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-206 General Specification . . . . . . . . . . . . . . . . . . . . 5A-206 Fastener Tightening Specifications . . . . . . . . . . 5A-210 Schematic and Routing Diagrams . . . . . . . . . . TCM Wiring Diagrams (Gasoline Engine) . . . . . TCM Wiring Diagrams (Diesel Engine) . . . . . . . Connector End View . . . . . . . . . . . . . . . . . . . . . 5A-211 5A-211 5A-213 5A-215
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 5A-42 Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-42 Faulty Shift Pattern . . . . . . . . . . . . . . . . . . . . . . 5A-43
Special Tools and Equipment . . . . . . . . . . . . . 5A-216 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-216
5A-2 AUTOMATIC TRANSMISSION

BTRA M74 4WD AUTOMATIC TRANSMISSION
The BTR Automotive Model 74 Four Speed Automatic Transmission is an electronically controlled overdrive four speed unit with a lock-up torque converter. The lock-up torque converter results in lower engine speeds at cruise and eliminates unnecessary slippage. These features benefit the customer through improved fuel economy and noise reduction. Max. Power (kW) Of primary significance is the Transmission Control Module (TCM) which is a microprocessor based control system. The TCM utilizes throttle position, rate of throttle opening, engine speed, vehicle speed, transmission fluid temperature, gear selector position and mode selector inputs, and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects. The TCM drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects. The output pressure of this solenoid is controlled as a function of transmission fluid temperature to maintain consistent shift feel throughout the operating range. Shift scheduling is highly flexible, and several independent schedules are programmed depending on the vehicle. Typically the NORMAL schedule is used to maximize fuel economy and driveability, and a POWER schedule is used to maximize performance. WINTER schedule is used to facilitate starting in second gear.
Configuration 260 mm Torque Converter-Wide Ratio Gear Set Splined Output for Transfer Case
320
160
KAA5A010
OPERATORS INTERFACES
There are three operator interfaces as the following; Gear Shift Control Lever Driving Mode Selector Indicator Light
Gear Shift Control lever

The transmission uses a conventional shift control lever. The gear shift control lever can be moved from one position to another within the staggered configuration of the shift control lever gate to positively indicate the gear selection.
P - Park position prevents the vehicle from rolling either forward or backward by locking the transmission output shaft. The inhibitor switch allows the engine to be started. For safety reasons, the parking should be used in addition to the park position. Do not select the Park position until the vehicle comes to a complete stop because it mechanically locks the output shaft. R - Reverse allows the vehicle to be operated in a rearward direction. The inhibitor switch enables reverse lamp operation. N - Neutral allows the engine to be started and operated while driving the vehicle. The inhibitor switch
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AUTOMATIC TRANSMISSION 5A-3

allows the engine to be started. There is no power transferred through the transmission in Neutral. But the final drive is not locked by the parking pawl, so thewheels are free to rotate. D - Overdrive range is used for all normal driving conditions. 4th gear (overdrive gear) reduces the fuel consumption and the engine noise. Engine braking is applied with reduced throttle. First to second (1 2), first to third (1 3), second to third (2 3), second to fourth (2 4), third to fourth (3 4), fourth to third (4 3), fourth to second (4 2), third to second (3 2), third to first (3 1) and second to first (2 1) shifts are all available as a function of vehicle speed, throttle position and the time change rate of the throttle position. Downshifts are available for safe passing by depress-ing the accelerator. Lockup clutch may be enabled in 3rd and 4th gears depending on vehicle type. 3 - Manual 3 provides three gear ratios (first through third) and prevents the transmission from operating in 4th gear. 3rd gear is used when driving on long hill roads or in heavy city traffic. Downshifts are available by depressing the accelerator. 2 - Manual 2 provides two gear ratios (first and second). It is used to provide more power when climbing hills or engine braking when driving down a steep hill or starting off on slippery roads. 1 - Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. When NORMAL mode is selected upshifts will occur to maximize fuel economy. When POWER mode is selected, upshifts will occur to give maximum performance and the POWER mode indicator light is switched ON. When WINTER mode is selected, starting in second gear is facilitated, the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF.
Indicator Light
The indicator light is located on the instrument panel. Auto shift indicator light comes ON when the ignition switch ON and shows the gear shift control lever posi-tion. POWER mode indicator light comes ON when the POWER mode is selected and when the kickdown switch is depressed. WINTER mode indicator light comes ON when the WINTER mode is selected.
CONTROL SYSTEMS
BTRA M74 4WD automatic transmission consists of two control systems. One is the electronic control system that monitors vehicle parameters and adjusts the transmission performance. Another is the hydraulic control system that implements the commands of the electronic control system commands.
ELECTRONIC CONTROL SYSTEM

The electronic control system comprises of sensors, a TCM and seven solenoids. The TCM reads the inputs and activates the outputs according to values stored in Read Only Memory (ROM). The TCM controls the hydraulic control system. This control is via the hydraulic valve body, which contains seven electromagnetic solenoids. Six of the seven solenoids are used to control the line pressure, operate the shift valves and the torque converter lock-up clutch, and to turn ON and OFF the two regulator valves that control the shift feel. The seventh solenoid is the proportional or Variable Pressure Solenoid (VPS) which works with the two regulator valves to control shift feel. Transmission Control Module (TCM) The TCM is an in-vehicle micro-processor based transmission management system. It is mounted under the drivers side front seat in the vehicle cabin. The TCM contains: Processing logic circuits which include a central microprocessor controller and a back-up memory system. Input circuits.
KAA5A020
Driving Mode Selector

The driving mode selector consists of a driving mode selector switch and indicator light. The driving mode selector is located on the center console and allows the driver to select the driving mode. The driving modes available to be selected vary with vehicle types. Typically the driver should have the option to select among NORMAL, POWER and WINTER modes.
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Output circuits which control external devices such as the Variable Pressure Solenoid (VPS) driver, On/ Off solenoid drivers, a diagnostics output and the driving mode indicator light.
Processing Logic Shift schedule and calibration information is stored in an Erasable Programmable Read Only Memory (EPROM). Throttle input calibration constants and the diagnostics information are stored in Electrically Erasable Programmable Read Only Memory (EEPROM) that retains the memory even when power to the TCM is disconnected. TCM continuously monitors the input values and uses these, via the shift schedule, to determine the required gear state. At the same time it monitors, via the solenoid outputs, the current gear state, whenever the input conditions change such that the required gear state is different to the current gear state, the TCM initiates a gear shift to bring the two states back into line. Once the TCM has determined the type of gearshift required the TCM accesses the shift logic, estimates
the engine torque output, adjusts the variable pressure solenoid ramp pressure then executes the shift. The TCM continuously monitors every input and output circuit for short or open circuits and operating range. When a failure or abnormal operation is detected the TCM records the condition code in the diagnostics memory and implements a Limp Home Mode (LHM). The actual limp home mode used depends upon the fail-ure detected with the object to maintain maximum drive-ability without damaging the transmission. In general input failures are handled by providing a default value. Output failures, which are capable of damaging the transmission, result in full limp mode giving only third or fourth gear and reverse. For further details of limp modes and memory retention refer to the Diagnostic Trouble Code Diagnosis Section. The TCM is designed to operate at ambient temperatures between - 40 and 85 C (- 40 and 185 F). It is also protected against electrical noise and voltage spikes, however all the usual precautions should be observed, for example when arc welding or jump starting.
KAA5A030
TCM Inputs To function correctly, the TCM requires engine speed, vehicle speed, transmission fluid temperature, throttle position, gear position and Kickdown Switch inputs to determine the variable pressure solenoid current ramp
and on/off solenoid states. This ensures the correct gear selection and shift feel for all driving conditions. The inputs required by the TCM are as follows;
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Engine Speed The engine speed signal is derived from the Controller Area Network (CAN) via Engine Control Module (ECM). Vehicle Speed The vehicle speed sensor, which is located in the transfer case, sends the output shaft speed signal to the Engine Control Module (ECM). The information is then transferred to the TCM via the CAN. Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission. This sensor is a typical Negative Temperature Coefficient (NTC) resistor with low temperatures producing a high resistance and high temperatures producing a low resistance. If the transmission fluid temperature exceeds 135 C (275 F), the TCM will impose converter lock-up at lower vehicle speeds and in some vehicles flashes the mode indicator light. This results in maximum oil flow through the external oil cooler and eliminates slippage in the torque converter. Both these actions combine to reduce the oil temperature in the transmission. Temperature ( C) -20 0 20 100 135 (Overheat Mode Threshold) Resistance (Ohms) Minimum 13,638 5,177 2,278 117 75 Maximum 17,287 6,616 2, 723 196 85
Pin No. Codes and colors in Solenoid Loom Pin No. 1 2 3 4 5 6 7 8 9 10 Wire Color Red Blue Yellow Orange Green Violet Brown Green White Red Connects to Solenoid 1 Solenoid 2 Solenoid 3 Solenoid 4 Solenoid 5 Solenoid 6 Solenoid 7 Solenoid 5 Temperature Sensor Temperature Sensor
KAA5A050
Throttle Position Sensor Gasoline Engine: The throttle position signal is sent from the ECM to the TCM via the CAN. Refer to Engine Section for further details. Diesel Engine: The throttle position sensor(TPS) is a resistance potentiometer which is installed on the injection pump. It transmits a signal to the TCU proportional to the throttle plate opening. The potentiometer is connected to the TCU by three wires: 5 volts positive supply, earth and variable wiper voltage. Throttle voltage adjustments are as follows: Closed throttle voltage is 0.2 V to 1.0 V. Wide open throttle voltage is 3 V to 4.5 V. These measurements are taken between pins 1 and 3 of the TPS connentor.
KAA5A040
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Maintaining good shift feel through the transmission life span is dependant on having an accurate measure of the engine throttle position. To achieve this the TCU continuously monitors the maximum and minimum throttle potentiometer voltages and, if a change occurs, stores the new voltage values. However these limits will be lost and will require relearning should a new TCU be installed, or the throttle calibration data is cleared by the execution of a particular sequence. This last instance depends on the installation, and reference should be made to the Diagnostics Section of this manual. The relearning will happen automatically. Readings for Resistance / Shift Lever Positions Shift Lever Position Manual 1 Manual 2 Manual 3 Drive Neutral Reverse Park Resistance (k ) 1 ~ 1.4 21.8 ~ 2.2 3 3 ~ 3.4 4.5 ~ 4.9 6.8 ~ 7.2 10.8 ~ 11.2 18.6 ~ 19
Kickdown Switch The Kickdown Switch is used to signal the TCM that the driver has pressed the acclerator to the floor and requires a kickdown shift. When this switch is used, the POWER light comes ON and the POWER shift pattern is used. Diagnostic Inputs The diagnostic control input or K-line is used to initiate the outputting of diagnostic data from the TCM to a diagnostic test instrument. This input may also be used to clear the stored fault history data from the TCMs retentive memory. Connection to the diagnostic input of the TCM is via a connector included in the vehicles wiring harness or computer interface. Battery Voltage Monitoring Input The battery voltage monitoring input is connected to the positive side of the battery. This signal is taken from the main supply to the TCM. If the battery voltage at the TCM falls below 11.3 V, the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited. All other shifts are allowed but may not occur because of the reduced voltage. This condition normally occurs only when the battery is in poor condition. If the battery voltage is greater than 16.5 V, the transmission will adopt limp home mode and all solenoids are turned OFF. When system voltage recovers, the TCM will resume normal operation after a 30 seconds delay period. TCM Outputs The outputs from the TCM are supplied to the components described below; Solenoids Mode Indicator Light
YAD5A250
Gear Position Sensor The gear position sensor is incorporated in the inhibitor switch mounted on the side of the transmission case.
KAA5A060
The gear position sensor is a multi-function switch providing three functions;
Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate the reverse lamps when Reverse is selected Indicate to the TCM which lever position has been selected by way of a varying resistance.
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Solenoids The TCM controls seven solenoids. Solenoids 1 to 6 (S1 to S6) are mounted in the valve body, while Solenoid 7 (S7) is mounted in the pump cover. Solenoid 1 and 2: S1 and S2 are normally open ON/ OFF solenoids that set the selected gear. These solenoids determine static gear position by operating the shift valves. Note that S1 and S2 solenoids also send signal pressure to allow or prohibit rear band engagement. Solenoid 3 and 4: S3 and S4 are normally open ON/ OFF solenoids that combine to control shift quality and sequencing. S3 switches the clutch regulator valve OFF or ON. S4 switches the front band regulator valve OFF or ON. S5 also provides the signal pressure for the converter clutch regulator valve. Solenoid 5: S5 is a variable pressure solenoid that ramps the pressure during gear changes. This solenoid provides the signal pressure to the clutch and band regulator, thereby controlling the shift pressures. S5 also provides the signal pressure for the converter clutch regulator valve.
Solenoid 6: S6 is a normally open ON/OFF solenoid that sets the high/low level of line pressure. Solenoid OFF gives high pressure. Solenoid 7: S7 is a normally open ON/OFF solenoid that controls the application of the converter clutch. Solenoid ON activates the clutch. Solenoid Logic for Static Gear States Gear 1st 2nd 3rd 4th Reverse Neutral Park S1 ON OFF OFF ON OFF OFF OFF S2 ON ON OFF OFF OFF OFF OFF
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Solenoid Operation during Gearshifts Shift 1-2 1-3 To Initiate Shift S1 OFF S4 ON S1 OFF S2 OFF S3 ON S4 ON 1-4 S2 OFF S3 ON S4 ON 2-3 S2 OFF S3 ON S4 ON 3-4 4-3 4-2 S1 ON S4 ON S4 ON S3 ON 750mA to 950mA 4-1 S3 ON S4 ON 3-2 S2 ON S4 ON 600mA to 450mA @ 20 kph. 550mA to 400mA @ 60 kph. 800mA to 650mA @ 100 kph. 3-1 S3 ON S4 ON 700mA to 950mA 2-1 Conv. Clutch ON OFF S7 ON 700mA to 400mA 600mA to 100mA S7 OFF S4 ON 800mA to 950mA S1 ON S2 ON S3 OFF S4 OFF S1 ON S4 OFF 600mA to 1000mA 750mA to 900mA S1 OFF S4 OFF S1 OFF S2 ON S3 OFF S2 ON S3 OFF S4 OFF S4 OFF 750mA to 600mA S4 OFF 700mA to 500mA S3 OFF S4 OFF 850mA to 750mA S3 OFF S4 OFF 850mA to 750mA S3 OFF S4 OFF Typical S5 Current Ramp 750mA to 600mA To Complete Shift S4 OFF
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Solenoid Valve Symbols (ON/OFF Solenoids) The solenoid symbol shown adjacent to each solenoid on the hydraulic system schematics indicates the state of the oil flow through the solenoid valve with the power ON or OFF. Normally Open (NO) Solenoid POWER ON: Line 500 port is closed. The output port is open to exhaust at the solenoid valve. POWER OFF: The exhaust port is closed. The output port is open to line 500. This applies full Line 500 pressure to the plunger and because Line 500 pressure is always greater than S5 pressure it squeezes the S5 oil out between the regulator valve and the plunger. The friction elements are then fed oil pressure equal to Line 500 multiplied by the amplification ratio. When a shift is initiated the required ON/OFF solenoid is switched ON cutting the supply of Line 500 to the plunger. At the same time the VPS pressure is reduced to the ramp start value and assumes control of the regulator valve by pushing the plunger away from the valve. The VPS then carries out the required pressure ramp and the timed shift is completed by switching OFF the ON/ OFF solenoid and returning the VPS to the standby pressure. This system enables either the band or clutch or both to be electrically controlled for each gearshift. Mode Indicator Light Depending on the application, the mode indicator light may be used to indicate the mode that has been selected or if an overheat condition exists. The mode indicator light is usually located on the instrument cluster.
KAA5A070
Communication Systems CAN The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator position etc. from ECM via CAN without any additional sensors. K-Line The K-line is typically used for obtaining diagnostic information from the TCM. A scan tool with a special interface is connected to the TCM via Data Link Connector (DLC) and all current faults, stored faults, runtime parameters are then available. The stored trouble codes can also be cleared by scan tool. The K-line can be used for vehicle coding at the manufacturers plant or in the workshop. This allows for one TCM design to be used over different vehicle mod-els. The particular code is sent to the microprocessor via the K-line and this results in the software selecting the correct shift and VPS ramp parameters. Data Link Connector (DLC) The Data Link Connector (DLC) is a multiple cavity connector. The DLC provides the means to access the serial data from the TCM. The DLC allows the technician to use a scan tool to monitor the various systems and display the Diagnostic Trouble Codes (DTCs).
Variable Pressure Solenoid Multiplexing System Friction element shifting pressures are controlled by the Variable Pressure Solenoid (VPS). Line pressure is completely independent of shift pressure and is a function of throttle position, gear state and engine speed. S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures. VPS pressure is multiplexed to the clutch regulator valve, the band regulator valve and the converter clutch regulator valve during automatic gearshifts. A variable pressure solenoid produces a hydraulic pressure inversely proportional to the current applied. During a gearshift the TCM applies a progressively increasing or decreasing (ramped) current to the solenoid. Current applied will vary between a minimum oaf 200 mA and a maximum of 1000 mA. Increasing current decreases output (S5) pressure. Decreasing current increases output (S5) pressure. Line 500 pressure, (approximately 440 to 560 kPa), is the reference pressure for the VPS, and the VPS output pressure is always below line 500 pressure. When the VPS is at standby, that is no gearshift is taking place, the VPS current is set to 200 mA giving maximum output pressure. Under steady state conditions the band and clutch regulator valve solenoids are switched OFF.
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The DLC connector is located within the drivers compartment, directly below the instrument panel on the drivers side. The pump cover contains the following; Primary regulator valve for line pressure Converter clutch regulator valve Converter clutch control valve Solenoid S7 The main case contains the following; B1R exhaust valve All upshifts are accomplished by simultaneously switching on a shift valve(s), switching VPS pressure to the band and/or clutch regulator valve, and then sending the VPS a ramped current. The shift is completed by switching the regulators OFF and at the same time causing the VPS to reach maximum pressure. All downshifts are accomplished by switching VPS pressure to the band and/or clutch regulator valve and sending a ramped current to the VPS. The shift is completed by simultaneously switching the regulators OFF, switching the shift valves and at the same time causing the VPS to return to stand-by pressure. The primary regulator valve is located in the pump cover and supplies four line pressures; high and low for forward gears, and high and low for reverse. This pressure has no effect on shift quality and merely provides static clutch capacity during steady state operation. Low pressure can be obtained by activating an ON/OFF solenoid with high line pressure being the default mode. Torque converter lock-up is initiated by toggling the converter clutch control valve with an ON/OFF solenoid. The actual apply and release of the clutch is regulated by the VPS via the converter clutch regulator valve. The solenoid supply pressure regulator valve provides reference pressure for all the solenoids.
A103A321
HYDRAULIC CONTROL SYSTEM

The hydraulic controls are located in the valve body, pump body and main case. The valve body contains the following; Manual valve Three shift valves Sequence valve Solenoid supply pressure regulator valve Line pressure control valve Clutch apply feed regulator valve Band apply feed regulator valve Solenoid S1 to S6 Reverse lockout valve
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HYDRAULIC CONTROL CIRCUIT
KAA5A08A
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Valve Body
KAA5A110 KAA5A090
Manual Valve The manual valve is connected to the vehicle selector mechanism and controls the flow of oil to the forward and reverse circuits. The manual valve function is identical in all forward gear positions except that in the Manual 1 position an additional supply of oil is directed to the 1-2 shift valve for application of the rear band and the C4 overrun clutch. The manual valve directs the line pressure into the PRND fluid circuits.
2-3 Shift Valve The 2-3 shift valve is a two position valve. It is used on all 2-3 and 3-2 gearshifts. The switching of this valve is achieved by S2 which is located at the end of the valve spool. In the 1, 2 position, second gear oil from the 1-2 shift valve is prevented from entering the third gear circuit. When the valve is moved to the 3, 4 position, oil from the second gear circuit is routed to the third gear circuit and the transmission is changed to third gear.
KAA5A100
KAA5A120
1-2 Shift Valve The 1-2 shift valve is a two position valve that must be switched to the 2, 3 and 4 position in order to get any forward gear other than first gear. It is used for all 1-2 and 2-1 gearshifts. The switching of this valve is achieved by using S1 and/ or S2. During a 1-2 gearshift drive oil from the manual valve passes through to the second gear circuit. During a 21 gearshift the band apply feed oil is allowed to exhaust via the 1-2 shift valve. The 1-2 shift valve works in conjunction with the 3-4 shift valve to disengage the C4 clutch in first gear, and engage C4 in second gear. When Manual 1 is selected the C4 clutch and rear band (B2) are engaged.
3-4 Shift Valve The 3-4 shift valve is a two position valve. It is used for all 3-4 and 4-3 gearshifts. The switching of this valve is achieved by S1 which is located at the end of the valve spool. During a 3-4 gearshift the 3-4 shift valve: Exhausts the front band release (B1R) circuit thereby allowing the application of the front band (B1). Connects the inner apply area of the front servo (B1AI) to the Band Apply Feed (BAF) circuit thus allowing greater apply forces to the front band. Exhausts the Overrun Clutch (OC) circuit which allows the C4 clutch to disengage.
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During a 4-3 gearshift, the C4 clutch is engaged and the front band (B1) is released. These actions are sequenced by the 4-3 sequence valve. The 3-4 shift valve also switches during 1-2 and 2-1 gearshifts where its function is to apply the overrun clutch (C4) in second gear but to release it in first gear. Note that the C4 clutch is applied in Manual 1 by virtue of the manual valve and the 1-2 shift valve. Refer to 1-2 Shift Valve in this section. line pressure control valve. When S6 pressure is applied to the end of the Primary Regulator Valve (PRV), it is opposed by spring force and causes LOW line pressure for light throttle application and cruising. Heavy throttle application causes the normally open S6 to open (switch Off) thus closing line 500 and opening S6 to exhaust. Removal of S6 pressure from the PRV results in HIGH line pressure.
KAA5A150
KAA5A130
4-3 Sequence Valve The 4-3 sequence valve is a two position spring loaded valve. It switches during 3-4 and 4-3 gearshifts although it performs no function during the 3-4 shift. During the 4-3 shift the 4-3 sequence valve delays the connection of the Clutch Apply Feed (CAF) circuit to the B1R circuit until the B1R circuit has been fully pressurized by using the third gear circuit. This prevents objectionable engine flare on completion of the 4-3 gearshift.
Clutch Apply Feed Regulator Valve The clutch apply feed regulator valve is a fixed ratio (2.25:1) valve. This valve provides a regulated pressure to the C1 clutch and controls the change rate of the clutch state to give the desired shift quality. Third gear oil supplied to the valve is regulated to provide an output pressure, Clutch Apply Feed (CAF) pressure, of 2.25 times the S5 signal pressure when S3 is ON. When S3 is OFF, the output pressure is 2.25 times the line 500 pressure.
KAA5A160
KAA5A140
Solenoid Supply Pressure Regulator Valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids (S1 to S7). Line pres-sure is used as the feeding oil to this regulator and the output is termed line 500. Line Pressure Control Valve Line pressure is controlled by S6, which acts as the
Band Apply Feed Regulator Valve The band apply feed regulator valve is a fixed ratio (1.4:1) valve. It provides a regulated pressure to the front servo, and controls the change rate of the front band (B1) state to give the desired shift quality. Second gear oil supplied to the valve is regulated to provide an output pressure, Band Apply Feed (BAF) pressure, of 1.4 times the S5 signal pressure when S4 is ON. When S4 is OFF the output pressure is 1.4 times the line 500 pressure.
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S1- S2 pressure is exhausted and the valve is held in the lockout position by the spring. In this position, engagement of B2 is prohibited. This feature protects the transmission from abuse by preventing the undesirable application of B2 at high speed, and by providing a reverse lockout function. Note that if the transmission is in failure mode, the rear band will be applied at all times in P, R and N. Pump Cover
KAA5A170
Reverse Lockout Valve The reverse lockout valve is a two position valve contained in the upper valve body. This valve uses S1-S2 pressure as a signal pressure and controls the application of the rear band (B2). While the manual valve is in D, 3, 2 or 1 positions, drive oil is applied to the spring end of the valve, overriding any signal pressures and holding the valve in the lockout position. This prevents the application of B2 in any of the forward driving gears except M1.
KAA5A190
KAA5A180
When the manual valve is in P, R or N positions, drive oil is exhausted and the reverse lockout valve may be toggled by S1-S2 pressure. B2 is applied in P, R, and N if the following conditions are satisfied; In P or N, vehicle speed = 3 km/h. In R, vehicle speed = 10 km/h. Engine speed = 1600 rpm. Throttle position = 12 %. Under these conditions, the TCM switches solenoids S1 and S2 to OFF. The reverse lockout valve toggles under the influence of the S1-S2 pressure, to connect the line pressure to the B2 feed. Oil is fed to both the inner and outer apply areas of the rear servo piston, applying B2. If any of the above conditions are not satisfied, the TCM switches solenoids S1 and S2 to ON.
Primary Regulator Valve The Primary Regulator Valve (PRV) regulates the transmission line pressure (or pump output pressure). This valve gives either high or low line pressure depending on whether S6 is switched OFF or ON. When S6 is switched ON, S6 pressure is applied to the PRV moving it against spring pressure and opening the line pressure circuit to the pump suction port resulting in reduced line pressure. Low line pressure is used during light throttle applications and cruising. Heavy throttle will cause S6 to switch OFF and thereby cause high line pressure. This stepped line pressure control has no detrimental effect on shift feel because all shifting pressures are controlled by separate band and clutch regulator valves, and the output of S5. When reverse gear is selected, both the low and high line pressure values are boosted to guard against slippage. This is achieved by applying reverse oil line pressure to the PRV to assist the spring load. The other end of the valve contains ports for line pressure feedback and S6 pressure. The PRV also regulates the supply of oil to the converter via the converter feed port. The cascade effect of the PRV ensures the first priority of the valve is to maintain line pressure at very low engine speeds. When the engine speed increases and the pump supplies an excess of oil the PRV moves to uncover the converter feed port thereby pressurizing the converter. If there is an excess of oil for the transmissions needs then the PRV moves further to allow oil to return to the suction port.
SSANGYONG Y200
KAA5A200
KAA5A220
Converter Clutch Regulator Valve The converter clutch regulator valve regulates the pressure of the oil which applies the converter clutch. Input oil from the line 500 circuit is regulated within the valve, with the output pressure being variable according to the signal pressure from the S5 circuit. Converter clutch apply and release application is smoothed by electronically varying the S5 circuit pressure.
B1R Exhaust Valve The B1R exhaust valve is a two position spring loaded valve located in the transmission case directly adjacent to the front servo. It permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band (B1). This prevents the need to force the oil back from the front servo through the valve body and through the 3-4 shift valve. The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa.
KAA5A210
Converter Clutch Control Valve The converter clutch control valve is a two position valve which applies or releases the converter clutch. The switching of this valve is governed by the signal pressure from S7. When the valve is in the OFF or released position, converter feed oil from the PRV is directed to the release side of the converter clutch. After flowing through the converter, oil returns to the converter clutch control valve and is then directed to the oil cooler. When the valve is in the ON or applied position, regulated oil from the converter clutch regulator valve is directed to the apply side of the converter clutch. This oil remains within the converter because the converter clutch piston is sealed against the flat friction surface of the converter cover. To provide oil flow to the cooler the converter clutch control valve directs converter feed oil from the PRV directly to the cooler circuit.
KAA5A240
POWER TRAIN SYSTEM

The Power Train System consists of; A torque converter with single face lock-up clutch Four multi-plate clutch assemblies Two brake bands Two one-way clutches Planetary gear set Parking mechanism A conventional six pinion Ravigneaux compound planetary gear set is used with overdrive (fourth gear) being obtained by driving the carrier. The cross-sectional arrangement is very modular in nature. Four main sub-assemblies are installed within the case to complete the build. These subassemblies are;
SSANGYONG Y200
Gear set-sprag-centre support C1 -C2 -C3 -C4 clutch sub-assembly Pump assembly Valve body assembly One, or a combination of selective washers are used between the input shaft flange and the number 4 bearing to control the transmission end float. This arrangement allows for extensive subassembly testing and simplistic final assembly during production. A general description of the operation of the Power Train System is detailed below. First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 shift is accomplished by applying the B1 band and overrunning the 1-2 OWC. The 2-3 shift is accomplished by applying the C1 clutch and releasing
the B1 band. The 3-4 shift is accomplished by reapplying the B1 band and overrunning the 3-4 OWC. Reverse gear is engaged by applying the C3 clutch and the B2 band. The C4 clutch is applied in the Manual 1, 2 and 3 ranges to provide engine braking. In addition, the C4 clutch is also applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting. The B2 band is also applied in the Manual 1 range to accomplish the low-overrun shift. Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static capacities when used with the new low static co-efficient transmission fluids. Nonasbestos friction materials are used throughout.
ELEMENTS ENGAGED Gear First Second Third Fourth Reverse Gear Ratio 2.741 1.508 1.000 0.708 2.428 X X C1 C2 X X X X X X X X X X X X C3 C4 B1 B2 1-2 OWC X 3-4 OWC X X X X X* X LU CLUTCH
Manual 1 2.741 X X * For Certain Vehicle Applications, Refer to the Owner's Manual.
KAA5A250
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-17 Torque Converter

The torque converter consists of a turbine, stator pump, impeller and a lock-up damper and piston assembly. As in conventional torque converters, the impeller is attached to the converter cover, the turbine is splined to the input shaft and the stator is mounted on the pump housing via a one way clutch (sprag). The addition of the damper and piston assembly enables the torque converter to lock-up under favorable conditions. Lock-up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions. Lock-up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover, locking-up the converter and eliminating unwanted slippage. Whenever lockup occurs, improved fuel consumption is achieved. Torsional damper springs are provided in the damper and piston assembly to absorb any engine torque fluctuations during lock-up.
Clutch Packs
There are four clutch packs. All clutch packs are composed of multiple steel and friction plates. C1 CLUTCH: When applied, this clutch pack allows the input shaft to drive the planet carrier. This occurs in third and fourth gears. C2 CLUTCH: When applied this clutch pack allows the input shaft to drive the forward sun gear via the 34 OWC. This occurs in all forward gears. C3 CLUTCH: When applied this clutch pack allows the input shaft to drive the reverse sun gear. This only occurs in reverse gear. C4 CLUTCH: When applied this clutch provides engine braking on overrun. This occurs in Manual 1, 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting.
KAA5A270
KAA5A260
SSANGYONG Y200
5A-18 AUTOMATIC TRANSMISSION Bands

The transmission utilizes two bands, the B1 band (sometimes known as the 2-4 band), and the B2 band (sometimes known as the low-reverse band). The B1 band is a flexible band which is engaged by the front servo piston. B1 is activated in second and fourth gear. When activated B1 prevents the reverse sun gear from rotating by holding the C3 clutch assembly stationary. In second gear only the outer area of the apply piston is utilized. In fourth gear both areas are utilized for greater clamping force. The B2 band is a solid band which is engaged by the rear servo piston. B2 is activated in Park, Reverse, Neutral and Manual 1. When activated B2 prevents the planet carrier assembly from rotating. In Manual 1 only the inner area of the apply piston is utilized. In Park, Reverse and Neutral, both areas are utilized for greater clamping force.
KAA5A290 KAA5A280
One Way Clutches

The transmission uses two OWCs, the 1-2 OWC and the 3-4 OWC. (Note that a third OWC is located in the torque converter, also known as a sprag.) The 1-2 OWC is located between the planetary carrier assembly and the center support. This allows the carrier to rotate around the center support in one direction only. The one way clutch is engaged only in Drive 1. This 3-4 OWC is located between the C4 and the C2 clutch assemblies. This allows the C2 clutch to drive the forward sun gear in first, second and third gears but unlocks in fourth gear and during overrun.
Planetary Gear Set

The planetary gear set used in the transmission is a conventional six pinion Ravigneaux compound gear set.
Parking Mechanism
When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl. The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case. When Park is not selected a return spring holds the parking pawl clear of the output shaft, preventing accidental engagement of Park.
KAA5A300
SSANGYONG Y200
POWER FLOWS
The power flows for the various transmission selections are listed below; Power Flow - Neutral and Park Power Flow - Reverse Power Flow - Manual 1 Power Flow - Drive 1 Power Flow - Drive 2
Power Flow - Drive 3 Power Flow - Drive 3 Lock Up Power Flow - Drive 4 (Overdrive) Power Flow - Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections.
ELEMENTS ENGAGED Gear State Park and Neutral Reverse Manual 1 Drive 1 Drive 2 and Manual 2 Drive 3 and Manual 3 Drive 3 Lock Up and Manual 3 Lock Up Drive 4 Overdrive Drive 4 Lock Up X X X X X X X X X C1 X X C2 X X X X X C3 X C4 X X X X B1 X B2 X X X 1-2 OWC X 3-4 OWC X X X X X LU CLUTCH X
SSANGYONG Y200
PARK AND NEUTRAL
KAA5A31A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-21 Power Flow - Park and Neutral

In Park and Neutral, there is no drive to the planetary gear set. The rear band is applied to eliminate clunk on engagement of the reverse gear, and to improve the low range engagement for 4WD applications. No other clutches or bands are applied. In Park the transmission is mechanically locked by engaging a case mounted pawl with teeth on the output shaft ring gear. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoids S1 and S2 are switched OFF.
Line (pump) pressure is applied to the Primary Regulator Valve (PRV) and to the solenoid supply pressure regulator valve. The converter, oil cooler, and lubrication circuits are charged from the primary regulator valve. The line 500 circuit is charged by the solenoid supply pressure regulator valve. The S5 circuit is charged by the variable pressure solenoid (S5). Line pressure is prevented from entering the drive circuit by the manual valve. The B1 circuit and all clutch circuits are open to exhaust.
ELEMENTS ENGAGED Gear State Park and Neutral C1 C2 C3 C4 B1 B2 X 1-2 OWC 3-4 OWC LU CLUTCH -
KAA5A320
SSANGYONG Y200
REVERSE
KAA5A33A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-23 Power Flow - Reverse

In Reverse, transmission drive is via the input shaft and the forward clutch cylinder to the hub of the C3 clutch. The elements of the transmission function as follows; The C3 clutch is engaged and drives the reverse sun gear in a clock-wise direction. The B2 band is engaged and holds the planetary gear carrier stationary causing the long pinion to rotate anti-clockwise about its axis on the pinion shaft. The long pinion drives the internal ring gear in the same direction. The internal ring being splined to the output shaft drives it in an anti-clockwise or reverse direction. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows; Solenoids S1 and S2 are switched OFF. Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear servo piston for B2 band application. Line pressure feeds the reverse oil circuit via the manual valve. Reverse oil is routed from the manual valve to the C3 clutch. Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value. All other clutch and band apply circuits are open to exhaust.
ELEMENTS ENGAGED Gear State Reverse C1 C2 C3 X C4 B1 B2 X 1-2 OWC 3-4 OWC LU CLUTCH -
KAA5A340
SSANGYONG Y200
MANUAL 1
KAA5A35A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-25 Power Flow - Manual 1

In Manual 1, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the trans-mission function as follows; The C2 clutch is engaged to drive the forward sun gear, via the 3-4 OWC. The B2 band is engaged to hold the planetary gear carrier stationary. The forward sun gear drives the short pinion anticlockwise. The short pinion drives the long pinion clockwise. The long pinion rotating about its axis drives the inter-nal ring gear and the output shaft in a clockwise or forward direction. The C4 clutch provides engine braking through the 3-4 OWC on overrun. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows; Solenoids S1 and S2 are switched ON. The 1-2, 2-3, and 3-4 shift valves are held in their first gear positions by line 500 pressure. Drive (line pressure) oil from the manual valve engages the C2 clutch. Lo-1st (line pressure) oil is routed through the 1-2 shift valve to the C4 clutch, and to the inner apply area of the rear servo piston for B2 band application.
ELEMENTS ENGAGED Gear State Manual 1 C1 C2 X C3 C4 X B1 B2 X 1-2 OWC 3-4 OWC X LU CLUTCH -
KAA5A360
SSANGYONG Y200
DRIVE 1
KAA5A37A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-27 Power Flow - Drive 1

In Drive 1, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : The C2 clutch is engaged to drive the forward sun gear via the 3-4 OWC. The forward sun gear drives the short pinion anticlockwise. The short pinion drives the long pinion clockwise. The 1-2 OWC prevents the planetary gear carrier from rotating under reaction force and the long pinion rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction. There is no engine braking on overrun. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoids S1 and S2 are switched ON. The 1-2, 2-3, and 3-4 shift valves are held in their first gear positions by line 500 pressure. Drive (line pressure) oil from the manual valve engages the C2 clutch.
ELEMENTS ENGAGED Gear State Drive 1 C1 C2 X C3 C4 B1 B2 1-2 OWC X 3-4 OWC X LU CLUTCH -
KAA5A380
SSANGYONG Y200
DRIVE 2 AND MANUAL 2
KAA5A39A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-29 Power Flow - Drive 2 and Manual 2

In Drive 2 and Manual 2, transmission drive is via the input shaft and forward clutch cylinder. The elements of the transmission function as follows; The C2 clutch is applied to drive the forward sun gear. The forward sun gear drives the short pinion anticlockwise. The short pinion drives the long pinion clockwise. The B1 band is applied holding the reverse sun gear stationary therefore the long pinion walks around the reverse sun gear taking the internal ring gear and output shaft with it in a clockwise or forward direction. The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows; Solenoid S1 is switched OFF. S2 is switched ON.
Drive (line pressure) oil from the manual valve engages the C2 clutch. When S1 switches OFF, S1 oil pressure, which is derived from line 500 pressure, moves the 3-4 shift valve to the left. At the same time S1 oil is directed to the 1-2 shift valve which moves the valve to the second gear position. 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve, and to the 2-3 shift valve. The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the Band Apply Feed (BAF) circuit. Band apply feed oil is directed to; - The outer apply area of the front servo - The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear - The 3-4 shift valve for use when the transmission is shifted into fourth gear Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
ELEMENTS ENGAGED Gear State Drive 2 and Manual 2 C1 C2 X C3 C4 X B1 X B2 1-2 OWC 3-4 OWC X LU CLUTCH -
KAA5A400
SSANGYONG Y200
DRIVE 3 AND MANUAL 3
KAA5A41A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-31 Power Flow - Drive 3 and Manual 3

In Drive 2 and Manual 2, transmission drive is via the input shaft and forward clutch cylinder. The elements of the transmission function as follows; The C2 clutch is engaged to drive the forward sun gear. The C1 clutch is engaged to drive the planet carrier. The short pinion drives the long pinion clockwise. The forward sun gear and the planet carrier are driven clockwise at the same speed therefore there is no relative motion between the sun gear and the pinions. The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed. The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows:
The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ra-tio) to the Band Apply Feed (BAF) circuit. Band apply feed oil is directed to; - The outer apply area of the front servo - The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear - The 3-4 shift valve for use when the transmission is shifted into fourth gear 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit. 3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 sequence valve. The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the Clutch Apply Feed (CAF) circuit. The CAF oil is directed to; - The C1clutch - The 4-3 sequence valve At the 4-3 sequence valve the CAF oil becomes Band 1 Release Feed (B1R-F) oil, and is directed through the 3-4 shift valve to the spring end of the 4-3 sequence valve, and to the release side of the front servo piston to hold band 1 OFF. Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
Solenoid S1 is switched OFF. S2 is switched OFF. With S1 and S2 switched OFF, the 2-3 and 3-4 shift valves are held in the third gear position by line 500 pressure. The 1-2 shift valve is held in the third gear position by S1-S2 oil pressure. 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply feed regulator valve and to the 2-3 shift valve.
ELEMENTS ENGAGED Gear State Drive 3 and Manual 3 C1 X C2 X C3 C4 X B1 B2 1-2 OWC 3-4 OWC X LU CLUTCH -
KAA5A420
SSANGYONG Y200
DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP
KAA5A43A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-33 Power Flow - Drive 3 Lock Up and Manual 3 Lock Up
In Drive 3 Lock Up and Manual 3 Lock Up, transmission drive is the same as for Drive 3 but with the application of the converter lock up clutch to provide positive noslip converter drive. Control Control for Drive 3 Lock Up and Manual 3 Lock Up is the same as for Drive 3 with the addition of the converter clutch circuit activated by solenoid S7.
When S7 is switched ON, S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid. This allows the valve to move to the clutch engage position. Regulated apply feed oil, drive oil at the converter clutch regulator valve, is directed by the converter clutch control valve to the engage side of the converter clutch. Converter clutch release oil is exhausted at the converter clutch control valve. Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication circuit.
ELEMENTS ENGAGED Gear State Drive 3 Lock Up and Manual 3 Lock Up C1 X C2 X C3 C4 X B1 B2 1-2 OWC 3-4 OWC X LU CLUTCH X
KAA5A440
SSANGYONG Y200
DRIVE 4 (OVERDRIVE)
KAA5A45A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-35 Power Flow - Drive 4 (Overdrive)

In Drive 4 (Overdrive), transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows; The C1 clutch is applied to drive the planet carrier clockwise. The B1 band is applied to hold the reverse sun gear stationary. As the planet carrier tuns, the long pinion walks around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i.e. in overdrive ratio. The forward sun gear is also driven faster than the input shaft and overruns the 3-4 OWC. The C2 clutch is engaged to reduce the speed differential across the 3-4 OWC. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows; Solenoid S1 is switched ON. S2 is switched OFF. With S1 switched ON, the 3-4 shift valve is held in the fourth gear position by line 500 pressure on the small end of the valve. With S2 switched OFF, the 2-3 shift valve is held in the fourth gear position by line 500 pressure on the large end of the valve.
The 1-2 shift valve is held in the fourth gear position by S2 oil pressure. 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply feed regulator valve, and to the 2-3 shift valve. The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ra-tio) to the Band Apply Feed (BAF) circuit. Band apply feed oil is directed to; - the outer apply area of the front servo - the inner apply area of the front servo piston via the 3-4 shift valve - the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit. 3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 sequence valve. The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the Clutch Apply Feed (CAF) circuit. The CAF oil is directed to; - the C1 clutch - the 4-3 sequence valve Drive oil (line pressure) from the manual valve engages the C2 clutch.
ELEMENTS ENGAGED Gear State Drive 4 Overdrive C1 X C2 X C3 C4 B1 X B2 1-2 OWC 3-4 OWC LU CLUTCH -
KAA5A460
SSANGYONG Y200
DRIVE 4 LOCK UP
KAA5A47A
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-37 Power Flow - Drive 4 Lock Up

In Drive 4 Lock Up, transmission drive is the same as for Drive 4 but with the application of the converter lock up clutch to provide positive no-slip converter drive. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows; When S7 is switched ON, S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid. This allows the valve to move to the clutch engage position.
Regulated apply feed oil, drived from drive oil at the converter clutch regulator valve, is directed by the converter clutch control valve to the engage side of the converter clutch. Converter clutch release oil is exhausted at the converter clutch control valve. Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication circuit.
ELEMENTS ENGAGED Gear State Drive 4 Lock Up C1 X C2 X C3 C4 B1 X B2 1-2 OWC 3-4 OWC LU CLUTCH -
KAA5A480
SSANGYONG Y200
DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS

BASIC KNOWLEDGE REQUIRED
You must be familliar with some basic electronics to use this section of the Service Manual. They will help you to follow diagnostic procedures. Notice: Lack of the basic knowledge of this transmission when performing diagnostic procedures could result in incorrect diagnostic performance or damage to transmission components. Do not, under any circumstances, attempt to diagnose a transmission problem without this basic knowledge. Notice: If a wire is probed with a sharp instrument and not properly sealed afterward, the wire will corrode and an open circuit will result. Diagnostic test probes are now available that allow you to probe individual wires without leaving the wire open to the environment. These probe devices are inexpensive and easy to install, and they permanently seal the wire from corrosion. Refer to the appropriate Diagnostic Trouble Code (DTC) information and repair the vehicle as directed. After repairing the vehicle, perform the road test and verify that the code has not set again. Perform the Electrical/Garage Shift Tests. Perform the Road Test Procedure in this section. Inspect the oil and check for metal or other contaminants in the oil pan.
TRANSMISSION FLUID LEVEL SERVICE PROCEDURE

This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in slipping and loss of drive/ reverse or delay on engagement of drive/ reverse when the vehicle is cold. The vehicle is first checked for transmission diagnostic messages on the scan tool. If the oil level is low, it is possible to register a vehicle speed signal fault. The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of drive. One symptom of low fluid level is a momentary loss of drive when driving the vehicle around a corner. Also when the transmission fluid level is low, a loss of drive may occur when the transmission fluid temperature is low. If there is no loss of drive when the vehicle is driven warm and a vehicle speed signal fault is registered, then fluid should be added to the transmission. When adding or changing transmission fluid use only Castrol TQ 95 automatic transmission fluid. The use of incorrect fluid will cause the performance and durability of the transmission to be severely degraded.
Special Tools
You should be able to use a Digital Volt Meter (DVM), a circuit tester, jumper wires or leads and a line pressure gauge set. The functional check procedure is designed to verify the correct operation of electronic components in the transmission. This will eliminate the unnecessary removal of transmission components.
FUNCTIONAL CHECK PROCEDURE

Begin with the Functional Check Procedure which provides a general outline of how to diagnose automatic transmission. The following functional check procedure will indicate the proper path of diagnosing the transmission by describing the basic checks and then referencing the locations of the specific checks. Check the fluid level according to the Fluid Level Service Procedure. Check the transmission fluid leak. Check if the transmission fluid is not burnt by smell. Notice: The specific fluid used in this transmission turns brown during normal operation. Brown fluid does not indicate a transmission fault. Ensure that the transmission is not in Limp Home Mode (LHM). Check the battery terminals and the earth connections for corrosion or looseness. Check that the cooler flow is not restricted. Check all electrical plug connections for tightness. Use on-board diagnostic tool or a scan tool to see if any transmission trouble codes have been set.
Fluid Level Diagnosis procedure

1. If the vehicle is at operating temperature allow the vehicle to cool down for two hours, but no greater than four hours. Or if the vehicle is at cool status, start the engine and allow the engine to idle for approximately 5 minutes or, if possible, drive the vehicle for a few kilometers. This will allow the transmission to be within the correct temperature range. Transmission fluid level should be checked at temperature 50 - 60 C (82 - 140 F). Caution: Removal of the fluid filler plug when the transmission fluid is hot may cause injury if fluid drains from the filler hole. 2. With the brake pedal pressed, move the gear shift control lever through the gear ranges, pausing a few seconds in each range. Return the gear shift control lever to P (Park). Turn the engine OFF.
SSANGYONG Y200

3. Park the vehicle on a hoist, inspection pit or similar raised level surface. The vehicle must be control level to obtain a correct fluid level measurement. 4. Place a fluid container below the fluid filler plug. 5. Clean all dirt from around the fluid filler plug. Remove the fluid filler plug. Clean the filler plug and check that there is no damage to the O ring. If fluid drains through the filler hole the transmission may have been overfilled. When the fluid stops draining the fluid level is correct. Install the fluid filler plug and tighten it to 33 Nm (24 lb-ft). If fluid does not drain through the filler hole, the transmission fluid level may be low. Install the filler pump into the filler hole. Lower the vehicle with the filler pump still connected and partially fill the fluid through the filler hole. Start the vehicle in P (Park) with the parking brake and the brake applied. With the engine idling, move the gear shift. control lever through the gear ranges, pausing a few seconds in each range and adding the fluid until gear application is felt. Return the gear shift lever to P (Park). Turn the engine OFF and raise the vehicle. When the three minutes passed after the engine stopped, remove the filler pump. Check if the fluid level is aligned with the bottom of the filler hole. If not, add a small quantity of fluid to the correct level. Install the fluid filler plug and tighten it to 33 Nm (24 lb-ft). If fluid does not drain through the filler hole although adding a total of 1.5 liters, the transmission should be inspected for fluid leaks and any leaks should be fixed before setting the transmission fluid level. 6. When the fluid level checking procedure is completed, wipe any fluid around the filler plug with a rag or shop towel. ranges, pausing a few seconds in each range and adding the fluid until gear application is felt. Then add an additional 0.5 litres of fluid. Return the gear shift lever to P (Park). Turn the engine OFF and raise the vehicle. Install the fluid filler plug and tighten it to 33 Nm (24 lb-ft). 5. Drive the vehicle at 3.5 to 4.5 kilometers with light throttle so that the engine does not exceed 2500 rpm. This should result in the transmission temperature being in the range 50 - 60 C (82 - 140 F). With the brake applied, move the shift lever through the gear ranges, pausing a few seconds in each range at the engine idling. 6. Return the gear shift lever to P (Park). Turn the en-gine OFF and raise the vehicle on the hoist, if applicable, ensuring the vehicle is level. When the three minutes passed after the engine stopped, remove the filler plug. Check if the fluid level is aligned with the bottom of the filler hole. If not, add a small quantity of fluid to the correct level. Install the fluid filler plug and tighten it to 33 Nm (24 lb-ft). 7. Wipe any fluid around the filler plug with a rag or shop towel.
FLUID LEAK DIAGNOSIS AND REPAIR

The cause of most external leaks can generally be located and repaired with the transmission in the vehicle.
Methods for Locating Leaks

General Method 1. Verify that the leak is transmission fluid. 2. Thoroughly clean the suspected leak area. 3. Drive the vehicle for approximately 25 km (15 miles) or until the transmission reaches normal operating temperature (88 C, 190 F). 4. Park the vehicle over clean paper or cardboard. 5. Turn the engine OFF and look for fluid spots on the paper. 6. Make the necessary repairs to correct the leak. Powder Method 1. Thoroughly clean the suspected leak area. 2. Apply an aerosol type powder (foot powder) to the suspected leak area. 3. Drive the vehicle for approximately 25 km (15 miles) or until the transmission reaches normal operating temperature (88 C, 190 F). 4. Turn the engine OFF. 5. Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak.
Fluid Level Set After Service

1. Depending on the service procedure performed, add the following amounts of fluid through the filler plug hole prior to adjusting the fluid level: Converter empty 8.0 liters (8.5 quarts) Converter full 3.8 liters (4.0 quarts) 2. Follow steps 1 through 4 of the Fluid Level Diagnosis Procedure. 3. Clean all dirt from around the fluid filler plug. Remove the fluid filler plug. Clean the filler plug and check that there is no damage to the O ring. 4. Lower the vehicle with the filler pump still connected and start the vehicle in P (Park) with the parking brake and the brake applied. With the engine idling, move the gear shift control lever through the gear
SSANGYONG Y200

6. Make the necessary repairs. Dye and Black Light Method 1. Add dye to the transmission through the transmission fluid filler plug. Follow the manufacturers recommen-dation for the amount of dye to be used. 2. Use the black light to find the fluid leak. 3. Make the necessary repairs.
Repairing the Fluid Leak

Once the leak point is found the source of the leak must be determined. The following list describes the potential causes for the leak: Fasteners are not torqued to specification. Fastener threads and fastener holes are dirty or corroded. Gaskets, seals or sleeves are misaligned, damaged or worn. Damaged, warped or scratched seal bore or gasket surface. Loose or worn bearing causing excess seal or sleeve wear. Case or component porosity. Fluid level is too high. Plugged vent or damaged vent tube. Water or coolant in fluid. Fluid drain back holes plugged.
ELECTRICAL / GARAGE SHIFT TEST

This preliminary test should be performed before a hoist or road test to make sure electronic control inputs are connected and operating. If the inputs are not checked before operating the transmission, a simple electrical condition could be misdiagnosed as a major transmission condition. A scan tool provides valuable information and must be used on the automatic transmission for accurate diagnosis. 1. Move gear shift control lever to P (Park) and set the parking brake. 2. Connect scan tool to Data Link Connector (DLC) terminal. 3. Start engine. 4. Turn the scan tool ON. 5. Verify that the appropriate signals are present. These signals may include: ENGINE SPEED VEHICLE SPEED
KICKDOWN SWITCH VOLTAGE 4WD LAMP LOW VOLTAGE 4WD LAMP HIGH VOLTAGE MODE SWITCH VOLTAGE BATTERY VOLTAGE 6. Monitor the A/C COMPRESSOR STATUS signal while pushing the A/C switch. The A/C COMPRESSOR STATUS should come ON when the A/C switch is pressed, and turn OFF when the A/C switch is repushed. 7. Monitor the GEAR SHIFT LEVER POSITION signal and move the gear shift control lever through all the ranges. Verify that the GEAR SHIFT LEVER POSITION value matches the gear range indicated on the instrument panel or console. Gear selections should be immediate and not harsh. 8. Move gear shift control lever to neutral and monitor the THROTTLE POSITION signal while increasing and decreasing engine speed with the accelerator pedal. THROTTLE POSITION should increase with engine speed.
THROTTLE POSITION ACCEL. PEDAL POSITION TRANSMISSION GEAR STATE GEAR SHIFT LEVER POSITION TRANSMISSION FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT CLOSED ACCEL. PEDAL POSITION LEARNT OPEN ACCEL. PEDAL POSITION LEARNT A/C COMPRESSOR STATUS KICKDOWN SWITCH STATUS 4WD STATUS MODE SWITCH THROTTLE POSITION VOLTAGE GEAR SHIFT LEVER POSITION VOLTAGE TRANS. FLUID TEMPERATURE VOLTAGE A/C SWITCH
ROAD TEST PROCEDURE

Perform the road test using a scan tool. This test should be performed when traffic and road conditions permit. Observe all traffic regulations.
SSANGYONG Y200
ELECTRONIC ADJUSTMENTS
Idle Speed Adjustments
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration

Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic trouble message, it may be re-established by the following procedure. Check that the hot engine idle speed is within specfication. Allow the engine to idle in 'Drive' for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle reference point in the TCU has now been set. Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open throttle reference point in the TCU has now been set.
Vehicle Coding
The vehicle coding is integrated as part of the diagnostic software. A scan tool has the function to code the ve-hicle through the K-line.
Throttle Clearing
The leant throttle clearing routine uses the mode switch and gear lever. Carry out the following steps to complete the automated throttle clearing procedure: 1. Switch ignition 'ON' with handbrake applied and engine 'OFF'. 2. Select the selector lever to 1st gear and 'WINTER' mode. 3. Move the selector lever to 2nd gear and 'ECONO' or 'POWER' mode. 4. Move the selector lever to 3rd gear and 'WINTER' mode.
SSANGYONG Y200
SYMPTOM DIAGNOSIS
DRIVE FAULTS
Condition No Drive in D Possible Causes Action
Insufficient auto transmission fluid. Blocked feed in C1/C2 cylinder. Z link displaced. Primary Regulator Valve (PRV) jammed open. Overdrive shaft or input shaft seal rings failed. 3-4 or 1-2 One Way Clutch (OWC) installed backwards or failed. C2 piston broken or cracked. Rear band or servo faulty. Failure in C3, C3 hub or C1/C2 cylinder. Damaged input shaft sealing rings. Jammed Primary Regulator Valve (PRV). Damaged/broken pump gears. Dislodged output shaft snap ring.
Check the fluid level. Top up as necessary. Inspect and clean C1/C2 feed. Reinstall/renew the z link. Remove, clean and re-install the PRV. Inspect and replace as necessary. Inspect and replace as necessary.
Inspect and replace as necessary. Check servo adjustment or replace rear band as necessary. Check for failure in C3, C3 hub or C1/C2 cylinder. Repair as necessary. Inspect and replace as necessary. Inspect and clean PRV. Inspect and replace pump gears as necessary. Inspect and repair as necessary.
No Drive in Reverse No engine braking in Manual 1 Engine braking in Manual 1 is OK
No drive in Drive and Reverse
SSANGYONG Y200
FAULTY SHIFT PATTERN

Condition 2-3 shift only (no 4th or 1st) Possible Causes Action
S1 always OFF.
1-4 shift only1-3-4 (Delayed 1-2 shift)
S1 always ON.
4-3 shift only
S2 always OFF.
Inspect S1. Repair or replace as necessary. Check for 12 Volts applied to S1 at all times or for wiring fault. Inspect S1. Repair or replace as necessary. Check for 12 Volts applied to S1 at all times or for wiring fault. Inspect S2. Repair or replace as necessary. Check for open circuit or wiring fault. Inspect S2. Repair or replace as necessary. Check for open circuit or wiring fault. Inspect and repair as necessary. Inspect and adjust as necessary. Inspect and repair as necessary. Inspect and replace or refit as necessary Inspect O ring. Refit or replace as necessary. Inspect the 2-3 shift valve. Repair or replace as necessary. Inspect C1 clutch. Repair or replace as necessary. Inspect ball. Refit or replace as necessary. Inspect rear band adjustment. Adjust as necessary. Inspect ball. Refit or replace as necessary. Inspect O ring. Refit or replace as necessary. Inspect the 1-2 shift valve. Repair or replace as necessary. Inspect the 2-3 shift valve. Repair or replace as necessary. Inspect inhibitor switch. Repair or replace as necessary. Inspect the 3-4 shift valve. Repair or replace as necessary.
1-2-Neutral (1st over run)
S2 always ON.
1-3 shift only
B1 failed. Loose band adjustment. Front servo piston or seal failed. S1/S2 ball misplaced, Smaller O ring on front servo piston failed or missing. 2-3 shift valve jammed. C1 clutch failed or slipping in 3rd and 4th. (Gives 1st in 3rd and 2nd in 4th.) Over-run Clutch (OC) /low ball misplaced. Rear band slipping when hot. Reverse/Low-1st ball misplaced. Rear servo inner O ring missing. 1-2 shift valve jammed. 2-3 shift valve jammed. Inhibitor switch fault, 1-2-3 only. 3-4 shift valve jammed.
1-3-4 only
1-2-1 only
No manual 4-3, 3-2 or 2-1 No manual 1st
1st gear only or 2nd,3rd, and 4th only 1st and 2nd only or 1st, 3rd and 4th only 1st, 2nd and 4th only or 1st, 2nd, and 3rd (tied up in 3rd)
SSANGYONG Y200

Condition Harsh 2-3 shift Possible Causes Action
Jammed band 1 release valve. Faulty S3 or S2 solenoid. Faulty clutch apply regulator valve. Missing or damaged clutch apply feed ball. Damaged input shaft sealing rings. Damaged C1 piston O rings. Damaged or dislodged C1 piston bleedball. Faulty S1 or S4 solenoid. Jammed band 1 release valve. Incorrect front band adjustment. Damaged front servo piston O rings. Faulty or damaged variable pressure solenoid (S5). Faulty band apply regulator valve.
Inspect the release valve. Repair or replace as necessary. Inspect S3 or S2. Repair or replace as necessary. Inspect the regulator valve. Repair or replace as necessary. Inspect the ball. Refit or replace as necessary. Inspect the sealing rings. Refit or replace as necessary. Inspect the O rings. Refit or replace as necessary. Inspect the bleed ball. Refit or replace as necessary. Inspect S1 or S4. Repair or replace as necessary. Inspect the release valve. Repair or replace as necessary. Inspect the band. Adjust as necessary. Inspect the O rings. Refit or replace as necessary. Inspect S5. Repair or replace as necessary. Inspect the regulator valve. Repair or replace as necessary.
Harsh 3-4 shift
SSANGYONG Y200
SHIFT QUALITY FAULTS

Condition All Shifts Firm Possible Causes Action
Incorrect auto transmission fluid (ATF). S5 faulty won, or incorrectly fitted. Band apply and clutch apply regulator springs misplaced. Over-run Clutch (OC) /Low-1st ball misplaced. C4 clutch worn or burnt. C4 wave plate not lined up with the holes in the piston. S5 worn. Incorrect C4 pack clearance. Damaged C4 clutch. Cracked C2 piston (leaking into C4). Incorrect band adjustment Front servo plastic plug missing B1R spring broken. B1R spring/plug left out. C1/B1R ball misplaced. C1 clutch damaged. Restriction in C1 feed. C1 piston check ball jammed. Overdrive or input shaft sealing rings damaged. C1/B1R ball misplaced. Overdrive or input shaft sealing rings damaged. C1 clutch damaged. Rear band incorrectly adjusted or damage Low-1st check ball misplaced. 4-3 sequence valve in backwards. Low-1st check ball misplaced.
Drain and fill with specified ATF. Check that S5 is fitted correctly, or replace S5. Inspect band apply and clutch apply regulator springs. Refit or replace as necessary Inspect the ball. Refit or replace as necessary. Inspect C4 clutch. Replace or repair as necessary. Check the alignment. Realign as necessary. Inspect S5 and replace as necessary. Check the clearance and adjust as necessary. Inspect C4. Repair or replace as necessary. Inspect piston. Repair or replace as necessary. Inspect and adjust band as necessary. Replace the plug. Replace the spring. Replace the spring/plug. Refit the ball. Inspect the clutch. Repair the clutch as necessary. Inspect and clean C1 feed. Replace the piston. Inspect and replace the sealing rings and/or shaft as necessary. Inspect and replace the ball. Inspect and replace the sealing rings and/or shaft as necessary. Inspect and repair the C1 clutch as necessary. Inspect and adjust or replace rear band. Inspect and re-fit the ball. Refit the valve. Replace the ball.
Manual 4-3-2-1 is soft delayed or missing
Firm 1-2 Hot 4th Tied up
Tied up on 2-3
Flare on 2-3
Slips in 4th
Slips in reverse, no manual 1st
Flare on 4-3, Flare on 3-2 Firm Manual low shift-high line press.
SSANGYONG Y200

Condition Harsh 1-2 shift Possible Causes Action
Faulty inhibitor switch. Faulty throttle position sensor. Incorrect front band adjustment. Damaged front servo piston O rings. Faulty or damaged variable pressure solenoid (S5). Faulty S1 or S4 solenoid. Faulty Band Apply Regulator (BAR) valve. Misassembled front servo return spring. Jammed Converter Clutch Control Valve (CCCV). Faulty solenoid 7.
Check the resistance. Replace the inhibitor switch as necessary. Inspect and replace the sensor as necessary. Inspect and adjust the band as necessary. Inspect and replace the O rings as necessary. Inspect, repair or replace S5 as necessary. Inspect, repair or replace S1 or S4 as necessary. Inspect, repair or replace the BAR as necessary. Inspect and repair as necessary. Inspect and clean CCCV. Inspect, repair or replace as necessary.
Stalls when Drive Or Reverse Selected Shudder on Rolldown
SSANGYONG Y200
AFTER TEARDOWN FAULTS

Condition C2 burnt Possible Causes Action
Gear shift lever linkage out of adjustment. S6 foiled - stuck low. Overdrive/output shaft sealing rings damaged. C2 piston cracked.
Inspect, repair C2 and adjust the linkage as necessary. Repair C2. Inspect, repair or replace S6 as necessary. Repair C2. Inspect, replace the sealing rings and/or shaft as necessary. Repair C2. Inspect, repair or replace the C2 piston as necessary. Inspect C4 and repair as necessary. Inspect and adjust the C4 pack clearance as necessary. Repair C4. Inspect and realign the wave plate as necessary. Repair C4. Inspect and realign the sealing rings and/or shaft as necessary. Repair C4. Inspect and replace the C2 piston as necessary. Repair C4. Inspect and refit the ball as necessary. Inspect and repair B1 and replace the spring as necessary. Replace sealing ring. Repair B1. Refit the ball as necessary. Inspect and repair C1 and replace the spring. Repair C1. Inspect and replace the sealing tongs and/or shaft as necessary. Repair C1. Inspect and replace the C1 piston as necessary. Repair C1. Inspect and refit the capsule as necessary. Repair C1. Inspect and refit the valve as necessary. Repair C1. Inspect and replace the ball as necessary. Inspect and adjust the band as necessary. Inspect and refit the ball as necessary.
C4 burnt
Incorrect C4 pack clearance.

B1 burnt
C4 wave plate not lined up properly. Overdrive or output shaft sealing rings damaged. C2 piston cracked. Over-run Clutch (OC) /low-1st ball misplaced. B1R spring broken. Input shaft sealing ring cut. C1/B1R ball misplaced. B1R spring left out. Overdrive or input shaft sealing rings damaged. C1 piston cracked. Ball capsule jammed. 4-3 sequence valve in backwards. Clutch Apply Feed (CAF) /B1R ball left out. Rear band incorrectly adjusted or damaged. Reverse-low/first ball misplaced.
C1 burnt
B2 burnt (Slips in reverse - no manual 1st )
SSANGYONG Y200

Condition Firm converter lock or unlock Possible Causes Action
Input shaft 'O' ring missing or damaged. Converter clutch regulator valve in backwards. Input shaft 'O' ring missing or damaged. C1 bias valve in backwards.
Inspect and replace the 'O' ring as necessary. Inspect and refit the valve as necessary. Inspect and replace the 'O' ring as necessary. Inspect and refit the valve as necessary.
No lock up at light throttle
SSANGYONG Y200
BLANK
SSANGYONG Y200
TROUBLE CODE DIAGNOSIS - GASOLINE VEHICLE

TCM DIAGNOSTIC SYSTEM OVERVIEW
Notice: To prevent Transmission Control Module (TCM) damage. The ignition key must be OFF when disconnection or reconnection the power to the TCM (for example bttery cable, TCM pigtail connector, TCM fuse, jumper cables, etc.). When the TCM detects a system fault, a Diagnostic Trouble Code (DTC) is set in the TCM. This code is present while the fault conditions are met and is stored as a 'History DTC' until cleared. Condition for setting and clearing each TCM DTC are provided in the relevant sections. In the case where the vehicle type is certified for Eure On-Board Diagnostic (EOBD) compliance, the Engine Control Module (ECM) provides the communication link to the EOBD scan tool to pass on any EOBD relevant codes from the TCM. The table below contains a list of all supported DTCs and the classification of each for EOBD purposes. Where a type B DTC has been set in an EOBD vehicle, the response to the fault may include action by the ECM, including the illumination of the Malfunction lndicator Lamp (MIL). Refer to Section 1F, Engine Control, for details on EOBD system function, checks and fault clearing.
CLEARING TROUBLE CODES

TCM DTCs should be cleared after repairs have been completed. Some diagnostic tables will tell you to clear the codes before using the chart, which will help to find the cause of the problem more quickly. Always note the DTCs present before clearing - this information may be helpful in the diagnostic process."
DIAGNOSTIC TROUBLE CODES

DTC P0706 P0707 P0708 P0710 P0790 P1703 P1704 P1708 P1709 P1712 P1713 P1714 P1715 P1717 P1718 P1719 P1720 P1721 P1722 P1733 P1734 P1735 P1736 P1737 Description Transmission Range Sensor Circuit Range/Performance Transmission Range Sensor Circuit Low input Transmission Range Sensor Circuit High input Transmission Fluid Temperature Sensor Circuit Malfunction Normal/Performance Switch Circuit Malfunction Engine Speed Signal Error Shaft Speed Signal Error TCM Supply Voltage Low TCM Supply Voltage High Kickdown Switch Circuit Malfunction Pedal Signal Error EEPROM Vehicle Code Error VPS Offset Error RAM Error ROM Error CAN Bus Error EEPROM Error Throttle Signal Error Vehicle Type Determination Error Solenoid 1 Circuit Open Solenoid 2 Circuit Open Solenoid 3 Circuit Open Solenoid 4 Circuit Open Solenoid 5 Circuit Open Type B B B D D D D D D D D D D D D D D D D D D D D D
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-51 DIAGNOSTIC TROUBLE CODES (Cont'd)

DTC P1738 P1739 P1741 P1742 P1743 P1744 P1745 P1746 P1747 Solenoid 6 Circuit Open Solenoid 7 Circuit Open Solenoid 1 Circuit Short Solenoid 2 Circuit Short Solenoid 3 Circuit Short Solenoid 4 Circuit Short Solenoid 5 Circuit Short Solenoid 6 Circuit Short Solenoid 7 Circuit Short Description Type D D D D D D D D D
DTC Types
Each DTC is directly related to a diagnostic test. The Diagnostic management system sets DTCs based on the failure of the tests during a driving cycle or cycles. The following are the two types of DTCs and the characteristics of those codes; Type B Emissions related. EOBD system "Armed" after one driving cycle with a fail. EOBD system "Disarmed" after one driving cycle with a pass. Illuminates the MIL on the second con-secutive driving cycle with a fail.
TCM stores a history DTC on the first driving cycle with a fail. EOBD system stores a history DTC on the second consecutive driving cycle with a fail, (the DTC will be armed after the first fail). EOBD system stores a freeze frame on the second consecutive driving cycle with a fail, (if empty).
Type D Non-Emissions related. Does not request illumination of any lamp. Stores a history DTC on the first driving cycle with a fail. EOBD system does not store a freeze frame.
SSANGYONG Y200
TROUBLE CODE DIAGNOSIS - DIESEL VEHICLE

TCM DIAGNOSTIC SYSTEM OVERVIEW
Notice: To prevent Transmission Control Module (TCM) damage. The ignition key must be OFF when disconnection or reconnection the power to the TCM (for example bttery cable, TCM pigtail connector, TCM fuse, jumper cables, etc.). When the TCM detects a system fault, a Diagnostic Trouble Code (DTC) is set in the TCM. This code is present while the fault conditions are met and is stored as a 'History DTC' until cleared. Condition for setting and clearing each TCM DTC are provided in the relevant sections.
CLEARING TROUBLE CODES

TCM DTCs should be cleared after repairs have been completed. Some diagnostic tables will tell you to clear the codes before using the chart, which will help to find the cause of the problem more quickly. Always note the DTCs present before clearing - this information may be helpful in the diagnostic process."

DTC P0707 P0708 P0710 P0790 P1703 P1704 P1708 P1709 P1710 P1712 P1714 P1715 P1716 P1717 P1718 P1720 P1721 P1722 P1733 P1734 P1735 P1736 P1737 P1738 P1739 P1741 P1742 P1743 P1744 Description Transmission Range Sensor Circuit Low Input Transmission Range Sensor Circuit High Input Transmission Fluid Temperature Sensor Circuit Malfunction Normal/Performance Switch Circuit Malfunction Engine Speed Signal Error Shaft Speed Signal Error TCM Supply Voltage Low TCM Supply Voltage High Air Conditioning Switch Circuit Malfunction Kickdown Switch Circuit Malfunction EEPROM Vehicle Code Error VPS Offset Error Throttle Not Learnt Error RAM Error ROM Error EEPROM Error Throttle Signal Error Vehicle Type Determination Error Solenoid 1 Circuit Open Solenoid 2 Circuit Open Solenoid 3 Circuit Open Solenoid 4 Circuit Open Solenoid 5 Circuit Open Solenoid 6 Circuit Open Solenoid 7 Circuit Open Solenoid 1 Circuit Short Solenoid 2 Circuit Short Solenoid 3 Circuit Short Solenoid 4 Circuit Short
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-53 DIAGNOSTIC TROUBLE CODES (Cont'd)

DTC P1745 P1746 P1747 Solenoid 5 Circuit Short Solenoid 6 Circuit Short Solenoid 7 Circuit Short Description
SSANGYONG Y200
YAD5A010
TCM DIAGNOSTIC SYSTEM CHECK

Circuit Description The Transmission Control Module (TCM) Diagnistic System Check is the starting point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/ physical check of the Transmission Control Module (TCM) and the transmission grounds for cleanliness and tightness. The TCM Diagnostic System Check is an organized approach to identifying a problem created by an electronic transmission control system malfunction. Diagnostic Aids An intermittent fault may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the TCM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
TCM Diagnostic System Check

Step 1 2. 3. 4. Action Turn the ignition OFF. Install the scan tool. Turn the ignition ON, with the engine OFF. Attempt to display the Transmission Control Module (TCM) Data List with the scan tool. Does the scan tool display the TCM data? Select the Trouble Code with the scan tool. Are any Diagnostic Trouble Codes (DTCs) stored? Value(s) Yes No
Go to Step 2 Go to applicable DTC table
Go to Step 3 System OK, Check Complete
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-55 TCM Diagnostic System Check (Cont'd)

Step 1. 2. 3. 4. 3 Action Turn the ignition OFF. Disconnect the TCM connector B. Turn the ignition ON. Check the serial data line from TCM connector terminal A22 to Data Link Connector (DLC) connector terminal 14 for an open, short to ground, or short to voltage. Also, check the DLC ignition feed circuit for an open or short to ground and the DLC ground circuit for an open. Is a problem found? Repair the open, short to ground or short to voltage in the serial data circuit or the DLC ignition feed circuit or the DLC ground circuit. Is a repair complete? Check the TCM ignition feed circuit for an open or short to ground and the TCM ground circuit for an open. Is a problem found? Repair the open or short to ground in the TCM ignition feed circuit or the TCM ground circuit. Is a repair complete? 1. Turn the ignition OFF. 2. Disconnect the TCM connector. Value(s) Yes No
Go to Step 4
Go to Step 5
Go to Step 1
Go to Step 6
Go to Step 7
Go to Step 1
Go to Step 1
SSANGYONG Y200
YAD5A020
DIAGNOSTIC TROUBLE CODE (DTC) P0706 TRANSMISSION RANGE SENSOR CIRCUIT RANGE/PERFORMANCE
Circuit Description The Transmission Range (TR) sensor is incorporated in the inhibitor switch mounted on the side of the transmis-sion case. The TR sensor Indicates to the TCM which gear position has been selected by way of a varying resistance. The TR sensor signal has discrete values indicating the positions selected by the gear shift control lever (PRND321). The Transmission Control Module (TCM) re-ceives that signal with a voltage varying from 0 V to 5 V. DTC P0706 sets when the TR sensor signal is not feasi ble. Conditions for Setting the DTC The engine temperature is greater than 60 C (140 F). The engine speed is greater than 2000 RPM and less than 4000 RPM. Engine load is greater than 60 %. DTCs P0707, P0708, P1703 and P1719 are not set. Transmission temperature is greater than 0 C (32 F) or if P0710 is present the engine coolant temperature is greater than 60 C (140 F). The TR sensor indicates that the transmission is in a neutral state, however the engine output torque indicates that a drive gear load is present. This condition must be continuously present for 5 seconds. Action Taken When the DTC Sets The Malfunction Indicator Lamp (MIL) will illuminate on the second consecutive driving cycle with the DTC present. The EOBD system will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. TR signal is assumed to be in the Drive position. The transmission is limited to 2nd and R gears only. Namely 1st, 3rd and 4th gears are inhibited. Torque Converter Clutch (TCC) is disabled. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds and TR is in P, R, N or D. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM and at the TR sensor connector. Look for possible bent, backed out, deformed or damaged ter-minals. Check for weak terminal tension as well. Also, check for chafed wires that could short to bare metal or other wiring. Inspect for broken wires inside the in-sulation.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-57 DTC P0706 Transmission Range Sensor Circuit Range/Performance
Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P0706? 1. Select Gear Lever Position on scan tool Data List. 2. Move the gear shift control lever through all of the gear ranges (P, R, N, D, 3, 2, 1). Does the scan tool display the correct gear lever positions? 1. Inspect the TR sensor for damage to its rotating part or its mountings. 2. Inspect the shaft driving the TR sensor for damage. Is a repair necessary? Replace the TR sensor or driving shaft as appropriate. Is the acting complete? Check for damage to the z-link within the transmission and repair as necessary. Is a repair necessary? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to "Diagnostic Aids"
Go to Step 6
Go to Step 4
Go to Step 6 -
5 6
Go to Step 7
SSANGYONG Y200
YAD5A020
DIAGNOSTIC TROUBLE CODE (DTC) P0707 TRANSMISSION RANGE SENSOR CIRCUIT LOW INPUT
Circuit Description The Transmission Range (TR) sensor is incorporated in the inhibitor switch mounted on the side of the transmis sion case. The TR sensor Indicates to the TCM which gear position has been selected by way of a varying resistance. The TR sensor signal has discrete values indicating the positions selected by the gear shift control lever (PRND321). The Transmission Control Module (TCM) receives that signal with a voltage varying from 0 V to 5 V. DTC P0707 sets when the TR sensor signal is faulty, causing the gear lever position signal to be less than 0.87 V. Conditions for Setting the DTC TR sensor signal is less than 0.87 V. The above condition must be continuously present for 100 milliseconds. Action Taken When the DTC Sets The Malfunction Indicator Lamp (MIL) will illuminate on the second consecutive driving cycle with the DTC present. The EOBD system will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Transmission range is assumed to be in the Drive position. The transmission is limited to 2nd and R gears only. Namely 1st,3rd and 4th gears are inhibited. Torque Converter Clutch (TCC) is disabled. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 3 seconds. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids The voltage measured by the TCM across the TR sensor input terminals has been below on acceptable level for a significant length of time. This would typically be caused by a short to ground in the wiring to, or within, the inhibitor switch which has caused the signal at the TCM to read about 0 V. Inspect the wiring for poor electrical connections at the TCM and at the TR sensor connector. Look for possible bent, deformed or damaged terminals. Also, check for chafed wires that could short to bare metal or other wiring. In searching for a possible intermittent short or open condition, move or massage the wiring harness while observing the test equipment for a change. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. This step simulates a DTC P0708 condition. If the scan tool displays the specified value, the TR sensor signal circuit and the TCM are OK.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-59 DTC P0707 Transmission Range Sensor Circuit Low Input
Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Turn the ignition ON, with the engine OFF. 2. Install a scan tool. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. 5. Review the TR Sensor value on the scan tool. Is the TR Sensor value less than the specified value? 1. Turn the ignition OFF. 2. Disconnect the Transmission Range (TR) sensor connector. 3. Turn the ignition ON. Is the TR Sensor value greater than specified value? Replace the TR sensor. Is the action complete? With a test light connected to B+, probe the TR sensor signal circuit at terminal 2. Does the test light illuminate? 1. Turn the ignition OFF. 2. Disconnect the Transmission Control Module (TCM) connector B. 3. Turn the ignition ON. 4. With a test light connected to B+, probe the TR sensor signal circuit at terminal 2. Does the test light illuminate? Repair the short to ground in the TR sensor signal circuit. Is a repair complete? Check for a poor connection at the TR sensor connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or DTC previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
0.87 V
Go to Step 3
4.12 V -
Go to Step 5 -
4 5
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 9
Go to Step 10
Go to Step 10
Go to Step 10
10
Go to Step 11 Go to applicable DTC table System OK, Check Complete
11
SSANGYONG Y200
YAD5A020
DIAGNOSTIC TROUBLE CODE (DTC) P0708 TRANSMISSION RANGE SENSOR CIRCUIT HIGH INPUT
Circuit Description The Transmission Range (TR) sensor is incorporated in the inhibitor switch mounted on the side of the transmission case. The TR sensor Indicates to the TCM which gear position has been selected by way of a varying resistance. The TR sensor signal has discrete values indicating the positions selected by the gear shift control lever (PRND321). The Transmission Control Module (TCM) receives that signal with a voltage varying from 0 V to 5 V. The transmission range sensor is faulty, causing the gear lever position signal to be greater than 4.12 V. Conditions for Setting the DTC TR sensor signal is greater than 4.12 V. The above condition must be continuously present for 100 milliseconds. Action Taken When the DTC Sets The Malfunction Indicator Lamp (MIL) will illuminate on the second consecutive driving cycle with the DTC present. The EOBD system will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Transmission range (gear lever) is assumed to be in the Drive position. The transmission is limited to 2nd and R gears only. Namely 1st,3rd and 4th gears are inhibited. Torque Converter Clutch (TCC) is disabled. Manually initiated downshifts will not be available. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 3 seconds. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids The voltage measured by the TCM across the shift lever input terminals has been above an acceptable level for a significant length of time. This would typically be caused by a loose connection or an open or short to B+ in the wiring to, or within, the inhibitor switch which has caused the signal at the TCM to read 5 V. If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw. Inspect the wiring for poor electrical connections at the TCM and at the TR sensor connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also, check for chafed wires that could short to other wiring. Inspect for broken wires inside the insulation. In searching for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.
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Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 4. This step simulates a DTC P0707 condition. If the scan tool displays the specified value, the TR sensor signal circuit and the TCM are OK.
DTC P0707 Transmission Range Sensor Circuit High Input

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Turn the ignition ON, with the engine OFF. 2. Install a scan tool. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. 5. Review the TR Sensor value on the scan tool. Is the TR Sensor value greater than the specified value? 1. Turn the ignition OFF. 2. Disconnect the Transmission Range (TR) sensor connector. 3. Turn the ignition ON. 4. With a test light connected to ground, probe the TR sensor signal circuit at terminal 2. Is the TR sensor value less than specified value? With a test light connected to B+, probe the TR sensor ground circuit at terminal 1. Does the test light illuminate? Check for a poor connection at the TR sensor connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Replace the TR sensor. Is the action complete? 1. Turn the ignition OFF. 2. Disconnect the Transmission Control Module (TCM) connector B. 3. Check the TR sensor signal circuit at terminal 1 for an open or short to voltage and repair as necessary. Is a repair necessary? Check the TR sensor ground circuit at terminal 1 for an open and repair as necessary. Is a repair necessary? Check for a poor connection at the TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
4.12 V
Go to Step 3
0.87 V
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 8
5 6
Go to Step 6 -
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
10
Go to Step 11
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5A-62 AUTOMATIC TRANSMISSION DTC P0707 Transmission Range Sensor Circuit High Input (Cont'd)
Step Action 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or DTCs previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
11
12
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BLANK
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YAD5A030
DIAGNOSTIC TROUBLE CODE (DTC) P0710 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT MALFUNCTION
Circuit Description The Transmission Fluid Temperature (TFT) sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission. This sensor is a typical Negative Temperature Coefficient (NTC) resistor with low temperatures producing a high resistance and high temperatures producing a low resistance. If the transmission fluid temperature exceeds 135 C (275 F), the TCM will impose converter lock-up at lower vehicle speeds. Favour a lower gear to increase engine speed, and in some vehicles flashes the mode indicator lamp. This results in maximum oil flow through the external oil cooler and eliminates slippage in the torque converter. Both these actions combine to reduce the oil temperature in the transmission. The DTC P0710 sets when the TFT sensor signal is not feasible. Conditions for Setting the DTC Transmission fluid temperature sensor signal is greater than 4.88 volts (immediate detection). Transmission fluid temperature sensor signal is less than 0.21 volts (immediate detection). Transmission temperature has not changed by 2 C in 15 minutes since ignition on and temperature is less than 20 C or greater than 125 C. Action Taken When the DTC Sets Conditions for Clearing the DTC The DTC will clear when the malfunction has not oc curred for 3 seconds. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids The voltage measured by the TCM across the transmission fluid temperature input terminals has been outside acceptable levels. If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also, check for chafed wires that could short to bare metal or other wiring. Inspect for broken wires inside the insulation. In searching for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 5. This step simulates a DTC P0710 condition. If the scan tool displays the specified value, the TFT sensor signal circuit and the TCM are OK.
Transmission fluid temperature is assumed to be 120 C (248 F). All shifts will be firm until the transmission has warmed up because a high transmission fluid temperature is assumed.
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AUTOMATIC TRANSMISSION 5A-65 DTC P0710 Transmission Fluid Temperature Sensor Circuit Malfunction
Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Select T/M Fluid Temperature on scan tool Data List. Is the TFT sensor value less than specified value? Is the TFT sensor value greater than specified value? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
0.21 V
Go to Step 4
Go to Step 3 Go to "Diagnostic Aids"
3 4.88 V 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector (additional DTCs will set). 3. Turn the ignition ON. Is the TFT sensor value greater than the specified value? 1. Turn the ignition OFF. 2. Disconnect the TCM connector B. 3. Turn the ignition ON. 4. With a test light connected to B+, probe the TFT sensor signal circuit, terminal 9 at the 10-way transmission connector. Does the test light illuminate? Replace the TFT sensor. Is the action complete? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector (additional DTCs will set). 3. Turn the ignition ON. 4. Jumper the TFT ground circuit terminal 10 to the TFT sensor signal circuit terminal 9 at the 10-way transmission connector. Is the TFT sensor value less than specified value? Repair the short to ground in the TFT sensor signal circuit as necessary. Is the repair complete? With a test light connected to B+, probe the TFT sensor ground circuit at terminal 10 at the 10-way transmission connector. Does the test light illuminate? 1. Turn the ignition OFF. 2. Disconnect the TCM connector B. 3. Turn the ignition ON. 4. Check the TFT sensor signal circuit, terminal 9 at the 10-way transmission connector for an open or short to voltage. Is a problem found? Go to Step 7
4.88 V
Go to Step 6
Go to Step 5
Go to Step 14 -
0.21 V
Go to Step 6
Go to Step 9
Go to Step 16
Go to Step 10
Go to Step 11
10
Go to Step 13
Go to Step 14
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5A-66 AUTOMATIC TRANSMISSION DTC P0710 Transmission Fluid Temperature Sensor Circuit Malfunction (Cont'd)
Step Action 1. Turn the ignition OFF. 2. Disconnect the TCM connector B. 3. Turn the ignition ON. 4. Check the TFT sensor ground circuit for an open. Is a problem found? Repair the TFT ground circuit for an open. Is a repair complete? Repair an open or short to voltage in the TFT sensor signal circuit as necessary. Is the repair complete? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 3 that have not been diagnosed? Value(s) Yes No
11
Go to Step 14 -
12 13
Go to Step 16
14
Go to Step 16
Go to Step 15
15
Go to Step 16
16
17
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BLANK
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YAD5A040
DIAGNOSTIC TROUBLE CODE (DTC) P0790 NORMAL/PERFORMANCE SWITCH CIRCUIT MALFUNCTION

Circuit Description The driving mode selector switch is located on the center console and allows the driver to select the driving mode. When NORMAL mode is selected upshifts will occur to maximize fuel economy. When POWER mode is selected, upshifts will occur to give maximum performance and the POWER mode indicator light is switched ON. When WINTER mode is selected, starting in second gear is facilitated, the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF. The DTC P0790 sets when an intermittent connection in the mode selector switch (mode switch) circuit has been detected. The mode switch input is rapidly changing states. The switching frequency is greater than 8.3 Hz. Conditions for Setting the DTC The mode switching frequency is greater than 8.3 Hz. The above condition must be continuously present for 4 state changes. Action Taken When the DTC Sets All shifts will occur as if the mode is set to NORMAL. The mode indicator will always be OFF indicating that NORMAL mode is selected. The mode indicator will not respond to the changes in switch setting. Conditions for Clearing the DTC The DTC will clear after 3 seconds without the fault. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids This fault is caused by too many changes in the mode input signal over a period of time. Typical causes would be an intermittent connection in the switch or wiring or an intermittent short to ground in the wiring. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Check mode switch signal circuit for an intermittent open / short 5. Check mode switch ground circuit for an intermittent open / short 8. Check mode switch feed circuit for an intermittent open / short
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AUTOMATIC TRANSMISSION 5A-69 DTC P0790 Normal/Performance Switch Circuit Malfunction

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P0790? 1. Turn the ignition OFF. 2. Disconnect the mode switch connector. Refer to Shift Control Lever in this section. 3. Turn the ignition ON. 4. Select Mode Switch on scan tool Data List. Is the Mode Switch value frequently changing? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Check the mode switch signal circuit for an intermittent open or short and repair as necessary. Is a repair necessary? Jumper the mode switch ground terminal 5 to the signal terminal 10. Is the Mode Switch value frequently changing? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Check the mode switch ground circuit for an intermittent open and repair as necessary. Is a repair complete? Check the fuse F4 for a malfunctioning and replace as necessary? Is a repair necessary? Jumper the mode switch feed terminal 11 to the signal terminal 10. Is the Mode Switch value frequently changed? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Check the mode switch feed circuit for an intermittent open and repair as necessary. Is a repair complete? Check for a poor connection at the mode switch and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 13
Go to Step 10
Go to Step 6
Go to Step 7
Go to Step 13
Go to Step 13
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 13
10
Go to Step 13
Go to Step 12
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5A-70 AUTOMATIC TRANSMISSION DTC P0790 Normal/Performance Switch Circuit Malfunction (Cont'd)
Step 11 Action Replace the mode switch. Refer to Shift Control Lever in this section. Is the action complete? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 13
12
Go to Step 13
13
14
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BLANK
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YAD5A010
DIAGNOSTIC TROUBLE CODE (DTC) P1703 ENGINE SPEED SIGNAL ERROR

Circuit Description The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator position etc. from ECM via CAN without any additional sensors. The DTC P1703 sets when the engine speed signal via CAN is out of range or not feasible: The engine speed signal is greater than 7000 rpm or less than 0 rpm, or the indicated engine speed is low while other signals indicate the car is moving (i.e. the vehicle speed has increased more than 125 rpm). Conditions for Setting the DTC Immediately upon the test indicating malfunction as follows. The engine speed signal is greater than 7000 rpm or less than 0 rpm under the precondition that DTC P1719 is not set. The indicated engine speed is low while other signals indicate the car is moving, i.e. the vehicle speed has increased more than 125 rpm under the following precondition; - Driving gear is selected. - The applied throttle is greater than 5 %. - The engine speed is less than 550 rpm. - DTCs P0706, P0707, P0708, P1704, P1719 and 1721 are not set. Action Taken When the DTC Sets Fault detection of some other signals will not possible. Conditions for Clearing the DTC The DTC will clear after 30 seconds without the fault. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM and ECM connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. When ECM finds a fault on the engine speed signals, ECM will adopt a default mode and send the default value and trouble message to TCM via CAN. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Check if there are any DTCs related to the engine speed sensor on the ECM side. 4. Check for a poor connection at the ECM and TCM connectors.
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AUTOMATIC TRANSMISSION 5A-73 DTC P1703 Engine Speed Signal Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1703? Check if there are any DTCs related to the engine speed sensor on the ECM side. Are any DTCs related to engine speed sensor found? Check for a poor connection at the ECM connector or TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3 Go to Section 1F, Engine Controls
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
SSANGYONG Y200
YAD5A010
DIAGNOSTIC TROUBLE CODE (DTC) P1704 SHAFT SPEED SIGNAL ERROR

Circuit Description The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator position etc. from ECM via CAN without any additional sensors. The DTC P1704 sets when the indicated drive shaft speed signal via CAN is out of range or not feasible or a shaft speed of 0 is present while other signals indicate the vehicle is being driven. Conditions for Setting the DTC Immediately upon the test indicating malfunction as follows. The shaft speed signal is greater than 9000 rpm or less than 0 rpm under the precondition that DTC P1719 is not set. The shaft speed indicates 0 rpm while all other signals indicate the car is moving under the following precondition; - Driving gear is selected. - The transmission range sensor has not recently changed state. - The engine speed is greater than 2800 rpm. - DTCs P0706, P0707, P0708, P1703 and P1719 are not set. The shaft speed has dropped from above 2100 rpm to 0 rpm within 20ms. Action Taken When the DTC Sets All skip downshifts disabled and fourth gear will be in-hibited. The torque converter will be unlocked at all times. Gears are selected by the shift control lever but all downshifts are inhibited by engine speed limits to prevent over-revving. D position selects 3rd gear. 1st and 2nd gears can be manually selected. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds and a non-zero speed is detected. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM and ECM connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation.
SSANGYONG Y200
If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. When ECM finds a fault on the vehicle speed signals, ECM will adopt a default mode and send the default value and trouble message to TCM via CAN.
Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Check if there are any DTCs related to the vehicle speed sensor on the ECM side. 4. Check a poor connection at the ECM and TCM connectors.
DTC P1704 Shaft Speed Signal Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1704? Check if there are any DTCs related to the vehicle speed sensor on the ECM side. Are any DTCs related to vehicle speed sensor found? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 4
Go to Step 5
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YAD5A010
DIAGNOSTIC TROUBLE CODE (DTC) P1708 TCM SUPPLY VOLTAGE LOW

Circuit Description The battery voltage monitoring input is connected to the positive side of the battery. This signal is taken from the main supply to the TCM. If the battery voltage at the TCM falls below the threshold value, DTC P1708 will be set and the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited. All other shifts are attempted but may not occur because of the reduced voltage. This condition normally occurs only when the battery is in poor condition. When system voltage recovers, the TCM will resume normal operation after a 30 seconds delay period. Conditions for Setting the DTC The engine speed is greater than 550 RPM. A driving gear is selected or one of DTCs P0706, P0707 and P0708 is set. The indicated supply voltage falls below a linear temperature characteristic threshold or below that required to operate the CPU. If the TCM measures the supply voltage at less than that required for it to be operating, the DTC sets immediately. Action Taken When the DTC Sets 1st gear is inhibited. S6 is inhibited. S5 standby current is zero. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids The minimum operating voltage depends on the transmission temperature but is typically between 8-9 V for a warm transmission. If the DTC sets when an accessory is operated, check for a poor connection. Look for possible bent, backed out, deformed or dam-aged terminals. Check for weak terminal tension as well. Also, check for chafed wires that could short to bare metal or other wiring. Inspect for broken wires inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 4. Check if the generator is malfunctioning under load condition. 8. Check the ignition feed circuit for excessive resistance.
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AUTOMATIC TRANSMISSION 5A-77 DTC P1708 TCM Supply Voltage Low

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1708? 1. Isolate the driven wheels from the ground and apply the hand brake. 2. Start the engine and allow it to idle. 3. Move the gear lever to Drive. 4. Select the Ignition Voltage on the scan tool Data List. Is the Ignition Voltage less than the specified value? While running the engine at the specified value, measure the battery voltage at the battery using a DVM. Is the battery voltage greater than the specified value? Check the fuse F4 for a malfunction and replace as necessary? Is a repair necessary? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Start the engine and raise the engine speed to specified value. 4. While running the engine at the specified value, measure the ignition voltage at the ignition feed circuit terminal A30 using a DVM. Is the ignition voltage greater than the specified value? Check for a malfunctioning connection at the TCM harness terminals and repair as necessary. Is a repair necessary? Repair the poor connection (high resistance) at the ignition feed circuit. Is the action complete? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
10 V Idle in Drive 12 V
Go to Step 4
Go to Step 10 Go to Section 1E, Engine Electrical
Go to Step 5
Go to Step 10
Go to Step 6
Idle in Drive 10 V
Go to Step 7
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 10
Go to Step 10
10
11
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YAD5A010
DIAGNOSTIC TROUBLE CODE (DTC) P1709 TCM SUPPLY VOLTAGE HIGH

Circuit Description The battery voltage monitoring input is connected to the positive side of the battery. This signal is taken from the main supply to the TCM. If the battery voltage is greater than 16.5 V, DTC P1709 will be set and the transmission will adopt limp home mode and all solenoids are turned OFF. Conditions for Setting the DTC The indicated supply voltage is greater than 16.5 V. The malfunction triggers immediately after this condi-tion exists. Action Taken When the DTC Sets All solenoids are turned OFF while the high battery voltage condition is detected. The transmission goes into Limp Home Mode (LHM). Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids The voltage measured by the TCM corresponding to the battery supply voltage has been outside the range of the maximum operating voltage of 16.5 V. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also, check for chafed wires that could short to bare metal or other wiring. Inspect for broken wires inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 4. Checks if the generator is malfunctioning under load conditions. 5. Check connection of other connectors.
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AUTOMATIC TRANSMISSION 5A-79 DTC P1709 TCM Supply Voltage High

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1709? 1. Start the engine and raise the engine speed to the specified value. 2. Select the Ignition Voltage on the scan tool Data List. Is the Ignition Voltage greater than the specified value? While running the engine at the specified value, measure the battery voltage at the battery using a DVM. Is the battery voltage less than the specified value? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Start the engine and raise the engine speed to the specified vale. 4. While running the engine at the specified value, measure the ignition voltage at the ignition feed circuit terminal A30 with respect to the ground terminal A14. Is the ignition voltage greater than the specified value? Check the wiring harness from the fuse F4 to TCM terminal A30 and from the ground G208 to TCM terminal A14 for damage. 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
1500 rpm 16.5 V 2000 rpm 16.5 V
Go to Step 4
Go to Step 8 Go to Section 1E, Engine Electrical
Go to Step 5
1500 rpm 16.5 V
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 8
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YAD5A190
DIAGNOSTIC TROUBLE CODE (DTC) P1710 AIR CONDITIONING SWITCH CIRCUIT MALFUNCTION
Circuit Description The Air Conditioning Switch circuit indicates the state of the air conditioning compressor clutch (on or off). This signal is available to the TCM only on vehicles fitted with air conditioning. The DTC 1710 sets when an intermittent connection in the air conditioning switch circuit has been detected. The switch input is rapidly changing states and the switching frequency is greater than 8.3 Hz. Conditions for Setting the DTC The mode switching frequency is greater than 8.3 Hz. The above condition must be continuously present for 4 state changes. Action Taken When the DTC Sets The TCM does not compensate for torque variation due to air conditioning compressor clutch activation. Conditions for Clearing the DTC The DTC will clear after 3 seconds without the fault. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids This fault is caused by too many changes in the mode input signal over a period of time. Typical causes would be an intermittent connection in the switch or wiring or an intermittent short to ground in the wiring.
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AUTOMATIC TRANSMISSION 5A-81 DTC P1710 Air Conditioning Switch Circuit Malfunction
Step 1 Action Perform a TCM Diagnostic System Check. Is the check performed? 1. 2. 3. 4. Install the scan tool. Turn the ignition ON, with the engine OFF. Record and then clear DTCs. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1710. 1. Turn the ignition OFF. 2. Disconnect the air conditioning compressor relay connector. 3. Turn the ignition ON. 4. Select Air Conditioning Compressor Switch on scan tool Data List. Is the value frequently changing? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Check the air conditioning compressor signal circuit for an intermittent open or short and repair as necessary. Is a repair necessary? 1. Jumper the air conditioning compressor relay connector terminal 30 and 87. 2. Turn the air conditioning switch ON. Is the air conditioning compressor switch value frequently changing? 1. Turn the ignition OFF. 2. Disconnect the TCM connector B. 3. Check the air conditioning compressor signal circuit for an intermittent open and repair as necessary. Is a repair complete? Check the fuse Ef3 for a malfunctioning and replace as necessary? Is a repair necessary Check for a poor connection at the air conditioning compressor relay and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Replace the air conditioning compressor relay. Is the action complete? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? Go to Step 2 Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 11
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 11
Go to Step 11
Go to Step 9
Go to Step 10 -
10
Go to Step 11
SSANGYONG Y200
5A-82 AUTOMATIC TRANSMISSION DTC P1710 Air Conditioning Switch Circuit Malfunction (Contd)
Step Action 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
11
12
SSANGYONG Y200
BLANK
SSANGYONG Y200
YAD5A050
DIAGNOSTIC TROUBLE CODE (DTC) P1712 KICKDOWN SWITCH CIRCUIT MALFUNCTION

Circuit Description The Kickdown Switch is used to signal the TCM that the driver requires kickdown indicating the driver pressed the accelerator to the floor. When this switch is used in high range non-winter mode driving, the POWER light comes ON. The DTC sets when the kickdown switch has an intermittent connection or is stuck ON. Kickdown Switch is closed when other signals indicate otherwise, i.e. the accelerator pedal is released and the engine is running. Or the switch is cycling open/closed more rapidly than the normal operation allows. Conditions for Setting the DTC DTCs P1703, P1713 and P1719 are not set. Kickdown Switch is closed when other signals indicate otherwise, i.e. the accelerator pedal is released and the engine is running. The switch is cycling open/closed more rapidly than normal operation allows : 10 state changes in less than 30 milliseconds. Action Taken When the DTC Sets Kickdown Switch feature is disabled while the fault exists. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds.
A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool.
Diagnostic Aids Typical causes would be an short circuit within the switch, or a short circuit to ground in the wiring to the switch. Inspect the wiring for poor electrical connections at the TCM and at the Kickdown Switch connector. Look for possible bent, backed out, deformed or damagednterminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 4. Checks if the kickdown signal circuit is malfunctioning. 7. Checks if the kickdown ground circuit is malfunctioning. 8. Check resistance between Kickdown Switch terminal 4 and 2. 12. Check connections of other connectors.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-85 DTC P1712 Kickdown Switch Circult Malfunction

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Select the Kickdown Switch on the scan tool. Is the Kickdown Switch value frequently changed ON/ OFF or continuously ON? Push the accelerator pedal fully to the Kickdown Switch. Is the Kickdown Switch value frequently changed OFF/ON? 1. Turn the ignition OFF. 2. Disconnect the Kickdown Switch connector. Refer to the Kickdown Switch in this section. 3. Turn the ignition ON, with the engine OFF. Is the Kickdown Switch value frequently changed ON/ OFF or continuously ON? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Check the Kickdown Switch signal circuit from Kickdown Switch connector terminal 1 to TCM terminal A3 for a short to ground. Is a short to ground found? Repair the short to ground or an open in the Kickdown Switch signal circuit. Is the action complete? 1. Turn the ignition OFF. 2. Disconnect the Kickdown Switch connector. Refer to the Kickdown Switch in this section. 3. With a test light connected to B+, probe the Kickdown Switch ground circuit, terminal 2. Does the test light illuminate? Check the resistance between Kickdown Switch terminal 1 and 2 when pushing the switch and not pushing. Is the resistance within the specified value? Replace the Kickdown Switch. Is the action complete? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Check the Kickdown Switch signal circuit from Kickdown Switch connector terminal 1 to TCM terminal A3 for an open. Is an open founded? Repair the open in the Kickdown Switch ground circuit. Is the action complete? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 4
Go to Step 7
Go to Step 3 Go to "Diagnostic Aids"
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 14
Go to Step 15
Push: less than 5 No push: Open Loop -
Go to Step 10 Go to "Diagnostic Aids" Go to Step 15
Go to Step 11
Go to Step 9 -
10
Go to Step 12 -
11
SSANGYONG Y200
5A-86 AUTOMATIC TRANSMISSION DTC P1712 Kickdown Switch Circult Malfunction (Cont'd)
Step Action Check for a poor connection at the Kickdown Switch connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Check the resistance between kickdown switch terminal 1 and 2 when pushing the switch. Is the resistance within the specified value and steady? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
12
Go to Step 15
Go to Step 13
13
less than 5
Go to Step 14
Go to Step 9
14
Go to Step 15
15
16
SSANGYONG Y200
BLANK
SSANGYONG Y200
YAD5A010
DIAGNOSTIC TROUBLE CODE (DTC) P1713 PEDAL SIGNAL ERROR

Circuit Description The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator pedal position etc. from ECM via CAN without any additional sensors. The DTC P1713 sets when the accelerator pedal signal via CAN is out of range. The accelerator pedal signal is greater than 254 steps. Conditions for Setting the DTC DTCs P1719 is not set. The accelerator pedal signal is greater than 254 steps. The malfunction is triggered immediately after this condition exists. Action Taken When the DTC Sets 4th gear is inhibited. Torque Converter Clutch (TCC) is inhibited. Default value is adopted for shift point decisions. Accelerator pedal is not used for P, R, or N B2 activation decisions. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds.
Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM and ECM connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. When ECM finds a fault on the accelerator pedal signals, ECM will adopt a default mode and send the default value and trouble message to TCM via CAN. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Check if there are any DTCs related to the accelerator pedal sensor on the ECM side. 4. Check for a poor connection at the ECM and TCM connectors.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-89 DTC P1713 Pedal Signal Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1713? Check if there are any DTCs related to the accelerator pedal sensor on the ECM side. Are any DTCs related to accelerator pedal sensor found? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 4
Go to Step 5
SSANGYONG Y200
DIAGNOSTIC TROUBLE CODE (DTC) P1714 EEPROM VEHICLE CODE ERROR

System Description The Electrically Erasable Programmable Read-Only Memory (EEPROM) is a permanent memory chip that is physically soldered within the Transmission Control Module (TCM) The EEPROM contains the program and the calibration information required for transmission and transmission diagnostics operation. The DTC P1714 sets when the vehicle ID stored in EEPROM is out of range when checked on initialization. The EEPROM Vehicle identification Number (VIN) value does not lie within the range 0-13. Conditions for Setting the DTC DTC P1720 is not set. The vehicle type is not recognized. The EEPROM Vehicle Identification Number (VIN) value does not lie within the range 0-13. The malfunction is triggered immediately after this condition exists. Action Taken When the DTC Sets If CAN is detected, OBD N32D VIN is selected. Or If CAN is not detected, P29 STi VIN is selected. Shift quality may by degraded. Conditions for Clearing the DTC This DTC can only be cleared by reprogramming the EEPROM with the correct vehicle code and than cycling power to the TCM. This is a factor procedure. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Perform the vehicle coding.
DTC P1714 EEPROM Vehicle Code Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1714? 1. Select the required VIN on TCM Coding of scan tool. 2. Perform the vehicle coding. 3. Turn the ignition OFF. 4. Turn the ignition ON, with the engine OFF. Does the scan tool display P1714? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 5
Go to Step 5
SSANGYONG Y200
DIAGNOSTIC TROUBLE CODE (DTC) P1715 VPS OFFSET ERROR

Circuit Description The VPS is used to regulate the clutch and band pressures during a shift. The TCM compares TP voltage, engine rpm and other inputs to determine the pressure appropriate for a given shift. The TCM will regulate pressure by applying a varying amperage to the Variable Pressure Solenoid (VPS) valve. The applied amperage can vary from 0 to 1.275 amps. The TCM then monitors the amperage at the return line. This VPS offsets calibrate the accuracy between actual and expected VPS current. The DTC P1715 sets when the VPS offset value stored in EEPROM is out of range when checked on initialization. The VPS offset is greater than 120 mA from nominal. Conditions for Setting the DTC DTC P1720 is not set. The VPS offset is greater than 120 mA from nominal. The malfunction is triggered immediately after this condition exists. Action Taken When the DTC Sets Default values are used which are typical of the calibrated values. Shift quality may be degraded. Conditions for Clearing the DTC This DTC can only be cleared by recalibrating the VPS and then cycling power to the TCM. This is a factory procedure.
DTC P1715 VPS Offset Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1715? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 5
Go to Step 4
SSANGYONG Y200
YAD5A200
DIAGNOSTIC TABLE CODE (DTC) 1716 THROTTLE NOT LEARNT ERROR

Circuit Description The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator etc. from ECM via CAN without any additional sensors. The DTC P1716 sets when the throttle signal via CAN is out of range. The throttle is greater than 254 steps. Conditions for Setting the DTC The minimum & maximum throttle positions have not been learnt by the TCU. Action Taken When the DTC Sets The minimum & maximum throttle positions are set to their factory default values. Incorrect sensitivity to driver demand. Incorrect gear shift points. Conditions for Clearing the DTC Throttle learns 0% position. This value must be greater than 0.2 V. Diagnostic Aids This fault indicates that the TCU has not learnt the throttle position correctly since installation in the vehicle or that the throttle setting have been cleared by a diagnostic tool. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 4. The Throttle Position Calibration Procedure needs to be carried out. This is given in this section.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-93 DTC P1716 Throttle Not Learnt Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1716? Check if there are any DTCs related to the throttle position sensor. Are any DTCs related to throttle position sensor found? Fulfill the Throttle Clearing and Throttle Position Calibration. Is the repair complete? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
SSANGYONG Y200
DIAGNOSTIC TROUBLE CODE (DTC) P1717 RAM ERROR

Circuit Description A normal function of the Transmission Control Module (TCM) programming is to perform an internal check that verifies the integrity of the RAM memory allocations. The DTC P1717 sets when the Random Access Memory (RAM) is not operating correctly when checked on initialization. An area of RAM has failed a read/ write test. Conditions for Setting the DTC An area of RAM has failed a read/ write test. Immediately after the above condition occurs. Action Taken When the DTC Sets Adopt Limp Home Mode (LHM)
The transmission adopts the third gear LHM strategy of operation, independent of the vehicle speed. The operation of TCM under this condition is difficult to predict. Its operation may be erratic.
Conditions for Clearing the DTC The DTC will clear if the malfunction is not present after cycling the ignition. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids When DTC P1717 sets, the replacement of TCM is recommended.
Outputs are disabled.
DTC P1717 RAM Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. Does the scan tool display P1717? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check" Go to "Diagnostic Aids"
Go to Step 2
Go to Step 3
Go to Step 4
SSANGYONG Y200
DIAGNOSTIC TROUBLE CODE (DTC) P1718 ROM ERROR

Circuit Description A normal function of the Transmission Control Module (TCM) programming is to perform an internal check that verifies the integrity of the ROM memory allocations. This function is called a checksum. The DTC P1718 sets when the Read Only Memory (ROM), program memory, is corrupted when checked on initialization. The calculated checksum disagrees with the stored checksum. Conditions for Setting the DTC TCM has been powered ON for greater than 7 seconds. The calculated checksum disagrees with the stored checksum. The malfunction is triggered immediately after this condition exists. Action Taken When the DTC Sets Adopt Limp Home Mode (LHM) The transmission adopts the third gear LHM strategy of operation, independent of the vehicle speed. The operation of TCM under this condition cannot be predicted. Its operation may be erratic. Conditions for Clearing the DTC The DTC will clear if the malfunction is not present after cycling the ignition. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids
When DTC P1718 sets, the replacement of TCM is recommended.
DTC P1718 ROM Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. Does the scan tool display P1718? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check" Go to "Diagnostic Aids"
Go to Step 2
Go to Step 3
Go to Step 4
SSANGYONG Y200
YAD5A060
DIAGNOSTIC TROUBLE CODE (DTC) P1719 CAN BUS ERROR

Circuit Description The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator position etc. from ECM via CAN without any additional sensors. The DTC P1719 sets when the information required by TCM is not available on the CAN. One or more CAN messages used by the TCM is timed out, i.e. not refreshed for 1 second. Conditions for Setting the DTC One or more CAN messages used by the TCM are timed out, i.e. not refreshed for 1 second. Action Taken When the DTC Sets TCM uses default values for all CAN dependent signals. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred for 30 seconds.
Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM and ECM connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 6. Check for a poor connection at the ECM and TCM connectors.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-97 DTC P1719 CAN Bus Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1719? 1. Turn the ignition OFF. 2. Disconnect the TCM connector A. 3. Disconnect the Engine Control Module (ECM) connector. 4. Check the wiring harness from ECM connector terminal 38 to TCM connector terminal A23 for an open or a short. Is a problem found? Repair the malfunctioning wiring harness. Is a repair complete? Check the wiring harness from ECM connector terminal 37 to TCM connector terminal A24 for an open or a short. Is a problem found? Check for a poor connection at the ECM connector or TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? 1. Turn the ignition OFF. 2. Replace the TCM with the original. 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 5 -
Go to Step 4
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 8
Go to Step 10 Go to Section 1F , Engine Control
Go to Step 9
10
11
SSANGYONG Y200
DIAGNOSTIC TROUBLE CODE (DTC) P1720 EEPROM ERROR

System Description The Electrically Erasable Programmable Read-Only Memory (EEPROM) is a permanent memory chip that is physically soldered within the Transmission Control Module (TCM) The EEPROM contains the calibration information required for transmission and transmission diagnostics operation. When the EEPROM malfunctions, DTC P1720 will set. The EEPROM memory is corrupted and the calculated checksum disagrees with the stored checksum or an EEPROM communication failure has occurred when checked on initialization. Conditions for Setting the DTC The calculated checksum disagrees with the stored checksum or an EEPROM communication failure has occurred when checked on initialization. Action Taken When the DTC Sets If CAN is detected, OBD N32D VIN is selected. Or If CAN is not detected, P29 STi VIN is selected. Default values are used which are typical of calibrated values. Shift quality may be degraded. Conditions for Clearing the DTC The DTC will only clear if the malfunction is not present after cycling the ignition. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids When DTC 1720 is set, it is likely the TCM will need replacing.
Immediately after the above condition occurs.
DTC P1720 EEPROM Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1720? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
SSANGYONG Y200
BLANK
SSANGYONG Y200
YAD5A060
DIAGNOSTIC TROUBLE CODE (DTC) P1721 THROTTLE SIGNAL ERROR

Circuit Description The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires, to share common information. This results in a reduction of sensors and wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and accelerator etc. from ECM via CAN without any additional sensors. The DTC P1721 sets when the throttle signal via CAN is out of range. The throttle is greater than 254 steps. Conditions for Setting the DTC DTC P1719 is not set. The throttle is greater than 254 steps. The malfunction triggers immediately after the above condition occurs. Action Taken When the DTC Sets The throttle signal is defaulted to 100 %. Shift quality is degraded. All shifts will be firm as full throttle and hence high engine torque is assumed. Line pressure will always stay high (S6 OFF) to cope with the assumed high throttle/ torque. Manual 1 gear selection is inhibited. Conditions for Clearing the DTC The DTC will clear if the malfunction is not present for 30 seconds.
Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM and ECM connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. When ECM finds a fault on the throttle signals, ECM will adopt a default mode and send the default value and trouble message to TCM via CAN. Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Check if there are any DTCs related to the throttle position sensor on the ECM side. 4. Check for a poor connection at the ECM and TCM connectors.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-101 DTC P1721 Throttle Signal Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1721? Check if there are any DTCs related to the throttle position sensor on the ECM side. Are any DTCs related to throttle position sensor found? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 4
Go to Step 5
SSANGYONG Y200
YAD5A060
DIAGNOSTIC TROUBLE CODE (DTC) P1722 VEHICLE TYPE DETERMINATION ERROR

Circuit Description The Electrically Erasable Programmable Read-Only Memory (EEPROM) is a permanent memory chip that is physically soldered within the Transmission Control Module (TCM) The EEPROM contains the program and the calibration information required for the transmission and transmission diagnostics operation. The DTC P1722 sets when TCM is unable to determine the vehicle type from EEPROM or CAN. CAN vehicle type information is in error or unavailable in time. By definition, there must by on EEPROM fault (P1720) or an EEPROM vehicle code error (P1714) to cause the TCM to try and determine the vehicle code by other means. The DTC P1722 is a reflection of the significance of the problem caused by the other error. Conditions for Setting the DTC EEPROM information is in error or unreliable. Vehicle type information on the CAN is not present or in error. The above condition exists for 1 second after power up. Action Taken When the DTC Sets If CAN is detected, OBD N32D VIN is selected. Or If CAN is not detected, P29 STi VIN is selected. Shift quality may be degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. If there are any other DTCs like P1714 or P1720, troubleshoot those prior to P1722.
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-103 DTC P1722 Vehicle Type Determination Error

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. Does the scan tool display P1722? Does the scan tool display DTC P1714. Value(s) Yes No Go to "TCM Diagnostic System Check" Go to "Diagnostic Aids" Go to DTC P1720 table
Go to Step 2
3 -
SSANGYONG Y200
YAD5A070
DIAGNOSTIC TROUBLE CODE (DTC) P1733 SOLENOID 1 CIRCUIT OPEN

Circuit Description The solenoid 1 is used to control fluid flow acting on the 1-2 shift valve. The solenoid 1 is a normally open ON/ OFF type solenoid that is used in conjunction with the solenoid 2 to allow four different shifting combinations. Refer to Solenoid Logic for Static Gear States. The solenoid is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1733 sets when the Solenoid 1 (S1) circuit is open or the switched leg of the solenoid 1 is shorted to battery positive. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S1 is OFF. S2 is OFF. The solenoid 1s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 1 is always OFF. TCM adopts a Limp Home Mode (LHM) operation. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCMs testing, solenoid 1 is turned OFF/ ON by a very small (4 millisecond) pulse. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections.
SSANGYONG Y200
Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Solenoid Logic for Static Gear States Gear 1st 2n d 3
rd
Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S1 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for open / short. 6. Check resistance between S1 terminal A and B. Standard value is 22 - 30 . 9. Check poor connections of other connectors
S1 ON OFF OFF ON OFF OFF OFF
S2 ON ON OFF OFF OFF OFF OFF
4 th Reverse Neutral Park
DTC P1733 Solenoid 1 Circuit Open

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1733? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 1 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. Check the wiring harness from 10-way transmission connector to Solenoid 1 (S1) on the valve body for an open or short to positive and repair as necessary. Is a repair necessary? Check the S1 ground circuit for an open and repair as necessary. Is a repair necessary? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 11
Go to Step 5
Go to Step 11
Go to Step 6
SSANGYONG Y200
5A-106 AUTOMATIC TRANSMISSION DTC P1733 Solenoid 1 Circuit Open (Cont'd)

Step 6 7 Action Using a Digital Volt Meter (DVM), measure the resistance between S1 terminal A and B. Is the resistance within the specified value? Replace the S1. Is the action complete? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 1 to TCM terminal B3 for an open or short to positive and repair as necessary. Is a repair necessary? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes Go to "Diagnostic Aids" Go to Step 11 No
22 - 30 -
Go to Step 7 -
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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BLANK
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YAD5A070

Circuit Description The solenoid 2 is used to control fluid flow acting on the 2-3 shift valve. The solenoid 2 is a normally open ON/ OFF type solenoid that is used in conjunction with the solenoid 1 to allow four different shifting combinations. Refer to Solenoid Logic for Static Gear States. The solenoid is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1734 sets when the Solenoid 2 (S2) circuit is open or the switched leg of the solenoid 2 is shorted to battery positive. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S2 is OFF. S1 is OFF. The solenoid 2s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 2 is always OFF. TCM adopts a Limp Home Mode (LHM) operation. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCMs testing, solenoid 2 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections.
SSANGYONG Y200
Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Solenoid Logic for Static Gear States Gear 1st 2n d 3
rd
Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S2 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for open / short. 6. Check resistance between S2 terminal A and B. Standard value is 22 - 30 . 9. Check connections of other connectors
S1 ON OFF OFF ON OFF OFF OFF
S2 ON ON OFF OFF OFF OFF OFF
4 th Reverse Neutral Park

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1734? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 2 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. Check the wiring harness from 10-way transmission connector to Solenoid 2 (S2) on the valve body for an open or short to positive and repair as necessary. Is a repair necessary? Check the S2 necessarycircuit for an open and repair as necessary. Is a repair complete? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 11
Go to Step 5
Go to Step 11
Go to Step 6
SSANGYONG Y200

Step 6 7 Action Using a Digital Volt Meter (DVM), measure the resistance between S2 terminal A and B. Is the resistance within the specified value? Replace the S2. Is the action complete? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 2 to TCM terminal B11 for an open or short to positive and repair as necessary. Is a repair necessary? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes Go to "Diagnostic Aids" Go to Step 11 No
22 - 30 -
Go to Step 7 -
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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BLANK
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YAD5A070

Circuit Description The solenoid 3 is a normally open ON/OFF type solenoid that is used in conjunction with the solenoid 4 to control the shift quality and sequencing. The solenoid 3 switches the clutch regulator valve OFF or ON and is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1735 sets when the Solenoid 3 (S3) circuit is open or the switched leg of the solenoid 3 is shorted to battery positive. The solenoid 3s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S3 is OFF. S7 is OFF. The solenoid 3s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 3 is always OFF. The 1 3, 1 4, 2 3, 2 4, 3 1, 3 2, 4 2 and 4 1 shift quality is degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCMs testing, solenoid 3 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmis-sion operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections.
SSANGYONG Y200
Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire in-side the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1735? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 3 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. Check the wiring harness from 10-way transmission connector to Solenoid 3 (S3) on the valve body for an open or short to positive and repair as necessary. Is a repair necessary? Check the S3 ground circuit for an open and repair as necessary. Is a repair necessary? Using a Digital Volt Meter (DVM), measure the resistance between S3 terminal A and B. Is the resistance within the specified value? Replace the S3. Is the action necessary? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 3 to TCM terminal B10 for an open or short to positive and repair as necessary. Is a repair necessary? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 11
Go to Step 5
6 7
22 - 30 -
Go to Step 6
Go to Step 7 -
Go to Step 11
Go to Step 9
SSANGYONG Y200

Step Action Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
SSANGYONG Y200
BLANK
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YAD5A070

Circuit Description The solenoid 4 is a normally open ON/OFF type solenoid that is used in conjunction with the solenoid 3 to control the shift quality and sequencing. The solenoid 4 switches the clutch regulator valve OFF or ON and is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1736 sets when the Solenoid 4 (S4) circuit is open or the switched leg of the solenoid 4 is shorted to battery positive. The solenoid 4s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S4 is OFF. S6 is OFF. The solenoid 3s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 4 is always OFF. The 1 2, 1 4, 2 3, 2 4, 3 2 (all including manual), 3 4, 4 1 and 4 3 shift quality is degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCMs testing, solenoid 4 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections.
SSANGYONG Y200
Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.

Step 1 Action Perform a Transmission Control Module (TCM) Diagnostic System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1736? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 4 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. Check the wiring harness from 10-way transmission connector to Solenoid 4 (S4) on the valve body for an open or short to positive and repair as necessary. Is a repair necessary? Check the S4 ground circuit for an open and repair as necessary. Is a repair necessary? Using a Digital Volt Meter (DVM), measure the resistance between S4 terminal A and B. Is the resistance within the specified value? Replace the S4. Is the action necessary? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 4 to TCM terminal B4 for an open or short to positive and repair as necessary. Is a repair necessary? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 11
Go to Step 5
Go to Step 6
6 7
22 - 30 -
Go to Step 7 -
Go to Step 11
Go to Step 9
SSANGYONG Y200

Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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BLANK
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YAD5A070

Circuit Description The solenoid 5 is a variable force solenoid that ramps the pressure during the gear changes and solenoid switching, to enhance the transmission shift quality. This solenoid provides the signal pressure to the clutch and band regulator, thereby controlling the shift pressure. The solenoid 5 is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1737 sets when the solenoid 5 (S5) circuit is open or the switched leg of the solenoid 5 is shorted to battery positive. The solenoid 5's driver Integrated Chip (IC) status indicates a fauty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. The solenoid 5's driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. The measured S5 current is greater than 100 mA below its expected lower limit. Action Taken When the DTC Sets Solenoid 5 is disabled (always OFF). The shift quality is degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids The current to solenoid 5 was outside acceptable limits. This fault results from a mismatch between the current set point for solenoid 5 and the current measured by the feedback within the TCM. Typical causes would be an open circuit or short circuit to power in the wiring to, from or within the solenoid. It is also possible that there has been a fault in the solenoid output circuit. But if this is the cause, the fault should be continually present. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire in-side the insulation.
SSANGYONG Y200
If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.
Test Description The number(s) below refer to the step number(s) on the Diagnostic Table.
3. Checks if the S5 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for open / short. 6. Check resistance between S5 terminal A and B. Standard value is 3.6 - 5.5 . 9. Check connections of other connectors

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1737? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side. 4. Turn the mode knob of STET to 5 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. Check the wiring harnesses from 10-way trans mission connector to Solenoid 5 (S5) on the valve body for an open or short to positive and repair as necessary. Is a repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S5 terminal A and B. Is the resistance within the specified value? Replace the S5. Is the action complete? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 5 to TCM terminal B7 for an open or short to battery and repair as necessary. Is a repair necessary? Check the wiring harness from 10-way transmission connector terminal 8 to TCM terminal B1 for an open and repair as necessary. Is a repair necessary? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 5
5 6
3.6 - 5.5 -
Go to Step 6 -
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
SSANGYONG Y200

Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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BLANK
SSANGYONG Y200
YAD5A070

Circuit Description The solenoid 6 is a normally open ON/OFF type solenoid that is used to set the high/ low level of line pressure. The Solenoid 6 (S6) OFF gives high pressure and the S6 is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1738 sets when the solenoid 6 circuit is open or the switched leg of the solenoid 6 is shorted to battery positive. The solenoid 6's driver Integrated Chip (IC) sta-tus indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S6 is OFF. S4 is OFF. The solenoid 6's driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 6 is disabled (OFF) resulting in high line pressure being applied continuously. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCM's testing, solenoid 6 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections.
SSANGYONG Y200

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1738? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 6 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. Check the wiring harness from 10-way transmission connector to Solenoid 6 (S6) on the valve body for an open or short to positive and repair as necessary. Is a repair necessary? Check the S6 ground circuit for an open and repair as necessary. Is a repair necessary? Using a Digital Volt Meter (DVM), measure the resistance between S6 terminal A and B. Is the resistance within the specified value? Replace the S6. Is the action complete? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 6 to TCM terminal B12 for an open and repair as necessary. Is a repair necessary? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 11
Go to Step 5
Go to Step 6
6 7
22 - 30 -
Go to Step 7 -
Go to Step 11
Go to Step 9
SSANGYONG Y200

Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
SSANGYONG Y200
BLANK
SSANGYONG Y200
YAD5A070

Circuit Description The solenoid 7 is a normally open ON/OFF type solenoid that is used to control the application of the Torque Converter Clutch (TCC). The Solenoid 7 (S7) ON activates the TCC and the S7 is attached to the pump body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1739 sets when the solenoid 7, Torque Converter Clutch Solenoid, circuit is open or the switched leg of the solenoid 7 is shorted to battery positive. The solenoid 7's driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S7 is OFF. S3 is OFF. The solenoid 7's driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 7 is always disabled (OFF) resulting in the TCC being unlocked always. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCM's testing, solenoid 7 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorede. Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector.
SSANGYONG Y200

Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. 3. Checks if the S7 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for open / short. If the problem is found in the wiring harness from 10-way transmission connector to contact point attached onto the transmission case, repair it with removing the valve cover. Refer to the Transmission in this section. 7. Check resistance between S7 terminal A and B. Standard value is 22 - 30 . 10. Check connections of other connectors.

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1739? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 7 and push the red button. Does the bulb of open circuit on the solenoids side of STET illuminate? 1. Remove the pump assembly. Refer to the Pump in this section. 2. Check the wiring harness from 10-way transmission connector to contact point attached onto the transmission case for an open or short to positive and repair as necessary. Is a repair necessary? Check the wiring harness from contact point attached onto the transmission case to S7 for an open or short to positive and repair as necessary. Is a repair necessary? Check the S7 ground circuit for an open and repair as necessary. Is a repair necessary? Using a Digital Volt Meter (DVM), measure the resistance between S7 terminal A and B. Is the resistance within the specified value? Replace the S7. Is the action complete? Value(s) Yes No Go to "TCM Diagnostic System Check"
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 9
Go to Step 12
Go to Step 5
Go to Step 12
Go to Step 6
Go to Step 7
7 8
22 - 30 -
Go to Step 8 -
SSANGYONG Y200

Step Action 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 7 to TCM terminal B9 for an open or short to positive and repair as necessary. Is a repair necessary? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 12
Go to Step 10
10
Go to Step 12
Go to Step 11
11
Go to Step 12
12
13
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BLANK
SSANGYONG Y200
YAD5A070
DIAGNOSTIC TROUBLE CODE (DTC) P1741 SOLENOID 1 CIRCUIT SHORT

Circuit Description The solenoid 1 is used to control fluid flow acting on the 1-2 shift valve. The solenoid 1 is a normally open ON/ OFF type solenoid that is used in conjunction with the solenoid 2 to allow four different shifting combinations. Refer to Static Gear Status. The solenoid is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1741 sets when the Solenoid 1 (S1) circuit is shorted to ground. The solenoid 1s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S1 is ON. The solenoid 1s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 1 is always OFF. TCM adopts a Limp Home Mode (LHM) operation. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle.
Diagnostic Aids During the TCMs testing, solenoid 1 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmis-sion operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be a short circuit to ground in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire in-side the insulation.
SSANGYONG Y200
If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Solenoid Logic for Static Gear States Gear 1 st 2 nd 3 rd 4 th Reverse Neutral Park S1 ON OFF OFF ON OFF OFF OFF S2 ON ON OFF OFF OFF OFF OFF
Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S1 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for short to ground. 6. Check resistance between S1 terminal A and B. Standard value is 22-30 . 9. Check connections of other connectors.
DTC P1741 Solenoid 1 Circuit Short

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 1 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector to Solenoid 1 (S1) on the valve body. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S1 terminal A and B. Is the resistance within the specified value? Replace the S1. Is the action complete? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Diagnostic Aids
Go to Step 4
Go to Step 8
Go to Step 5 Go to Step 11 Go to Diagnostic Aids Go to Step 11
Go to Step 6 -
20 - 30 -
Go to Step 7 -
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5A-134 AUTOMATIC TRANSMISSION DTC P1741 Solenoid 1 Circuit Short (Contd)

Step Action 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 1 to TCM terminal B3. Does the test light illuminate? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 5
Go to Step 9
Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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YAD5A070

Circuit Description The solenoid 2 is used to control fluid flow acting on the 2-3 shift valve. The solenoid 2 is a normally open ON/ OFF type solenoid that is used in conjunction with the solenoid 1 to allow four different shifting combinations. Refer to Static Gear Status. The solenoid is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1742 sets when the Solenoid 2 (S2) circuit is shorted to ground. The solenoid 2s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S2 is ON. The solenoid 2s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 2 is always OFF. TCM adopts a Limp Home Mode (LHM) operation. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle.
Diagnostic Aids During the TCMs testing, solenoid 2 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be a short circuit to ground in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections. Inspect the wiring for poor electrical connections at the TCM and at the transmission 10-way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation.
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If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Solenoid Logic for Static Gear States Gear 1 st 2 nd 3 rd 4 th Reverse Neutral Park S1 ON OFF OFF ON OFF OFF OFF S2 ON ON OFF OFF OFF OFF OFF
Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S2 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for short to ground. 6. Check resistance between S2 terminal A and B. Standard value is 22 - 30 . 9. Check connections of other connectors.

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1742? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 2 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector to Solenoid 2 (S2) on the valve body. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S2 terminal A and B. Is the resistance within the specified value? Replace the S2. Is the action complete? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 6 -
5 6
20 - 30 -
Go to Step 7 -
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Step Action 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 2 to TCM terminal B11. Does the test light illuminate? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 5
Go to Step 9
Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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YAD5A070

Circuit Description The solenoid 3 is a normally open ON/OFF type solenoid that is used in conjunction with the solenoid 4 to control the shift quality and sequencing. The solenoid 3 switches the clutch regulator valve OFF or ON and is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1743 sets when the Solenoid 3 (S3) circuit is shorted to ground. The solenoid 3s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S3 is ON. The solenoid 3s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 3 is always OFF. The 1 3, 1 4, 2 3, 2 4, 3 1, 3 2, 4 2 and 4 1 shift quality is degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle.
Diagnostic Aids During the TCMs testing, solenoid 3 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be a short circuit to ground in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation.
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3. Checks if the S3 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for short to ground. 6. Check resistance between S3 terminal A and B. Standard value is 22 - 30 . 9. Check connections of other connectors.

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1743? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 3 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector to Solenoid 3 (S3) on the valve body. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S3 terminal A and B. Is the resistance within the specified value? Replace the S3. Is the action complete? 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 3 to TCM terminal B10. Does the test light illuminate? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 6 -
6 7
20 - 30 -
Go to Step 7 -
Go to Step 5
Go to Step 9
Go to Step 11
Go to Step 10
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Step 10 Action 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 11
11
12
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YAD5A070

Circuit Description The solenoid 4 is a normally open ON/OFF type solenoid that is used in conjunction with the solenoid 3 to control the shift quality and sequencing. The solenoid 4 switches the band regulator valve OFF or ON and is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1744 sets when the Solenoid 4 (S4) circuit is shorted to ground. The solenoid 4s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S4 is ON. The solenoid 4s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 4 is always OFF. The 1 2, 1 4, 2 3, 2 4, 3 1, 3 2 (all including manual), 3 4, 4 1 and 4 3 shift quality is degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle. A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50 C) and without a fault. History DTCs can be cleared by using a scan tool. Diagnostic Aids During the TCMs testing, solenoid 4 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be a short circuit to ground in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections.
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Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S4 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for short to ground. 6. Check resistance between S4 terminal A and B. Standard value is 22 - 30 . 9. Check connections of other connectors.

Step 1 Action Perform Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1744? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 4 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector to Solenoid 4 (S4) on the valve body. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S4 terminal A and B. Is the resistance within the specified value? Replace the S4. Is the action complete? 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 4 to TCM terminal B4. Does the test light illuminate? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 6 -
6 7
20 - 30 -
Go to Step 7 -
Go to Step 5
Go to Step 9
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Go to Step 11
Go to Step 10
10
Go to Step 11
11
12
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YAD5A070

Circuit Description The solenoid 5 is a variable force solenoid that ramps the pressure during the gear changes and solenoid switching, to enhance the transmission shift quality. This solenoid provides the signal pressure to the clutch and band regulator, thereby controlling the shift pressure. The solenoid 5 is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1745 sets when the Solenoid 5 (S5) circuit is shorted to ground. The solenoid 5s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S5 is ON. The solenoid 5s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets Solenoid 5 is disabled (always OFF) The shift quality is degraded. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle.
Diagnostic Aids The current to solenoid 5 was outside acceptable limits. This fault results from a mismatch between the current set point for solenoid 5 and the current measured by the feedback within the TCM. Typical causes would be a short circuit to ground in the wiring to, from or within the solenoid. It is also possible that there has been a fault in the solenoid output circuit. But if this is the cause, the fault should be continually present. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or dam-aged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.
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Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S5 circuit in the transmission is malfunctioning. 4. Check cable in the transmission for short to ground. 6. Check resistance between S5 terminal A and B. Standard value is 3.6 - 5.5 . 10. Check connections of other connectors.

Step 1 Action Perform Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1745? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side. 4. Turn the mode knob of STET to 5 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. With a test light connected to B+ probe the wiring harnesses from 10-way transmission connector to Solenoid 5 (S5) on the valve body. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S5 terminal A and B. Is the resistance within the specified value? Replace the S5. Is the action complete? 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 5 to TCM terminal. Does the test light illuminate? Probe the wiring harness from 10-way transmission connector terminal 8 to TCM terminal B1. Does the test light illuminate? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 6 -
6 7
3.6 - 5.5 -
Go to Step 7 -
Go to Step 5
Go to Step 9
Go to Step 5
Go to Step 10
10
Go to Step 12
Go to Step 11
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Step 11 Action 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are any there DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 12
12
13
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YAD5A070

Circuit Description The solenoid 6 is a normally open ON/OFF type solenoid that is used to set the high/ low level of line pressure. The solenoid 6 (S6) OFF gives high pressure and the S6 is attached to the valve body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1746 sets when the Solenoid 6 (S6) circuit is shorted to ground. The solenoid 6s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S6 is ON. The solenoid 6s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 6 is disabled (OFF) resulting in high line pressure being applied continuously. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle.
Diagnostic Aids During the TCMs testing, solenoid 6 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be a short circuit to ground in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short to bare metal or other wiring. Inspect for broken wire inside the insulation.
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Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S6 circuit in the transmission is malfunctioning.
4. Check cable in the transmission for short to ground. 6. Check resistance between S6 terminal A and B. Standard value is 22 - 30 . 9. Check connections of other connectors.

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1746? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 6 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the valve cover. Refer to the Transmission in this section. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector to Solenoid 6 (S6) on the valve body. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? Using a Digital Volt Meter (DVM), measure the resistance between S6 terminal A and B. Is the resistance within the specified value? Replace the S6. Is the action complete? 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 6 to TCM terminal B12. Does the test light illuminate? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Is a repair necessary? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 6 -
6 7
20 - 30 -
Go to Step 7 -
Go to Step 5
Go to Step 9
Go to Step 11
Go to Step 10
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Step 10 Action 1. Turn the ignition OFF. 2. Replace the TCM. Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Check if any DTCs are set. Are there any DTCs displayed or previously recorded at Step 2 that have not been diagnosed? Value(s) Yes No
Go to Step 11
11
12
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YAD5A070

Circuit Description The solenoid 7 is a normally open ON/OFF type solenoid that is used to control the application of the Torque Converter Clutch (TCC). The Solenoid 7 (S7) ON activates the TCC and is attached to the pump body within the transmission. Voltage is supplied directly to the solenoid through the Transmission Control Module (TCM). The DTC P1747 sets when the solenoid 7, Torque Converter Clutch Solenoid, circuit is shorted to ground. The solenoid 7s driver Integrated Chip (IC) status indicates a faulty circuit. Conditions for Setting the DTC DTCs P1717 and P1718 are not set. S7 is ON. The solenoid 7s driver Integrated Chip (IC) status indicates a faulty circuit. This condition must be continuously present for 60 milliseconds. Action Taken When the DTC Sets The solenoid 7 is always disabled (OFF) resulting in the TCC being unlocked continuously. Conditions for Clearing the DTC The DTC will clear when the malfunction has not occurred after ignition cycle.
Diagnostic Aids During the TCMs testing, solenoid 7 is turned OFF/ ON by a very small (4 millisecond) pulses. This pulse is too short for the solenoid to react so the transmission operation is not affected. The solenoid feedback voltage is measured before the (4 millisecond) pulse and again during the pulse. If the difference is outside the acceptable limits the relevant fault is recorded. Typical causes would be a short circuit to ground in the wiring to or within the solenoid. If several faults of solenoids are present, check the wiring or connectors that are common to the selected solenoids, especially the earth connections. Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for chafed wires that could short tobare metal or other wiring. Inspect for broken wire inside the insulation.
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Test Description The number(s) below refer to the step number(s) on the Diagnostic Table. 3. Checks if the S7 circuit in the transmission is malfunctioning.
4. Check cable in the transmission for short to ground. 7. Check resistance between S7 terminal A and B. Standard value is 22 - 30 . 10. Check connections of other connectors.

Step 1 Action Perform a Transmission Control Module (TCM) System Check. Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3. Record and then clear DTCs. 4. Operate the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool display P1747? 1. Turn the ignition OFF. 2. Disconnect the 10-way transmission connector. (additional DTCs will set) 3. Connect Solenoid/Thermistor Electrical Tester (STET) to the 10-way transmission connector of transmission side and to the good ground. 4. Turn the mode knob of STET to 7 and push the red button. Does the bulb of close circuit on the solenoids side of STET illuminate? 1. Remove the pump assembly. Refer to the Pump in this section. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector to contact point attached onto the transmission case. Does the test light illuminate? Repair the short to ground in the wiring harness. Is the repair complete? With a test light connected to B+, probe the wiring harness from contact point attached onto the transmission case to S7. Does the test light illuminate? Using a Digital Volt Meter (DVM), measure the resistance between S7 terminal A and B. Is the resistance within the specified value? Replace the S7. Is the action complete? 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 7 to TCM terminal B9. Does the test light illuminate? Value(s) Yes No Go to TCM Diagnostic System Check
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 8
Go to Step 6 -
Go to Step 15 Go to Diagnostic Aids Go to Step 12
Go to Step 7
7 8
20 - 30 -
Go to Step 8 -
Go to Step 5
Go to Step 10
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10
Go to Step 12
Go to Step 11
11
Go to Step 12
12
13
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TRANSMISSION
1. Disconnect the negative battery cable. 2. Disconnect the connectors from transfer case. 3. Disconnect the speedometer connector from transfer case. 4. Disconnect the inhibitor connector, gear position sensor connector and transmission case connector.
YAD5A080
5. Remove the rear propeller shaft bolts. Installation Notice Tightening Torque 70-80 Nm (52-59 lb-ft)
YAD5A090
6. Remove the cross member bolts and nuts. Installation Notice Tightening Torque 70-80 Nm (52-59 lb-ft)
YAD5A100
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7. Remove the front propeller shaft bolts from transfer case. Installation Notice Tightening Torque 70-80 Nm (52-59 lb-ft)
YAD5A110
8. Remove the transfer case-to-transmission housing bolts and remove the transfer case. Installation Notice Tightening Torque 44 Nm (33 lb-ft)
9. Disconnect the 10-Pins Plug connector from transmission.
YAD5A120
10. Separate the locking clip on shift lever and remove the shift rod. Notice: Removal and installation performed when the shift procedure should be lever is in D range.
YAD5A130
11. Remove the oil cooler pipes. Installation Notice Tightening Torque 25-35 Nm (18-26 lb-ft)
YAD5A140
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12. Remove the service hole cover in the engine block. 13. Put the alignment mark for installation, and remove the six mounting bolts for torque converter from drive plate through the service hole by rotating the engine and remove the torque converter. Installation Notice Tightening Torque 42 Nm (31 lb-ft)
Screw the six bolts mounting the torque converter through the service hole by using a mirror and rotating the engine.
KAA5A2N0
14. Remover the starter. Refer to Section 1E, Engine Electrical .
15. Remove the extension housing to case bolts and remove the transmission assembly. Installation Notice Tightening Torque 55-65 Nm (41-48 lb-ft)
Be careful not to drop the torque converter while removing the transmission. 16. Installation should follow the removal procedure in the reverse order.
YAD5A150
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UNIT REPAIR
REBUILD WARNINGS
Prior to rebuilding a transmission system, the following warnings are to be noted. Ensure that, before replacing a transmission the cooler lines are flushed out to remove any debris. This can be done by applying compressed air to the rear cooler line forcing oil and any contaminants out of the front cooler line. The cooler flow should be checked after the transmission has been fitted. With the front cooler line connected and the rear line run into a suitable container, measure the flow over 15 seconds with the vehicle idling in park. The flow rate should exceed 1 liter in 15 seconds. Be wary of any situation where water enters the transmission. This may result in fluid foaming and leaking through the breather. Ensure that both earth straps (one at the battery terminal and one on the vehicle body) are connected in the vehicle before connecting the positive side of the battery. Follow the throttle position calibration procedure in this manual if the engine control module/ transmission control module (ECM/TCM) is swapped.
KAA5A710
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Transmission
Tools Required 0555-336256 Transmission Bench Cradle 0555-336257 Pump Puller Notice:
Remove the inhibitor switch before washing the transmission in solvent or hot wash. It is assumed that the transmission fluid has been drained when the transmission was removed from the vehicle and that the special tools quoted are available. The transmission is dismantled in a modular fashion, and the details of disassembly for each module are given under the appropriate subject. Refer to Special Tools Table in this chapter for details of all special tools required when performing disassembly procedures. Technicians overhauling these transmissions will also require a selection of good quality Torx bit sockets, in particular numbers 30, 40 and 50, and an 8mm, 10mm and 12 mm double hex socket.
1. Remove the converter and the converter housing. 2. Mount the transmission on the transmission bench cradle 0555-336256. 3. Remove the oil pan and the oil pan seal.
KAA5A500
4. Remove each end of the filter retaining clip from the valve body and remove the filter. 5. Disconnect the wires from each solenoid and ground and lay the wiring to one side. 6. Remove the valve body securing screws and remove the valve body from the case.
KAA5A510
SSANGYONG Y200

7. Remove the front servo cover circlip. 8. Remove the front servo cover, piston and spring. Notice: The plastic servo block is retained by the piston return spring only. 9. Remove the adaptor housing bolts and adaptor housing.
KAA5A520
10. Remove the pump to case bolts using a multi-hex 8 mm spanner. 11. Using the pump puller 0555-336257, remove the pump and pump cover.
KAA5A530
12. Remove the input shaft, forward clutch cylinder, and the overdrive shaft as an assembly, withdrawing them through the front of the case. 13. Remove the C3 clutch cylinder and sun gears.
KAA5A540
14. Remove the front band struts. Remove the front band.
KAA5A550
SSANGYONG Y200

15. Remove the two centre support retaining bolts using a T50 Torx bit. 16. Remove the centre support retaining circlip. Notice: Do not hammer the output shaft to remove the centre support as this will cause permanent damage to the thrust bearing surfaces. 17. Remove the centre support, 1-2 one way clutch, and planetary gear set as an assembly. 18. Remove the parking rod cam plate using a T40 Torx bit.
KAA5A560
19. Remove the rear band struts and remove the band. Notice: Vise the both end of rear band using the plier and lean forward about 15 degrees 20. Remove the output shaft assembly.
KAA5A570
Transmission Case
Tools Required 0555-336258 Cross Shaft Pin Remover/Installer (Detent Lever) 0555-336261 Cross Shaft Seal Remover 0555-336265 Cross Shaft Pin Remover/Installer (Inhibitor Switch) 1. Remove the pin from the side of cross shaft inhibitor switch using cross shaft pin remover/ installer (inhibitor switch) 0555-336265. 2. Remove the inhibitor switch bolts and inhibitor switch from the case. 3. Remove the cross shaft seals with cross shaft seal remover 0555-336261. 4. Remove the circlip from the cross shaft. Pull the shaft to release the drive pin from the selector quadrant.
KAA5A580
KAA5A590
SSANGYONG Y200

5. Using cross shaft pin remover/installer (detent lever) 0555-336258, press the pin from the cross shaft and withdraw the shaft from the case. 6. Remove the cross shaft pin and spring. 7. Remove the manual valve lever and the park rod.
KAA5A600
8. Depress the tangs and withdraw the 10 pin connector into the case. Remove the wiring loom assembly.
KAA5A610
9. Detach the No.7 solenoid wire from the front of the case. 10. Remove the parking pawl pivot pin and the pawl and spring from the case. 11. Remove the shaft and the rear servo lever.
KAA5A620
12. 13. 14. 15.
Remove the rear servo cover and piston assembly. Remove the B1R circlip, valve and spring. Remove both band adjustment shims. Inspect the output shaft bushing in the case and replace if necessary. 16. Inspect cooler line fittings and replace as necessary. 17. Inspect the case for damage.
KAA5A630
SSANGYONG Y200

18. To remove the park rod lever: Remove the circlip from the inner end of the pivot shaft and tap the outer end of the shaft until it moves free from the case, then using a wide shallow tapered drift as a wedge, drive the pin out from the inside of the case and remove the lever and spring. Notice: Do not remove the park rod lever unless absolutely necessary.
KAA5A640
Forward Clutch Cylinder

Tools Required 0555-336259 Clutch Spring Compressor 1. Place the assembly in a horizontal position.
KAA5A650
2. Remove the No. 4 needle bearing (2) and adjustment shims (1) from the input shaft. 3. Remove the circlip from the front of the clutch cylinder and remove the input shaft. 4. Remove the overdrive shaft and the C1 clutch hub assembly from the clutch cylinder. 5. Remove the C1 clutch plates from the cylinder.
KAA5A660
6. Remove the circlip retaining the C3 clutch hub in the rear of the clutch cylinder and remove the hub. 7. Remove the C2/C4 clutch hub assembly and remove the No. 5 needle bearing from the C4 hub. 8. Removethe C2 clutch plates.
KAA5A670
SSANGYONG Y200

9. Invert the clutch cylinder and remove the C4 clutch sleeve, clutch plates and the two wave washers. The 3-4 one way clutch is located between the C2 and C4 clutch hubs, and the hubs may be separated by rotating one hub clockwise and withdrawing it from the other. 10. Remove the thrust block from the C4 clutch cylinder hub.
KAA5A680
11. Mount the clutch cylinder on clutch spring compressor 0555-336259 with the C2/C4 end uppermost and compress the piston return spring. Remove the spring retaining circlip. Release the tool and remove the circlip, keeper and spring. Notice: Make sure that the spring keeper is not caught in the circlip groove, and that all the spring pressure is released, before removing the tool. 12. Invert the clutch cylinder on the compressor tool and removethe C1 clutch piston return spring in asimilar manner.
KAA5A690
13. To remove the clutch pistons from the clutch cylinder, apply air pressure to the apply ports in the bore of the cylinder.
KAA5A700
C3 Clutch Cylinder
Tools Required 0555-336259 Clutch Spring Compressor 1. Remove the forward sun gear, No.7 needle bearing (2) thrust washer (1) and lipped thrust washer (3) from the C3 clutch cylinder. 2. Remove the thrust plate (4), No.6 needle bearing (5), thrust plate (6) and nylon thrust plate (7) from the clutch cylinder hub. 3. Remove the clutch plate retaining circlip and remove the clutch plates.
KAA5A720
SSANGYONG Y200

4. Mount the clutch assembly on clutch spring compressor 0555-336259 and compress the piston return spring. 5. Remove the circlip and release the spring. 6. Remove the tool, circlip, keeper and spring. Notice: Make sure that the spring keeper has not been caught in the circlip groove, and that all spring pressure has been released, before removing the tool.
KAA5A730
7. Remove the sealing rings from the C3 clutch cylinder. 8. To remove the clutch piston from the clutch cylinder, apply air pressure to the port between the iron sealing rings on the bearing journals of the cylinder. 9. Remove the reverse sun gear and C3 washer from the cylinder.
KAA5A740
Planet Carrier Assembly and Centre Support

1. Remove the No. 9 (2) needle bearing and washer (1) from the output shaft and the planet carrier. 2. Separate the centre support from the planet carrier by rotating it anti-clockwise.
KAA5A750
3. Lift the one way clutch (1) from the planet carrier (5). 4. Remove the circlip (2) retaining the one way clutch outer race (3) in the planet carrier and remove the race. 5. Remove the one way clutch retainer (4) from the planet carrier.
KAA5A760
SSANGYONG Y200
5A-170 AUTOMATIC TRANSMISSION Pump

Notice: The following valves are housed in the pump cover:
Solenoid 7 Converter clutch control valve Converter clutch regulator valve Primary regulator valve
1. Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit. 2. Remove the five washer head bolts from the cover plate using a multi-point 8 mm socket. 3. Remove the five Torx head screws from the cover plate with T30 Torx bit. Note that the long screw holds the pump body to the pump body cover. Notice: Do not strike the converter support tube to loosen the pump body.
KAA5A770
4. Separate the pump body from the pump cover. 5. Remove the cover plate, gasket and seal from the cover.
KAA5A780
6. Remove the ball check valve and one spring from the pump cover.
KAA5A790
SSANGYONG Y200

7. Depress the plug inward and remove the retaining pin for each of the three valves. Notice: Some of the valves and plugs are preloaded by springs and may unexpectedly fall out of the cover when the pins are removed. 8. Remove the four valves, plugs and springs.
KAA5A800
9. Remove the pump gears from the pump body. 10. Remove the lip seal from the front of the pump body.
KAA5A810
Valve Body
1. Remove the manual valve detent spring and retainer plate using a T40 Torx bit. 2. Slide the manual valve out of the lower valve body. Notice: Be aware that the manual valve will fall out of the valve body. 3. Take note of the angular relationship of the solenoid terminals to the valve body and remove the solenoids 1, 2, 3, 4, 5, 6 and valve assemblies. Notice: Take care that the bracket is not separated from the solenoid. 4. Place the valve body assembly on the bench with the upper body uppermost. 5. Remove the 24 clamping screws with a No. 30 Torx bit. Separate the upper and lower valve bodies by lifting the upper body and the separator plate togeth-er. 6. Turn the upper body over and place it on the bench with the separator plate uppermost.
KAA5A820
KAA5A830
SSANGYONG Y200

7. Lift the separator plate and gaskets from the upper valve body. 8. Remove the five nylon check balls exposed in the valve body. 9. Remove the retaining plate, plug, spring and reverse lockout valve.
KAA5A840
10. Remove the filter (1) and the large nylon check ball (2) from the lower valve body. 11. Remove the retaining plates and pins from the 12, 2-3, 3-4, BAR and CAR valves. The pins can be removed with a magnet. Notice: Once the pins are removed, the plates are loose in the valve body and will drop out when the valve body is turned over. 12. Remove the 1-2, 2-3 and 3-4 shift valves.
KAA5A85A
13. Depress the 4-3 sequence valve plug and remove the retaining plate. Notice: The plug is preloaded by the spring and may unexpectedly fall out of the valve body. 14. Remove the plug, spring and valve
KAA5A860
15. Depress the solenoid 5 valve. Remove the retaining in and remove the valve, damper guide and spring. Notice: The valve is preloaded by the spring and may unexpectedly fall out of the valve body. 16. Depress the line pressure release valve, remove the retaining pin, disc (if fitted), spring and valve. 17. Drive out the retaining pin and remove the spring and ball check valve adjacent to the BAR valve.
KAA5A870
SSANGYONG Y200
ASSEMBLY PROCEDURE
Transmission
Tools Required 0555-336256 Transmission Bench Cradle 0555-336258 Cross Shaft Pin Remover/Installer (Detent Lever) 0555-336262 Cross Shaft Seal Installer 0555-336263 Cross Shaft bullet 0555-336265 Cross Shaft Pin Remover/Installer (Inhibitor Switch) Notice:
The transmission is assembled in modular fashion and details of assembly for each module are given under the appropriate subject. Technicians overhauling these transmissions will also require a selection of good quality Torx bit sockets, in particular numbers 30, 40 and 50, and an 8 mm, 10 mm and 12 mm double hex socket. Ensure that the B1R circlip is fitted to the case. (If this is not fitted, the valve will peen its way into and through the separator plate) Ensure that the Eclip is fitted to the cross shaft. Ensure that all aspects of the parking mechanism are working.
1. Turn the transmission case upside down on the bench and mount it to the transmission bench cradle 0555-336256. 2. Install all fittings, plugs and the breather, applying a sealant where applicable, Tighten the fittings to specifications. Ensurethatthebreatheris clear, andcheckthat the lube fitting in the rear of the case is fittedand clear of obstruction.
KAA5A500
3. Assemble the B1R valve and spring, and secure with the circlip. Ensure that the circlip is completely seated in its groove.
KAA5A880
SSANGYONG Y200

4. Install the rear servo lever and pivot pin. Notice: The lever must pivot freely on its pin.
KAA5A890
5. Assemble the park rod lever, complete with the return spring and pivot pin, applying a small amount of sealant to the outer end of the pivot pin. Notice: Care must be taken when applying sealant to ensure that it is not applied between the pin and the lever. 6. Secure the pivot pin with the circlip. Notice: The lever must pivot freely on its pin and the spring must return the park rod lever to its correct location.
KAA5A640
7. Install the parking pawl pivot pin and spring. Notice: The pawl must pivot freely on its pin.
KAA5A900
8. Connect the park rod to the manual valve detent lever. Ensure the spring and cam collar is firmly installed on the rod. 9. Check that the cam collar slides freely on the rod. 10. Insert the cross shaft into the case, from the side opposite to the inhibitor switch, then install the antirattle spring on the shaft.
KAA5A910
SSANGYONG Y200

11. Poition the manual valve detent lever, aligning it with the cross-shaft bore in the case. 12. Push the shaft through the detent lever until it starts in the detent lever side of the case.
KAA5A920
13. Install the detent lever drive pin in the shaft using cross shaft pin remover/installer (detent lever) 0555-336258 with the adaptor over the pin. 14. Press the pin into the shaft until the tool bottoms. 15. Remove the tool and fit the spring retaining circlip to the shaft.
KAA5A600
16. Install the new cross shaft seals using cross shaft seal installer 0555-336262 (1) and cross shaft bullet 0555-336263 (2).
KAA5A930
17. Install the inhibitor switch on the case. Torque the bolts as per specifications. Press the pin into the shaft until the tool bottoms using cross shaft pin installer/ remover (inhibitor switch) 0555-336265. Installation Notice Tightening Torque 4-6 Nm (35-53 lb-in)
18. Thoroughly check the terminal wiring loom for condition and continuity.
KAA5A580
SSANGYONG Y200

19. Position the wiring loom and locate the solenoid 7 contact and terminal in the pump mounting flange at the front of the case. The solenoid 7 wire is routed under the park rod and cross shaft in the case.
KAA5A940
20. Install the 10 pin connector in the case engaging the tangs on the connector in the notches in case.
KAA5A610
Output Shaft and Gear Assembly

1. Check that the output shaft bush is not worn or damaged. Replace if necessary. 2. Check for damage to parking pawl teeth on the ring gear. Replace if necessary. 3. Check that the sealing ring grooves have not been damaged. 4. Lubricate the sealing rings with automatic transmission fluid. 5. Assemble the sealing rings to the output shaft with the scarf cut uppermost.
KAA5A970
6. If previously dismantled, assemble the ring gear to the output shaft and secure with circlip. Ensure that the circlip is firmly seated in its groove. 7. Install the No. 10 needle bearing assembly onto the output shaft using petroleum jelly. 8. Carefully install the output shaft assembly in the case to prevent damage to the sealing rings.
KAA5A980
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-177 Rear Band Assembly

1. Check the rear band for any cracks or damage along the lining and metal backing. 2. Install the reaction anchor strut into the main case, without shims. 3. Carefully install the rear band into the transmission case and ensure that it is properly fitted in the case. Notice: If fitting a new band, soak the new band in automatic transmission fluid for a minimum of five minutes prior to assembly.
KAA5A950
4. Position the apply strut on the rear band then engage the apply strut in the servo lever. 5. Install the cam plate and tighten the screws to specification. Installation Notice Tightening Torque 16-22 Nm (12-16 lb-ft)
KAA5A960
Rear Servo Assembly

1. Check the servo piston O rings and gasket for any damage. 2. Lubricate the servo piston O rings with automatic transmission fluid, and fit the O rings to the piston grooves. 3. Assemble the piston to the cover, ensuring that O ring compression is adequate but not excessive. 4. Align the spring on the piston spigot, then position the rear servo rod into the spigot.
KAA5A630
5. Assemble the gasket to the cover and fit the assembly to the case. Notice: Do not use petroleum jelly on the gasket. 6. Apply additional Loctite 202 or equivalent as required to the rear servo to case bolts. Install the bolts and tighten to specification. Installation Notice Tightening Torque 30-35 Nm (22-26 lb-ft)
KAA5A990
SSANGYONG Y200
5A-178 AUTOMATIC TRANSMISSION Planet Carrier Assembly and Centre Support

1. Check the carrier and planet assembly for any damage or irregularity and ensure that all pinions rotate freely and that the pinion end float is within 0.10 mm - 0.50 mm.
KAA5A0A0
2. Install the One Way Clutch (OWC) retainer (1) to the planet carrier with the inner edge pointing downwards. Inspect the OWC race and the sprag assemblies for wear or damage. Replace if necessary. 3. Install the outer (3) race in the drum. Press the race to the bottom of the drum and install the retaining circlip (2). Ensure the circlip is firmly seated in its groove. 4. Install the OWC (1) into the outer race with the lip edge uppermost. Lubricate the sprags with automatic transmission fluid.
KAA5A760
5. Check that the plugs are fitted to the centre support, then assemble the centre support into the OWC, ensuring that the support will rotate in an anti-clock-wise direction only. 6. Lubricate the No. 9 needle bearing and washer with petroleum jelly and fit them to the rear face of the planet carrier.
KAA5A750
7. Install the planet assembly and the centre support into the case, and align the centre support mounting bolt holes. 8. Install the centre support bolts finger tight. 9. Install the circlip retainer ensuring that the circlip is completely seated in the groove of the case. 10. Remove the centre support bolts and apply Loctite 222 or equivalent to the threads. Install the bolts and torque to specifications. Installation Notice Tightening Torque
KAA5A560
20-27 Nm (15-20 lb-ft)
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-179 Adaptor Housing Assembly

1. Install a new seal to the adaptor housing. 2. Position a new gasket onto the adaptor housing. Notice: Do not use petroleum jelly to hold the gasket in position. 3. Apply additional Loctite 202 or equivalent as required to the adapter housing bolts. Install the adaptor housing and torque the bolts to specification. Installation Notice
KAA5A0B0
Tightening Torque
30-35 Nm (22-26 lb-ft)
Front Servo Assembly

1. Lubricate the cover O ring with automatic transmission fluid and fit to the cover. 2. LubricatethepistonO rings with automatic transmission fluid and fit to the piston. 3. Assemble the piston, push rod, spring, belleville washer, seat and retaining ring. 4. Fit the piston push rod assembly into the front servo cover.
KAA5A0C0
5. Install the front servo block and spring into the case. 6. Install the front servo assembly into the case.
KAA5A520
7. Compress the servo cover and fit the servo cover retaining circlip, aligning the gap with the pan rail, and ensuring that it is completely seated in its groove. Notice: Ensure that the front servo snap ring is installed correctly. Orient the circlip with the gap at the bottom, near the pan rail.
KAA5A0D0
SSANGYONG Y200
5A-180 AUTOMATIC TRANSMISSION Front Band Assembly

1. Install the reaction anchor strut to the case. 2. Check the band for all cracks or damage along its lining and metal backing. 3. Position the strut retainers on the band.
KAA5A0E0
4. Install the front band into the transmission case, ensuring that it is properly seated in place. Notice: If fitting a new band, soak the band in automatic transmission fluid for a minimum of 5 minutes prior to assembly. 5. Position the reaction strut in its retaining clip and engage it with the band and anchor strut. 6. Position the apply strut in its retaining clip and engage it with the band and the servo piston rod.
KAA5A550
C2/C4 Clutch Assembly

Tools Required 0555-336259 Clutch Spring Compressor 0555-336260 Clutch Pack Clearance Kit Notice:
Check pistons for cracks. Do not mix the clutch piston return springs. Ensure that the snap rings are fitted correctly.
1. Check the feed orifices in the cylinder bore are clear of obstructions. 2. Check the C2 piston bleed orifices are clear of obstructions. 3. Lubricate the O rings with Automatic Transmission Fluid (ATF) 4. Fit the small O ring onto the inner groove, and the large O ring onto the outer groove of the piston. Notice: O rings must not be twisted in the grooves.
KAA5A0F0
SSANGYONG Y200

5. Check the C4 piston bleed orifices are clear of obstructions. 6. Lubricate the O rings with ATF. 7. Fit the small O rings onto the inner groove and the large O rings onto the outer groove of the piston. 8. Position the clutch cylinder with the C2/C4 cavity facing upwards. 9. Fit the C4 piston into the C2 piston with the bleed orifices in alignment. 10. Install the C2/C4 piston assembly into the cylinder, with the piston bleed orifices aligned with the holes on the outside of the cylinder, until the outer diameter of the C2 piston enters the inner diameter of the cylinder.
KAA5A0G0
11. Assemble the piston return spring to the piston, and fit the spring retainer over the spring. 12. Using 0555-336259 clutch spring compressor, compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groove, then remove the tool. Notice: The wire diameter of this spring is 4.3 mm. 13. Check the C1 piston check valves are not damaged and are free to move, and that the cylinder feed orifices are clear of obstructions. 14. Lubricate the O rings with ATF and fit them to their respective grooves. Notice: O rings must not be twisted in the grooves.
KAA5A690
SSANGYONG Y200

15. Position the cylinder with the C1 cavity upwards. Install the piston into the cylinder until the outer diameter of the piston enters the inner diameter of the cylinder. 16. Install the spring and spring retainer onto the piston. 17. Using 0555-336259 clutch spring compressor, compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groove, then remove the tool. Notice: The wire diameter of this spring is 5.26 mm.
KAA5A0H0
18. Install the C2 wave washer into the cylinder with the crest of one wave covering one of the bleed orifices inthe C2 piston.
KAA5A0I0
19. Measure and record the thickness of the flange of the C2 sleeve. 20. Install the C4 clutch plates and wave washer into the C2 actuating sleeve, with the rounded edge of the steel plates down, in the following sequence: Steel plate (selective) Friction disc Steel plate Friction disc Steel plate Friction disc Steel plate Wave washer
SSANGYONG Y200

21. Holding the cylinder horizontal, install the sleeve and clutch plate assembly into the cylinder, with the crest of one wave of the washer in line with one of the holes in the outside of the cylinder, until the sleeve contacts the C2 wave washer. 22. Check the C4 clutch pack clearance using 0555336260 clutch pack clearance kit.
KAA5A0J0
KAA5A0K0
Notice: With the C2 wave spring compressed, and the clutch Pack supporting a 2 kg weight, the dimension from the underside of the C2 pressure plate to the selective steel is to be between 1.4 - 1.8 mm. If the clutch is to be gauged from the top of the pressure plate, then the dimension is to be the actual thickness of the pressure plate plus 1.4 - 1.8 mm. 23. Use selective plates to achieve the correct specification. If new friction plates are being fitted, remove the clutch pack and soak the friction plates in ATF for a minimum of 5 minutes prior to reassembly. Notice: The clutch pack clearance must be taken before the elements are soaked in ATF. 24. Reassemble the sleeve and clutch pack into the cylinder. Observe the alignment of the wave washer to the hole in the cylinder. 25. Install the C2 clutch plates in the cylinder in the following sequence: Friction disc Steel plate Friction disc Steel plate Steel plate (0574-000013, `014, `015, `016, `019, `022), or Friction disc (0574-000012 & `017) Steel plate (selective) Friction disc Steel plate (selective) Friction disc
KAA5A0L0
SSANGYONG Y200

26. Check the clutch pack clearance using only the weight from 0555-336260 clutch pack clearance kit. Notice: With the clutch pack supporting a 2 kgweight, the dimension from the C3 clutch hub locating step to the friction plate is to be between 0.80 - 1.05 mm. 27. Use selective plates to achieve the correct specifica-tion. If new friction plates are being fitted, remove the clutch pack and soak the friction plates in ATF for a minimum of 5 minutes prior to reassembly. Notice: The clutch pack clearance must be taken before the elements are soaked in ATF. 28. Lubricate and fit the 3-4 OWC and end caps to the C2 hub.
KAA5A0M0
29. Align the tangs and fit the nylon thrust washer onto the C4 hub. 30. Align and fit the C4 hub to the C2 clutch and the OWC assembly. 31. Check the rotation of the C2 hub. While holding the C4 hub, the C2 hub should rotate in the clockwise direction and lockup in the anticlockwise direction when viewed from the C2 hub.
KAA5A0N0
32. Apply petroleum jelly to the No. 5 needle bearing and fit it to the C4 hub. 33. Remove the C2 clutch plates from the clutch cylinder. 34. Fit the thrust plate over the cylinder inner hub. 35. Engage the C2/C4 clutch hub assembly in the C4 clutch plates. 36. Install the C2 clutch plates. 37. Install the C3 hub and secure it with the circlip, ensuring that the circlip is firmly seated in its groove.
KAA5A0O0
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-185 C3 Clutch and Reverse Sun Gear Assembly

Tools Required 0555-336259 Clutch Spring Compressor 0555-336260 Clutch Pack Clearance Kit 1. Check the orifices in the cylinder are clear of obstructions. 2. Check the C3 cylinder bush outside diameter and the centre support inside diameter are in good condition and not damaged. Coat the sealing rings with automatic transmission fluid and fit into the C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and thrust face for condition. Coat the O ring with automatic transmission fluid and fit it to the groove of the reverse sun gear. 4. Lubricate the C3 washer with petroleum jelly and fit to the inner face of the reverse sun gear. 5. Install the reverse sun gear in the C3 cylinder, ensuring that the O ring compression is adequate but not excessive. Notice: O rings must not be twisted in the grooves.
KAA5A0P0
6. Coat the C3 piston O rings with automatic transmission fluid and fit the small O ring onto the inner ring and the large O ring onto the outer ring of the C3 piston. 7. Check that the bleed orifices of the piston are clean and clear of obstructions. 8. Install the C3 piston in the cylinder until the outside diameter of the piston enters the inside diameter of the cylinder. Notice: Take care not to cut the O ring.
KAA5A0Q0
9. Assemble the spring and spring retainer on the piston. Using 0555-336259 clutch spring compressor compress the spring sufficiently to enable the installation of the retaining circlip, ensuring that the circlip is firmly seated in the groove, and remove the tool. 10. Fit the C3 wave plate to the C3 piston face, ensuring that one crest of the wave plate of the C3 piston face is aligned over one of the piston orifices.
KAA5A730
SSANGYONG Y200

11. Assemble the clutch plates and discs into the cylinder in the following sequence : Steel plate Friction disc Steel plate Steel plate (0574-000013, `014, `015, `016, `019, `022), or Friction disc (0574-000012, `017) Steel plate (selective) Friction disc Steel plate (selective) Friction disc 12. Align and fit the pressure plate with the counterbore facing away from the clutch plates.
KAA5A0R0
KAA5A0S0
13. Install the circlip. 14. Check the C3 clutch clearance using 0555-336260 clutch pack clearance kit in the following manner (weight only). a. Place the weight on the pressure plate and measure the distance from the end of the cylinder to the top of the pressure plate. b. Record this figure. c. Remove the weight. d. Lift the pressure plate up against the circlip and measure the distance from the end of the cylinder to the top of the pressure plate. e. Record this figure. f. Subtract the second reading from the first reading to obtain the clutch pack clearance.
SSANGYONG Y200

Notice: With the clutch pack supporting a weight of 2kg, the clearance between the snap ring and the top of the pressure plate is to be between 1.07 - 1.45 mm. 15. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic transmission fluid for a minimum of five minutes prior to reassembly. Notice: The clutch pack clearance must be taken before the elements are soaked in automatic transmission fluid.
KAA5A0TA
Forward Sun Gear and C3 Clutch Pack Assembly

1. Fit the No.7 needle bearing assembly over the forward sun gear, ensuring that the thrust washer is between the bearing and the sun gear. 2. Lubricate the lipped thrust plate with petroleum jelly and fit the thrust plate onto the reverse sun gear.
KAA5A0U0
3. Align and fit the C3 clutch assembly over the forward sun gear.
KAA5A0V0
4. Lubricate the No.6 needle bearing with petroleum jelly and fit it to the thrust plate. Ensure the lugs on the outside diameter of the bearing fit in the thrust plate counterbore. 5. Align and fit the plastic thrust washer to the thrust plate with petroleum jelly. 6. Install the assembly over the forward sun gear shaft against the No. 6 needle bearing. 7. Place the assembly to one side.
KAA5A0W0
SSANGYONG Y200
5A-188 AUTOMATIC TRANSMISSION C1 Clutch Overdrive Shaft and Input Shaft Assembly
Tools Required 0555-336260 Clutch Pack Clearance Kit Notice: Ensure that the snap rings are fitted correctly. Check pistons for cracks, especially the C1 piston. Do not mix clutch piston return springs. If the C1/C2 clutch packs separate from the C3 clutch pack, make sure the No. 6 bearing doesnt drop out of the bearing retainer. 1. Check the overdrive shaft grooves for any defect. 2. Coat the sealing rings, large and small, with petroleum jelly and fit them to the overdrive shaft. The sealing rings may be held in place with a small amount of petroleum jelly.
KAA5A0X0
KAA5A0Y0
3. Assemble the clutch plate and disc into the cylinder in the following sequence: Steel plate Friction disc Steel plate Friction disc Steel plate Steel plate ( 0574-000013, `014, `015, `016, `019, `022), or friction disc (0574-000012 & `017) Steel plate (selective) Friction disc Steel plate (selective) Friction disc
SSANGYONG Y200

4. Check the clutch pack clearance using 0555336260 clutch pack clearance kit. 5. Use selective plates to achieve the correct specification. Notice: With the clutch pack supporting a 2 kg weight, the dimension from the input shaft locating stop to the friction disc must be 0.70 - 0.90 mm. 6. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic transmission fluid for a minimum of five minutes prior to assembly.
KAA5A0Z0
Notice: The clutch pack clearance must be taken before elements are soaked in automatic transmission fluid.
KAA5A660
7. Check the fit of the C1 clutch hub on the overdrive shaft. If it is loose, the hub and shaft assembly must be replaced. 8. Coat the small nylon thrust spacer with petroleum jelly and install it over the overdrive shaft. 9. Carefully fit the overdrive shaft into the C1 cylinder so as not to damage the sealing ring. 10. Fit the small bronze C1 hub thrust washer in place with petroleum jelly. 11. Check the input shaft for any defect. Fit the input shaft into the cylinder and secure it with the circlip, ensuring that the circlip is completely seated in the groove. 12. Coat the sealing rings with petroleum jelly and fit onto the input shaft.
KAA5A1A0
SSANGYONG Y200

13. Assemble the C1/C2/C4 clutch assembly to the C3 clutch and sun gear assembly. 14. Install this assembly in the transmission case.
KAA5A1B0
Pump Cover and Converter Support

Notice: Do not wash the nose of solenoids in solvent. Ensure that the correct O ring is fitted for the application. Be careful not to damage the needle bearings on the assembly. Avoid any axial impact loads during assembly. Check the transmission end float. This will help to detect any missing parts or incorrect assembly.
1. Check the pump body for any damage, chips or irregularity. Check that the bush is firmly staked in the drive gear. 2. Install the seal flush with the front face of the pump body. 3. Lubricate the pump bush, and the drive and driven gears, with automatic transmission fluid.
KAA5A1C0
4. Install the pump driven gear and the pump drive gear into the pump body. 5. Using a straight edge and thickness gauge, check that the clearance between pump face and gears is 0.04 - 0.018 mm. 6. Lubricate the pump body O ring with automatic transmission fluid and fit it to the pump body. Put the pump body to one side.
KAA5A810
SSANGYONG Y200

7. Ensure that the pump cover cavities, ports and holes are clean and free of any obstruction. 8. Lubricate all loose parts with automatic transmission fluid prior to assembly.
KAA5A1D0
9. Assemble the primary regulator valve, spring and plunger to the pump cover, ensuring that the regulator valve slides freely, then fit the regulator valve plug and O ring. 10. Install the retaining pin.
KAA5A1E0
11. Install the converter clutch regulator valve, plug, spring and O ring.
KAA5A1F0
12. Install the retaining pin.
KAA5A1GO KAA5A1G0
SSANGYONG Y200

13. Install the converter clutch control valve, spring, plug, and O ring. 14. Install the retaining pin.
KAA5A1H0
15. Install the converter release check ball and spring. 16. Install the gasket on the pump cover.
KAA5A1J0
17. Install the cover plate, solenoid 7 with the retainer and the solenoid wiring retainer to the pump cover, ensuring that the periphery of the cover plate is flush with the periphery of the pump cover. 18. Tighten the screws to specification in the order. (1-5) Installation Notice Tightening Torque 13-16 Nm (10-12 lb-ft)
19. Tighten the solenoid 7 screw. Installation Notice

KAA5A1K0
Tightening Torque
13-16 Nm (10-12 lb-ft)
Check that neither the wiring nor the connector protrudes excessively, in order that at assembly neither the wiring and the connector contacts or rubs on the input shaft or the C1/ C2 clutch cylinder.
SSANGYONG Y200

20. Assemble the pump to the pump cover. 21. Tighten all bolts and the crescent screw finger tight, ensuring that the pump is flush against the pump cover. Tighten the bolts and the screw to specification in the order. (A-F) Installation Notice Tightening Bolt (A-E) : 24-27 Nm (18-20 lb-ft) Torque Screw (F) : 13-16 Nm (10-12 lb-ft) 22. Install the pump to transmission case gasket onto the case. 23. Fit the O ring to the pump cover outer diameter. 24. Install the pump and cover assembly over the input shaft being careful not to damage the sealing rings. Apply additional Loctite 202 or equivalent as required to the pump cover to case bolts. Install and tighten bolts to specification. Installation Notice Tightening Torque 24-34 Nm (18-25 lb-ft)
KAA5A1L0
KAA5A1M0
KAA5A1N0
25. Check that the transmission end float is 0.50 0.65 mm. If the unshimmed end float clearance is greater than specification, shims are to be placed between the No. 4 bearing and the input shaft bearing surface. If the end float clearance is less than 0.5 mm then the transmission has been assembled incorrectly or the parts are out of specification. 26. Perform the following steps to check the end float : a. Attach a dial indicator to the front of the transmission case with the stylus resting on the end of the input shaft. b. Apply a force of approximately 250 N or 25 kg to the input shaft. c. Zero the dial indicator. d. Place a small lever behind the forward clutch cylinder and lever the cylinder forward. e. The measurement recorded on the dial indicator is the transmission end float or clearance between the No.4 bearing and the converter support tube. 27. On completion of this procedure, adjust the front and rear bands to specifications. Refer to Front and Rear Band Adjustment in this section.
SSANGYONG Y200
5A-194 AUTOMATIC TRANSMISSION Valve Body

Notice: Do not wash the nose of solenoids in solvent. Be aware of ball positions in the upper valve body. Be aware of 1-2 and 3-4 shift valve positions, they can be swapped. Check the 4-3 sequence valve and spring orientation. Check that the 12 mm ball is in the lower body. Check the line pressure relief valve for swarf, and be aware of replacing the shims. When servicing the transmission, ensure that the solenoid 5 damper spring is not broken. Locate the detent spring central to the detent lever. Wash the upper and lower valve bodies thoroughly with cleansing solvent and blow dry.
Check the valve body cavities, ports and holes for damage or obstructions. The orifices in the valve body are for stability and safeguard. Do not drill them larger. Thoroughly wash all loose components. Check that all valves slide freely in their location.
1. Install the detent lever locating pin 2. Install the Band Apply Regulator (BAR) valve, springs, plunger and retaining pin.
KAA5A1O0
3. Install the line pressure relief valve, tapered end first, spring and disc. Secure with the retaining pin.
KAA5A1P0
SSANGYONG Y200

4. Install the solenoid 5 damper guide and spring, piston and retaining pin.
KAA5A870
5. Install the 4-3 sequence valve, spring, plug and retaining plate.
KAA5A860
6. Install the 1-2 shift valve, plug and retaining pin.
KAA5A1Q0
7. Install the 2-3 shift valve and retaining pin.
KAA5A1R0
SSANGYONG Y200

8. Install the 3-4 shift valve and retaining pin.
KAA5A1S0
9. Install the Clutch Apply Regulator (CAR) valve, springs, plunger and retaining pin.
KAA5A1T0
10. Install the solenoid supply valve, spring and retaining plate. Notice: This aluminum valve is easily damaged. 11. Install solenoid 6 plunger, spring and retaining pin.
KAA5A1U0
12. Position the third feed ball (large nylon) in the valve body and install the solenoid 6 filter. 13. Check the separator plate for burrs and damage. Repair or replace the separator plate as necessary. 14. Check the upper and lower valve body gaskets for damage. Replace the gaskets as necessary. 15. Install the lower valve body gasket on the lower valve body.
KAA5A850
SSANGYONG Y200

16. Install the reverse lockout valve, spring, plug and retaining plate. Ensure that the valve is correctly oriented.
KAA5A1V0
17. Position the five nylon ball checks in the upper valve body. 18. Fit the upper valve body gasket. Install the separator plate over the upper valve body.
KAA5A840
19. Holding the separator plate to the upper valve body to prevent the check balls from falling out, install the upper valve body on the lower valve body. Install all screws finger tight then tighten the screws to specification in the prescribed sequence. Installation Notice Tightening Torque 11-16 Nm (8-12 lb-ft)
20. Install solenoids 1, 2, 3, 4 and 6. Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification.
KAA5A830
Installation Notice Tightening Torque 8-12 Nm (71-106 lb-in)
The wiring loom ground wire eyelet terminal is secured beneath the solenoid 1 retainer.
SSANGYONG Y200

21. Install solenoid 5. Ensure that the solenoid is pushed firmly into the valve body by the retainer and that the screw is tightened to specification. Installation Notice Tightening Torque 8-12 Nm (71-106 lb-in)
KAA5A1W0
22. Install the detent spring assembly (spring, support plate and screw), ensuring that the screw is tightened to specification. Check the spring for wear or damage. Installation Notice Tightening Torque 20-22 Nm (15-16 lb-ft)
KAA5A1X0
23. Install the manual shift valve. Notice: Be aware that the manual valve will fall out of the valve body.
KAA5A1Y0
24. Align the valve body assembly on the transmission case and install the manual valve lever to manual valve link. Fit the long end of the link to the manual valve first. Install the securing bolts and tighten to specification in the specified sequence. Installation Notice Tightening Torque 8-13 Nm (71-115 lb-in)
KAA5A1Z0
SSANGYONG Y200

25. Check the alignment of the detent roller and the manual lever quadrant. 26. Connect the solenoid wiring as detailed below: Solenoid 1 - red Solenoid 2 - bIue Solenoid 3 - yellow Solenoid 4 - orange Solenoid 5 - green Solenoid 6 - violet Notice: All hardware must be correctly installed and torqued to specification.
KAA5A2A0
Oil Filter and Pan Assembly

Notice: Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has occurred. To aid the assembly of the pan gasket, use a small amount of Vaseline at the pan/gasket interface. This ensures that the gasket remains on the pan ridge. Do not over torque pan bolts as this may distort the pan and cause leaks. Ensure that the internal line pressure plus in the valve body is fitted.
KAA5A510
1. Lubricate the oil filter sealing ring with automatic transmission fluid.
2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted. 3. Secure the oil filter assembly with the retainer. 4. Check that the magnet is located in the dimple in the corner of the oil pan. 5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
KAA5A2B0
SSANGYONG Y200

6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence Do not over torque. Installation Notice Tightening Torque 4-6 N m (35-53 lb-in)
KAA5A2C0
Torque Converter and Housing Assembly

1. Locate the torque converter housing on the transmission main case. 2. Apply additional Loctite 202 or equivalent as required to the converter housing to case bolts. Install and tighten bolts to specification. Installation Notice Tightening Torque 54-68 Nm (40-50 lb-ft)
KAA5A2D0
All the hardware must be correctly installed and torqued to specification. 3. Fit the converter ensuring that the tangs are engaged in the pump gear. Ensure that the tangs do not contact the pump seal.
Output Flange Assembly (2WD Mode)

1. Position the transmission detent lever into the park position and lock the output shaft. 2. Clear the threads on the output shaft and apply Loctite 243 or equivalent as required to threads. 3. Install the flange, O ring and torque the nut to specification. Installation Notice Tightening Torque
KAC5A040 KAC5A040
35 N m (26 lb-ft)
SSANGYONG Y200
FRONT AND REAR BAND ADJUSTMENT

Front Band Setting Procedure
KAA5A2E0
1. Measure the projection of the front servo push rod from the transmission case dimension A . a. Apply air at 650/700 kPa to the front servo apply area (B1 outer) b. Measure the travel of the push rod and subtract 3 mm to find the shim size required. c. Release the air. Notice: A minimum of one shim is required at all times - minimum shim size is 1 mm. The thickness of available shims are listed in the table below. Thickness(mm) 0.95/1.05 1.15/1.25 1.44/1.56 1.73/1.87 1.93/2.07 2.12/2.28 2.42/2.58 2.61/2.79 Part Number 0574-037017 0574-037018 0574-037019 0574-037020 0574-037021 0574-037022 0574-037023 0574-037024
2. Fit the selected shim(s) to the shank of the anchor strut as follows: a. Inspect the shim(s) for damage, wear or corrosion. Replace as necessary. b. The shim(s) are to be installed between the case abutment face and the anchor strut flange. c. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced. d. Shim(s) are to be pressed on by hand until an audible click is heard. The click indicates that the shim is clipped home correctly. 3. Re-check that the push rod travel. (3mm 0.25mm)
SSANGYONG Y200
5A-202 AUTOMATIC TRANSMISSION Rear Band Setting Procedure
KAA5A2F0
1. Measure distance A from the rear servo piston to the inner face of the transmission case using vernier calipers. a. Apply air at 650/700 kPa to the rear servo apply area (B2 outer) b. Measure the travel of the piston, subtract 3.75 mm and divide the remainder by 2.5 to find shim size. c. Release the air. Notice: A minimum of one shim is required at all times - minimum shim size is 1 mm. The thickness of available shims are listed in the table below. Thickness(mm) 0.0.95/1.05 1.15/1.25 1.44/1.56 1.73/1.87 1.93/2.07 2.12/2.28 2.42/2.58 2.61/2.79 Part Number 0574-037017 0574-037018 0574-037019 0574-037020 0574-037021 0574-037022 0574-037023 0574-037024
2. Fit the selected shim(s) to the shank of the anchor strut as follows. a. Inspect the shim(s) for damage, wear or corrosion and replace as necessary. The shim(s) are to be installed between the case abutment face and the anchor strut flange. b. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced c. The shim(s) are to be pressed on by hand until an audible click is heard. The click indicates that the shim is clipped home correctly. 3. Re-check that the piston travel. (3.75 mm 0.625 mm)
SSANGYONG Y200
KAA5A2G0
SSANGYONG Y200
GEAR SHIFT CONTROL LEVER

Disassembly and Assembly Procedure
1. Disconnect the negative battery cable. 2. Remove the gear shift control lever assembly. Refer to Section 9G, interior Trim. 3. Remove the gear shift control lever knob. 4. Separate the upper and middle housing from the gear shift control lever assembly by unlocking the lock. 5. Remove the upper housing.
KAA5A5P0
6. Disconnect the P position lamp by turning it from the middle housing.
7. Remove the P position switches assembly bolts. 8. Remove the middle housing with the mode selector switch wiring harness from the gear shift control lever assembly. 9. Separate the P position switches assembly with the P position lamp wiring harness from the gear shift control lever assembly. Notice: Adjust the brake transmission shift interlock ease the operation well.
KAA5A5Q0
10. Remove the clips supporting the springs and bushes from the pin of the pin of the gear shift control lever. 11. Remover the spring and bushes from the pin of the gear shift control lever. 12. Remove the gear shift control lever by pushing the pin. 13. Installation should follow the removal procedure in the reverse order.
KAA5A5R0
SSANGYONG Y200
KICKDOWN SWITCH
1. Separate the Kickdown Switch from the Kickdown Switch bracket by pushing the lock. 2. Disconnect the Kickdown Switch connector. 3. Installation should follow the removal procedure in the reverse order.
KAA5A5S0
TRANSMISSION CONTROL MODULE

1. Disconnect the negative battery cable. 2. Push the driver's seat and disconnect the transmission control module connector.
YAD5A160
3. Removal the TCM mounting bolts and TCM. Installation Notice Tightening Torque 10 N m (89 lb-ft)
YAD5A170
YAD5A180
SSANGYONG Y200
SPECIFICATIONS
GENERAL SPECIFICATION
Model Part Numbers And Applications
SYMC P/NO 36100-05442 36100-05432 36100-05412 Transmission 0574-000013 0574-000012 0574-000014 Engine Version E23 E32 662LA Torque Converter 179K 150K 150K
Model Specifications
Application Torque Converter Mean Diameter of Fluid Circuit Description Maximum Torque Multiplication Gear Ratios First Second Third Fourth Reverse Lubricant Type Capacity Dry System Service Refill Gear Train End Float Gear Set Pinion End Float 9.0 Liters (approx.) 4.5 Liters (approx.) 0.50 - 0.65 mm (0.020 - 0.026 in.) 0.10 - 0.50 mm (0.004 - 0.020 in.) Castrol TQ95 2.741 : 1 1.508 : 1 1.000 : 1 0.708 : 1 2.429 : 1 260 mm (10.2 in.) 2.0 : 1 Descriprtion
Clutch Pack Details

0574-000012 C1 Composition Steel C2 Composition Steel C3 Composition Steel C4 Composition Steel 3 4 3 4 4 4 3 5 5 4 4 5 5 5 4 6 0574-000013 (14)
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-207 Model Part Numbers and Applications E23 Gasoline Engine
MODE THROTTLE OPENING 0% 16 % 31 % NORMAL MODE 49 % 50 % 58 % 64 % 71 % 100 % (WOT) Kidkdowm 0% 16 % 31 % POWER MODE 49 % 50 % 58 % 64 % 71 % 100 % (WOT) Kickdown 1/2 10.1 10.1 13.9 22.3 22.8 27.2 30.9 34.1 47.4 47.9 11.9 11.9 22.5 27.2 30.7 35.1 37.6 40.1 47.4 47.9 2/3 19.3 19.3 30.9 46.1 46.4 53.2 59.4 66.5 91.9 94.0 22.8 22.8 42.0 56.9 64.3 73.2 77.4 81.1 91.9 94.0 3/4 36.4 36.4 47.0 70.5 71.7 89.0 94.0 103.3 147.2 149.6 42.0 42.0 70.0 87.2 96.5 110.8 116.3 121.2 147.2 149.6 4/3 20.8 20.8 28.4 41.8 42 52.7 60 69.3 98.9 139.7 20.8 20.8 33.4 42.0 49.5 60.6 68 77.7 115.0 139.7 SHIFT (km/h) 3/2 8.9 8.9 12.4 18.9 19.2 24.7 28.4 32.6 45.5 86.9 8.9 8.9 17.3 24.7 29.7 37.8 42.5 47.7 66.7 86.9 2/1 9.2 9.2 9.2 9.3 9.3 10.9 12.1 18.6 34.6 45.4 9.2 9.2 9.2 9.2 10.4 15.1 18.1 20.8 33.0 45.4 UNL3 50.7 50.7 50.7 50.7 50.7 59.4 66.8 71.7 81.6 90.7 73.0 73.0 73.0 73.6 76.2 81.6 86.6 86.6 86.6 90.7 LCK3 79.1 79.1 79.1 90.3 58.1 66.8 74.2 76.7 95.1 95.5 75.4 75.4 79.1 94.0 103.9 110.8 116.3 121.2 136.0 95.5 UNL4 71.7 71.7 71.7 74.2 75.4 81.6 86.6 95.8 134.3 147.2 73.0 73.0 73.0 73.6 76.2 81.6 87.8 97.7 142.2 147.2 LCK4 79.1 79.1 79.1 90.3 91.5 100.2 106.4 115.0 147.2 149.6 75.4 75.4 79.1 94.0 103.9 110.8 116.3 121.2 147.2 149.6
SSANGYONG Y200
5A-208 AUTOMATIC TRANSMISSION E32 Gasoline Engine

MODE THROTTLE OPENING 0% 15 % 25 % NORMAL MODE 32% 35 % 45 % 55 % 70 % 100 % (WOT) Kidkdowm 0% 15 % 25 % POWER MODE 32 % 35 % 45 % 55 % 70 % 100 % (WOT) Kickdown SHIFT (km/h) 1/2 11.7 11.7 13.3 16.8 18.6 24.0 31.9 42.1 56.7 57.0 12.3 14.0 23.4 24.6 26.3 32.2 38.6 46.7 56.7 57.0 2/3 20.2 22.8 30.4 36.6 40.1 49.7 66.1 85.4 110.0 110.6 24.6 27.8 43.9 49.1 52.6 65.8 76.9 90.8 110.0 110.6 3/4 39.5 39.5 67.3 76.0 80.4 93.6 114.1 146.2 170.4 175.5 40.9 43.9 65.8 76.6 81.9 105.3 125.8 146.2 170.4 175.5 4/3 24.6 24.6 32.2 38.0 40.9 52.6 70.2 90.7 119.9 163.8 24.6 29.2 39.5 46.1 51.2 67.3 87.7 113.3 148.4 163.8 3/2 10.2 10.2 14.6 19.7 21.9 27.8 32.2 39.5 46.8 104.7 10.2 10.2 17.5 24.9 27.8 37.3 51.2 66.5 89.9 104.7 2/1 10.5 10.5 10.5 11.0 11.7 13.9 17.3 21.9 26 50.3 10.5 10.5 11.0 11.6 12.0 15.4 21.4 28.7 42.4 50.3 UNL3 37.4 37.4 37.4 39.5 40.9 46.8 54.1 64.3 93.6 116.4 76.0 76.0 76.0 81.9 84.8 102.4 111.1 111.1 111.1 116.4 LCK3 81.9 81.9 81.9 83.4 62.9 70.2 79.0 93.6 114.1 119.3 81.9 81.9 81.9 90.7 96.5 117.0 125.8 146.2 170.4 119.3 UNL4 73.1 73.1 73.1 73.1 74.6 81.9 102.4 128.7 152.1 166.7 76.0 76.0 76.0 81.9 84.8 102.4 114.1 128.7 152.1 166.7 LCK4 81.9 81.9 81.9 83.4 86.3 93.6 114.1 146.2 170.4 175.5 81.9 81.9 81.9 90.7 96.5 117.0 125.8 146.2 170.4 175.5
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-209 662LA Diesel Engine

MODE THROTTLE OPENING 0% 25 % 40 % NORMAL MODE 60 % 61 % 70 % 75 % 80 % 100 % (WOT) Kidkdowm 0% 25 % 40 % POWER MODE 60 % 61 % 70 % 75 % 80 % 100 % (WOT) Kickdown SHIFT (km/h) 1/2 11.4 11.4 12.2 14.7 14.7 16.6 18.2 21.8 28.6 34.8 11.7 11.7 14.1 21.8 28.0 29.9 31.3 32.7 34.0 34.8 2/3 20.4 20.4 25.4 36.5 36.7 40.0 43.3 51.7 62.6 68.0 21.8 21.8 27.5 44.6 57.1 59.9 61.8 64.8 67.8 68.0 3/4 35.4 35.4 40.8 61.8 62.0 70.7 76.2 84.4 104.5 110.2 38.1 38.1 43.5 69.4 88.7 93.9 96.6 100.4 105.3 110.2 4/3 26.7 27.2 29.9 38.1 38.4 43.5 49.0 54.4 69.4 100.7 26.7 31.3 32.7 47.6 54.4 61.2 65.3 70.7 83.0 100.7 3/2 9.3 9.3 13.6 21.8 22.0 25.9 28.6 31.3 38.1 63.9 9.3 9.3 16.3 27.2 35.4 40.8 46.3 50.3 54.4 63.9 2/1 9.5 9.5 9.5 9.5 9.5 12.2 13.6 15.0 19.6 31.3 9.5 9.5 10.2 12.8 14.4 15.8 17.4 20.4 23.1 31.3 UNL3 47.6 47.6 47.6 47.6 47.6 47.6 47.6 49.0 57.1 61.2 61.2 61.2 61.2 61.2 61.2 61.2 61.2 61.2 61.2 61.2 LCK3 76.2 76.2 76.2 76.2 50.3 51.7 54.4 57.7 62.6 68.0 76.2 76.2 76.2 76.2 88.7 93.9 96.6 100.4 105.3 68.0 UNL4 72.1 72.1 72.1 72.1 72.1 72.1 72.1 75.1 92.5 100.7 72.1 72.1 72.1 72.1 72.1 72.1 75.1 81.6 92.5 100.7 LCK4 76.2 76.2 76.2 76.2 76.2 77.0 81.6 89.0 104.5 110.2 76.2 76.2 76.2 76.2 88.7 93.9 96.6 100.4 105.3 110.2
SSANGYONG Y200

Application Adaptor Housing to Case Bolts Cam Plate to Case (Parking Pawl) Screws Centre Support to Case Bolts Detent Spring Screw Extension Housing to Case Bolts Front Propeller Shaft Bolts Inhibitor Switch to Case Bolts Oil Cooler Pipes Oil Pan to Case Bolts On/Off Solenoid Retainer Screws Output Flange Nuts Pump Cover Plate to Crescent Screw Pump Cover Plate to Pump Cover Screws Pump Cover to Case Bolts Pump to Pump Cover Bolts Rear Propeller Shaft Bolts Rear Servo Cover to Case Bolts TCM Mounting Bolt Torque Converter Housing to Case Bolts Torque Converter Mounting Bolts Transfer Case to Transmission Housing Bolts Transmission Filler Plug Upper Valve Body to Lower Valve Body Screws Valve Body To Case Bolts Variable Pressure Solenoid (S5) Retainer Screw Nm 30 - 35 16 - 22 20 - 27 20 - 22 54 - 68 70 - 80 4-6 40 - 45 4-6 8 - 12 35 13 - 16 13 - 16 24 - 34 24 - 27 70 - 80 30 - 35 10 54 - 68 42 35 - 60 30 - 35 11 - 16 8 - 13 8 - 12 Lb-Ft 22 - 26 12 - 16 15 - 20 15 - 16 40 - 50 52 - 59 29 - 33 26 10 - 12 10 - 12 18 - 25 18 - 20 52 - 59 22 - 26 40 - 50 31 26 - 44 22 - 26 8 - 12 Lb-Ft ----
SSANGYONG Y200
TCM WIRING DIAGRAM (GASOLINE ENGINE-1 OF 2)
YAD5A210
SSANGYONG Y200
TCM WIRING DIAGRAM (GASOLINE ENGINE-2 OF 2)
YAD5A220
SSANGYONG Y200
TCM WIRING DIAGRAM (DIESEL ENGINE-1 OF 2)
YAD5A230
SSANGYONG Y200
TCM WIRING DIAGRAM (DIESEL ENGINE-2 OF 2)
YAD5A240
SSANGYONG Y200
CONNECTOR END VIEW
KAA5A5O0
SSANGYONG Y200

SPECIAL TOOLS TABLE
0555 - 336256 Transmission Bench Cradle
0555 - 336257 Pump Puller
KAA5A2P0
KAA5A2Q0
0555 - 336259 Clutch Spring Compressor
KAA5A2R0
KAA5A2S0
0555 - 336260 Clutch Pack Clearance Kit
0555 - 336261 Cross Shaft Seal Remover
KAA5A2T0
KAA5A2U0
0555 - 336262 Cross Shaft Seal Installer
0555 - 336263 Cross Shaft Bullet
KAA5A2V0
KAA5A2W0
SSANGYONG Y200
SPECIAL TOOLS TABLE (Cont'd)
0555 - 336265 Cross Shaft Pin Remover / Installer (Inhibitor Switch)
0555 - 336266 Adaptor Housing Seal Installer
KAA5A2X0
KAA5A2Y0
0555 - 336267 Pump Alignment Tool
0555 - 336268 Pump Seal Installer
KAA5A2Z0
KAA5A3A0
0555 - 336269 End Float Measuring Adaptor
0555 - 336270 End Float Measuring Shaft
KAA5A3B0
KAA5A3C0
0555 - 336302 Output Shaft Bullet
0555 - 336045 Solenoid Bench Tester
KAA5A3D0
KAC5A050
SSANGYONG Y200
SPECIAL TOOLS TABLE (Cont'd)
0555 - 332083 Solenoid /Thermistor Electronic Tester
KAC5A060
SSANGYONG Y200
SECTION 6A
POWER STEERING
TABLE OF CONTENTS
General Description and Operation ..................... 6A-2 Specifications ...................................................... 6A-2 Diagnostic Information and Procedures .............. 6A-3 Component Locator ............................................ 6A-4 Power Steering System Locator ............................ 6A-4 Steering Gear Box Cross Section ......................... 6A-5 Power Steering Assembly .................................... 6A-6 General Inspection ............................................... 6A-7 Oil Pump Pressure ............................................... 6A-7 Power Steering Gear Preload Adjustment ............. 6A-8 Oil Change .......................................................... 6A-8 Oil Quantity Check and Air Bleeding .................... 6A-9 Maintenance and Repair ................................... 6A-12 On-Vehicle Service ............................................... 6A-12 Power Steering Pipe/Hose .................................. 6A-12 Power Steering Box Assembly ........................... 6A-13 Steering Gear Pump .......................................... 6A-14 Assembly Installation ........................................ 6A-14 Unit Repair .......................................................... 6A-17 Steering Gear Box ............................................. 6A-17 Special Tools and Equipment ............................ 6A-23 Special Tools Table ............................................ 6A-23
6A-2 POWER STEERING

SPECIFICATIONS
Steering Wheel Steering Gear Box Number of spoke Outer Diameter Type Gear Ratio Steering Angle Oil pump Type MAX. Pressure Outlet Size Tilt column Angle Upper Lower Turning Radius Oil Type Capacity Inner Outer 36 17 32 40 Vane 82 ~ 92 kgf/cm 10.5L/min 124mm 4 4 5.7 m ATF DEXRON II 1L 4-Spoke Type 390 mm Rack and pinion
SSANGYONG Y200
POWER STEERING 6A-3

Phenomena Hard Steering Checks Lack of Lubrication Abnormal Wear or Binding of Steering Ball Joint Damaged or Faulty Steering Gear Improper Preload of Steering Pinion Faulty Steering Shaft Joint Steering Fluid Leaks Lack of Fluid or Air-in System Faulty Steering Oil Pump Steering Pulls to One Side Damaged or Loosened Pump Drive Belt Clogging Oil Line Damaged Wheel or Tire Faulty Suspension System Damaged Steering Linkage Damaged Wheel and Tire Faulty Brake System Faulty Suspension System Excessive Wheel Play Worn Steering Gear Worn or Damaged Steering Ball Joint Loosened Steering Gearbox Bolts Poor Return of Steering Wheel Damaged or Binding Steering Ball Joint Improper Preload of Steering Pinion Damaged Wheel or Tire Faulty Suspension System Steering Wheel Shimmy Damaged Steering Linkage Loosened Steering Gearbox Mounting Bolt Damaged or Binding Steering Ball Joint Worn or Damaged Front Wheel Bearing Damaged Wheel or Tire Faulty Suspension System Abnormal Noise From Steering System Loosened Steering Gearbox Mounting Bolt Faulty Steering Gear Steering Column Linterference Loosened Steering Linkage Damaged or Loosened Oil Pump Drive Belt Loosened Oil Pump Bracket Loosened Oil Pump Mounting Bolt Air-in System Faulty Oil Pump Action Lubricate Replace Replace gear assembly Adjust Replace Repair or replace Replenish or bleed Replace Adjust or replace Repair or replace Repair or replace Repair or replace Repair Repair or replace Repair or replace Repair or replace Replace gear assembly Replace Retighten Replace Replace gear assembly Repair or replace Repair or replace Replace Retighten Replace Replace Repair or replace Repair or replace Retighten Replace gear assembly Replace Retighten Adjust or replace Retighten Retighten Bleed Replace
SSANGYONG Y200
6A-4 POWER STEERING
COMPONENT LOCATOR
POWER STEERING SYSTEM LOCATOR
1
A
YAD6A020
A Mounting Position
1 Steering Component
SSANGYONG Y200
POWER STEERING 6A-5
STEERING GEAR BOX CROSS SECTION
10 1 2 3 4 5 6
YAD6A030
1 2 3 4 5
Tie Rod End Tie Rod Bellows Rack Housing Feed Tube
6 7 8 9 10
Mounting Bracket Tie Rod End Tie Rod End Cylinder Tube Valve Assembly
SSANGYONG Y200
6A-6 POWER STEERING
POWER STEERING ASSEMBLY
12
2
11 10
13
14
9
3
11
10
4
6
YAD6A150
1 2 3 4 5 6 7
Power Steering Pump Reservoir Assembly Power Steering Pump Cap Assembly Clip Return Line Pressure Line Power Steering Gear Power Steering Pipe Mounting Bracket Clip.
8 9 10 11 12 13 14
Hexagon Bolt Fan Screw (M5) Welded Nut Pipe Clamp Hexagon Bolt Nut Bolt
SSANGYONG Y200
POWER STEERING 6A-7
GENERAL INSPECTION
OIL PUMP PRESSURE
Do the pressure checking followed to check the defect of power steering pump. Notice: Before checking, check the power steering oil level and belt tension. When tightening of removing the fitting, prepare the oil container because the oil may drop down. 1. Remove the pressure line fitting of power steering pump. 2. Install the pressure check gauge between the power steering pump and power steering oil pressure line. 3. Put the transmission in neutral position. 4. Pull the lever of parking brake. 5. Open the installed pressure check gauge valve completely. 6. Start the engine and keep it to the idling. 7. Turn the steering wheel several times until the oil temperature is up to the normal operating temperature. 8. Close the pressure check gauge valve completely and then measure the oil pressure. Notice: Do not keep the valve closed for more than 10 seconds to protect the damage of pump. A 53 - 58 kgf/cm
YAD6A040
9. Open the gauge valve completely and then measure the oil pressure. A 3 - 5 kgf/cm
10. If the pressure is within specified value, the pump is normal. If not, replace the power steering pump.
SSANGYONG Y200
6A-8 POWER STEERING
POWER STEERING GEAR PRELOAD ADJUSTMENT

1. Place the steering wheel in front direction. 2. Lift the vehicle using the lifter safely. 3. Remove the adjustment plug lock nut. 4. Measure the torque of adjustment plug.
YAD6A050
5. If torque is excessive or too little, adjust it as specified value. Place the rack gear in center position. Tighten the adjustment plug by 100 kg.cm Turn the pinion gear in order that rack gear move to the left/right end five times. Remove the adjustment plug. Tighten the adjustment plug by 45 - 55 kg.cm Tighten the adjustment plug by 67.5 to C.C.W direction. 6. Tighten the adjustment plug lock nut.
YAD6A060
OIL CHANGE
1. Lift the vehicle slightly using the lifter. 2. Separate the oil supply hose from the power steering pump. 3. Discharge the oil in the oil tank. 4. Connect the oil supply hose with the power steering pump. 5. Separate the oil return line from the oil tank. 6. Remove the high pressure cable in the ignition coil. 7. Operating the ignition motor periodically, turn the steering wheel from lock to lock and discharge the oil through the return line. 8. Connect the return line with the oil tank. 9. Charge the oil in the oil tank as specified quantity. 10. Do bleeding procedure.
MAX MIN
YAD6A070
SSANGYONG Y200
POWER STEERING 6A-9
OIL QUANTITY CHECK AND AIR BLEEDING

Oil Quantity Check
MAX 5mm MIN
1. Place the vehicle on flat road and start the engine and keep it idling. 2. Turn the steering wheel from lock to lock several times until the oil temperature gets to the normal operating condition. 3. The oil level should be placed between MAX and MIN.
YAD6A080
Air Bleeding
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock several times. 2. Connect the fuel feed line and start the engine at idle steed. 3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir. 4. Connect the oil lever is within specification. 5. By turning the steering wheel left to right, check the oil level change.
YAD6A090
Notice: Do bleeding with engine cranking. If bleed with idling, there con be a air contact with oil. If oil is not changes more than 5mm, do bleeding again. If oil level rises suddenly when stopped engine, do bleeding again.
SSANGYONG Y200
6A-10 POWER STEERING
Belt tension Check/Adjustment

1. Check the wear, crack and damage of belt, and if necessary, replace it. 2. Push the center position of belt (10 kg) and then check the deflection of belt.
YAD6A100
3. If the measurement value is not within the specified value, remove the bolt of power steering pump. Adjust the belt tension as moving the pump assembly.
YAD6A110
Power steering wheel Freeplay Check

15mm 15mm
1. Start the engine and place the wheels in straight ahead position. 2. Slightly move the steering wheel to the left/right and measure the steering wheel free play when the front wheel is start to move. Standard Max. 30 mm
Notice: If exceeds standard, the steering column shaft and steering linkage clearance. Replace or repair if necessary.
YAD6A120
Steering Angle Check

1. Place the front wheel on a measuring tool. 2. Rotate steering wheel to the left/right direction and measure steering angle. Standard Inner Outer 36 17 32 40
Notice: If out of standard, check or adjust toe-in.
YAD6A130
SSANGYONG Y200
POWER STEERING 6A-11
Steering Effort Check

1. Place a vehicle on the paved flat ground with front wheels In a straight ahead position. 2. Start the engine and run it at 1,000 rpm. 3. Using a scale, measure the steering effort in both directions. Standard Max. 3.0 kg
Notice: The difference in steering effort of left/ right should be within 0.6 kg.
YAD6A140
SSANGYONG Y200

2
POWER STEERING PIPE/HOSE

Removal
1. Remove the supply pipe (1) and return hose (2) which is installed in power steering pump. Notice: When removing/installing the pipe and hose, prepare the oil container in order that the oil may not drop down.
1
YAD6A160
2. Remove the supply/return pipe installed in power steering gear box.
YAD6A170
3. Remove the oil pipe bracket bolt installed in front bumper and pull off the oil pipe. Notice: First, remove the pipe from the pipe clamp installed in front panel and then pull off the pipe.
YAD6A180
SSANGYONG Y200
POWER STEERING GEAR BOX ASSEMBLY

1. Remove the tie rod installed in steering knuckle. Disassembly the split pin and sloted nut in tie rod end and pull off the tie rod using the special tool.
YAD6A190
2. Remove the joint blot of steering lower shaft and separate the lower shaft from the gear box.
YAD6A200
3. Remove the center bolt in gear box and left mounting bolt. Remove the supply/return pipe connection bolt.
YAD6A210
4. Remove the clamping bolt and pull off the steering gear box assembly.
YAD6A220
SSANGYONG Y200
STEERING GEAR PUMP

1. Separate the drive belt from pump pulley after each pipe and hose is removed.
YAD6A230
2. Remove the bolts/nuts in pump and pull off the pump assembly from engine.
YAD6A240
ASSEMBLY INSTALLATION
1. Install the power steering pump in engine and tighten the bolt/nut as specified torque. Nut Bolt Upper Lower Torque 23 Nm (17 lb-ft) 23 Nm (17 lb-ft)
YAD6A250
2. Install the power steering gear box in frame. Tighten the mounting bolts slightly and then install the gear box clamp in left. Tighten the bolt/nut as specified torque. Notice: Because the length of bolt is same, install them after checking. Installation Notice 95 mm Bolt/Nut (Upper) 95 mm Bolt/Nut (Lower) 70 - 90 Nm (52 - 66 lb-ft) 70 - 90 Nm (52 - 66 lb-in)
YAD6A260
SSANGYONG Y200

3. Completely tighten the mounting bolt/nut which is tightened slightly. Notice: First tighten the center bolt/nut and then tighten bolt/nut as specified torque. Installation Notice Center Bolt/Nut Left Bolt/Nut 70 - 90 Nm (52 - 66 lb-ft) 70 - 90 Nm (52 - 66 lb-in)
YAD6A270
4. Install the steering lower shaft to the gearbox. The joint bolt on the lower shaft should be tightened toward B (threaded) from A (non-threaded). Installation Notice
Tightening Torque
25 - 30 N m (18 - 22 lb-ft)
Notice: When installing the lower shaft to the gear box, the joint bolt (1) should be installed anto the gearbox pinion shaft splines.
YAD6A280
5. Install the tie rod end in steering knuckle. Tighten the sloted nut and then insert the new split pin. Tightening Torque 35 - 45 N m (26 - 33 lb-ft)
YAD6A290
Installation Notice 6. Install the clamp of return pipe in front end panel. Installation Notice Tightening Torque 7 - 10 N m (62 - 89 lb-in)
YAD6A300
SSANGYONG Y200

7. Install the supply/return pipe in gear box housing. Installation Notice Supply Pipe 2
1
12 - 18 Nm (9 - 13 lb-ft) 12 - 18 Nm (9 - 13 lb-ft)
Return Pipe 1
YAD6A310
8. Install the supply pipe in steering gear pump.
YAD6A320
9. Insert the return hose (2) Into the reservoir tank (1) and then insert the spring clamp (3) as like the picture. Notice: After inserting the hose into the reservoir tank completely, install in order that the spring clamp is placed in the center of nipple. 10. After installing completely, do bleeding.
3
2
YAD6A330
SSANGYONG Y200
UNIT REPAIR
STEERING GEAR BOX
Disassembly
1. Disassembly the tie rod end boot (a).
YAD6A340
2. Remove the cylinder tube (2) in gear box.

2
1
3. Remove the valve tube (1) in gear box.
YAD6A350
1
2
3
4. Remove the lock nut (1) and separate the plug (2) and spring (3).
YAD6A360
5. Remove the dust cover (1) and pull off the retainer ring (2).
YAD6A370
SSANGYONG Y200

6. Remove the pinion dust cover (lower) (3) and remove the pinion lock nut (4). Notice: When removing the steering pinion lock nut, be sure to fix the pinion gear n order to protect the damage of pinion gear.
3
YAD6A380
7. Tapping the pinion lower part carefully using the plane draft and hammer, remove the steering pinion (5) from the pinion bearing.
5
Notice: Tap the draft using the hammer as lik the picture.
YAD6A390
8. Tapping the pinion bearing softly using the plane and long draft and rubber hammer, remove the bearing.
6
YAD6A400
7
8
9
9. Remove the pinion shaft seal (7), needle bearing (8), retainer ring (9). Notice: Do not overhaul the power steering gear housing and rack gear, if the damage happened, replace them with assembly.
YAD6A410
SSANGYONG Y200
Rack Gear Shaft Checks

3
2
1. Check the rack gear damage. Set up the v-block (1) on the plane table.
Put the rack gear (2, 4) on the V-block. Measure the straightness of rack gear using the dial gauge (3). Check the rack gear for the wear or damage.
YAD6A420
2. Check the steering pinion gear for the damage.
Check the pinion gear (1) for the wear or damage. Check the looseness and normal operating of bearing (2).
1
YAD6A430
3. Check the tie rod end, rack and pinion bellows for the damage. Check the tie rod end boot (1) for the crack or wear. Check the rack and pinion boot for the crack or wear.
YAD6A440
4. Check the steering gear housing for the crack, deformation and wear.
a
YAD6A450
SSANGYONG Y200

5. Check the tie rod end and ball joint for the damage. Check the tie rod end ball joint for the normal operating,
Check the tie rod ball joint for the normal operating and the deflection by the self-weight of tie rod.
6. After checking, if out of specified value or damaged, replace them with the new one.
YAD6A460
7. Check the tie rod end and the rotation part of ball joint for the damage.
YAD6A470
8. Check the tie rod end and rack/pinion boot for the crack and wear. 9. Check the metal part for the damage.
Check the pinion gear for the damage or wear. Check the rack gear for the damage or wear. Check the steering gear housing for the damage or wear.
YAD6A480
1
2
10. Check the bearing and oil seal for the damage. Check the pinion shaft seal for the wear or leakage. Check the needle bearing for the wear. Check the steering pinion bearing for the wear. 11. After checking, if out of specified value or damaged, replace them with the new one.
YAD6A490
SSANGYONG Y200
Assembly
1. Install the steering pinion assembly gear. Install the retaining ring.
1
Install the needle bearing. Tapping the pinion shaft seal carefully in diagonal direction using the thin draft (1), assemble them.
YAD6A500
2. Tighten the steering pinion lock nut (4) as specified torque. Notice: Because the pinion bearing is inserted into the pinion lock nut by force, be careful not to be eccentric.
4
YAD6A510
3. Tighten the steering pinion dust cover (5) as specified torque. Install the retaining ring (6). Install the plastic dust cover (7).
5
YAD6A520
4. Install the rack bearing. Install the adjustment spring. Tighten the adjustment plug as specified torque. Tighten the adjustment plug lock nut. Adjust the steering gear preload.
YAD6A480
SSANGYONG Y200

5. Install the fluid pressure line in power steering gear and tighten them as specified torque. 1 Tighten the fitting to the piston side. 2 Tighten the fitting to the cylinder side.
YAD6A530
6. Assemble the tie rod end boot. Notice: Apply the grease to the tie rod end ball joint and boot.
YAD6A540
SSANGYONG Y200

SPECIAL TOOLS TABLE
Tie Rod End Remover
YAD6A550
SSANGYONG Y200
SECTION 6E
STEERING COLUMN
TABLE OF CONTENTS
General Description and Operation ............... Steering Wheel ................................................. Column & Shaft Assembly ............................... Lower Shaft ....................................................... Tightening Torque ............................................. 6E-2 6E-2 6E-2 6E-2 6E-3 Steering Column & Wheel ................................ 6E-7 Maintenance and Repair .................................. 6E-8 On-Vehicle Service .............................................. 6E-8 Steering Column ............................................... 6E-8 Steering Wheel & Shaft ................................... 6E-11 Unit Repair ........................................................ 6E-15 Steering Gear Box ...........................................6E-15 Special Tools And Equipment ........................ 6E-16 Special Tools Table ......................................... 6E-16
Diagnostic Information and Procedures ........ 6E-4 Component Locator ......................................... 6E-5 Steering Column Assembly .............................. 6E-5 Steering Assembly Cross Section ................... 6E-6
6E-2 STEERING COLUMN

The steering wheel and column have the function of steering. When collidings they soften the impact by the steering wheel and also are designed in order that the steering column shaft may be folded or absorb the impact. The ignition switch and lock cylinder is installed in steering column. If pulling the ignition switch in LOCK position and draw out the key, as the lock cylinder installed in column operates, you cannot steer the vehicle.
COLUMN & SHAFT ASSEMBLY
STEERING WHEEL
YAD6E020
LOWER SHAFT
YAD6E010
Type Outer Diameter
4 Spoke Type 390 mm
The vibration absorbing damper is mounted in steering wheel in order that the vibration may be minimized.
YAD6E030
Type Angle
4 Spoke Type 390 mm
Because the lower shaft uses the constant velocity joint which the angular belocity change is not, torque fluctuation is very little.
SSANGYONG Y200
STEERING COLUMN 6E-3
TIGHTENING TORQUE
Item Steering Column Shaft Steering Column Mounting Bolt (upper) Steering Column Mounting Bolt (lower) Steering Wheel and Steering Column shaft Lock Nut Steering Column and Airbag Module Connection Bolt Steering Column and Lower Shaft Connection Bolt Power Steering Gear Box Steering Gear Box and Gear Box Cross Member Mounting Bolt Steering Gear Box and Lower Shaft Connection Bolt Tie Rod End and Steering Lock Connection Nut Tie Rod End Lock Nut Steering Gear Box and Pressure Hose Connection Nut Steering Gear Box and Return Line Connection Nut Power Steering Pump Power Pump Bracket and Timing Gear Case Cover Mounting Bolt Power Pump and Pressure Hose Connection Nut Power Steering Line Return Line and Cilp Connection Bolt 40 - 50 Nm (30 - 37 lb-ft) 9 - 14 Nm (80 - 124 lb-in) 25 - 30 Nm (18 - 22 lb-ft) 35 - 45 Nm (26 - 33 lb-ft) 65 - 80 Nm (48 - 59 lb-ft) 15 - 20 Nm (11 - 15 lb-ft) 15 - 20 Nm (11 - 15 lb-ft) 20 - 23 Nm (15 - 17 lb-ft) Torque 20 - 25 Nm (15 - 18 lb-ft) 20 - 25 Nm (15 - 18 lb-ft) 40 - 60 Nm (30 - 44 lb-ft) 7 - 11 Nm (62 - 97 lb-in) 25 - 30 Nm (18 - 22 lb-ft) 70 - 90 Nm (52 - 66 lb-ft)
SSANGYONG Y200

Phenomena Noise (When operating the steering wheel) Excessive Steering Force Poor Operating of Ignition Switch Inner Defect of Lock Cylinder Inner Defect of Ignition Switch Replace steering column Replace ignition switch Checks Loosened or Poor Tightening Steering Column Nut Worn or Damaged Steering Shaft Bearing Lossened or Poor Interm shaft Pinch Bolt Worn or Damaged Steering Shaft Bearing Action Retightening Replace steering column Retightening Replace steering column
SSANGYONG Y200
COMPONENT LOCATOR
STEERING COLUMN ASSEMBLY
1 2 3
YAD6E040
1 Steering Wheel 2 Column Shaft Assembly
3 Lower Shaft Assembly 4 Steering Gear Assembly
SSANGYONG Y200
STEERING ASSEMBLY CROSS SECTION

Side
Rear
YAD6E050
SSANGYONG Y200
STEERING COLUMN & WHEEL
5
6 7
YAD6E060
1 2 3 4
Steering Column shaft Lower Shaft Bolt Nut
5 Bolt 6 Washer 7 Bolt
SSANGYONG Y200

STEERING COLUMN
Removal
1. Disconnect the negative terminal of battery and place the tires in front straight direction. 2. Untighten the fixing screw in the left/right of steering wheel and remove the horn pad (airbag module assembly) in the wheel. At this time, remove the airbag module connector simultaneously.
YAD6E070
3. Untighten the wheel fixing nuts and remove the steering wheel using the special tool. Notice: When you remove the wheel, be sure to do alignment mark in column shaft and wheel. Remove the remote control switch connector (airbag connector, horn connector)
YAD6E080
4. Remove the fuel filler door release cable, hood release cable, side mirror switch.
YAD6E090
SSANGYONG Y200

5. Remove the instrument panel side cover and untighten the fixing bolts of inner fuse box.
YAD6E100
6. Untighten the side fixing bolts/screws of instrument panel and then remove the panel.
YAD6E110
7. Ntighten the column fixing bolts from the steering column shaft and then remove the upper/lower column cover.
YAD6E120
8. Disconnect the connector connected with the combination switch and the fuel cut vacuum hose. Notice: Be sure to check the fuel cut hose because the identification color is marked.
YAD6E130
SSANGYONG Y200

9. Remove the contact coil from the steering column shaft.
YAD6E140
10. Remove the combination switch assembly from the column shaft which the airbag module is separated.
YAD6E150
11. Mark the assembly marking on the column shaft and lower shaft and then untighten the upper fixing bolt of column shaft.
YAD6E160
12. Untighten the housing floor fixing bolts of steering column shaft.
YAD6E170
SSANGYONG Y200

13. Untighten the upper fixing bolts (2EA) of steering column shaft and then remove the steering column assembly.
YAD6E180
STEERING WHEEL & SHAFT

Removal
1. Remove the upper bolt of lower shaft. 2. Remove the bolt of lower shaft and steering gear box coupling and then remove the lower shaft Notice: Mark the assembly marking.
YAD6E190
Installation
B A
1. Insert the lower shaft into the gear box (spline part) and then tighten the blots as specified torque. Notice: Install the lower shaft to tighten the bolt in nonspline part of upper spline part Install to align the assembly marking Installation Notice Tightening Torque
YAD6E200
30 - 40 N m (22 - 30 lb-ft)
2. Install the steering column shaft in the lower shaft to align the assembly marking and then tighten the bolt. Notice: Install the lower shaft to tighten the bolt in nonspline part of upper spline part Install to align the assembly marking Installation Notice Tightening Torque
YAD6E210
30 - 40 N m (22 - 30 lb-ft)
SSANGYONG Y200

3. Tighten the floor bolt of steering column as specified torque. Installation Notice Tightening Torque 20 - 25 N m (15 - 18 lb-ft)
4. Tighten the upper bolt of steering column shaft as specified torque. Installation Notice Tightening Torque
YAD6E220
20 - 25 N m (15 - 18 lb-ft)
5. Connect each wiring connector of steering column.
YAD6E230
6. Install the combination switch assembly in steering column shaft.
YAD6E240
7. Install the contact coil in steering column shaft which the combination switch is installed. Notice: When you adjust the neutral position of contact coil, rotate the contact coil to C.W. direction until it stops and then again rotate it by 2.9 0.2 to C.C.W. direction. Align the mark ( ) Which is marked in contact coil.
YAD6E250
SSANGYONG Y200

8. Connect the fuel cut vacuum hose with the connector. Notice: The identification color is marked in fuel cut vacuum hose. Classification Fuel Cut Vacuum Hose-Inlet Fuel Cut Vacuum Hose-Outlet Color Green Blue
YAD6E260
9. Install the steering column cover and instrument panel.
YAD6E270
10. Install the fuse box in the panel, each cable and switch. Insert the panel side cover. Notice: The panel side cover should be inserted to the inside of molding and then installed.
YAD6E280
11. Install the steering wheel in order that it is aligned to the assembly marting of column shaft. Notice: Apply the grease to the shaft spline part in order that the wheel is installed easily.
YAD6E220
SSANGYONG Y200

12. Before installing the horn pad in steering wheel, first install each connector and then install the horn pad. Notice: When installing the pad, insert the safety pin to the wheel hold and align the shaf end part with the pad groove. 13. Tighten the left/right screw of steering wheel and connect the negative terminal of battery.
YAD6E290
SSANGYONG Y200
UNIT REPAIR
1
STEERING GEAR BOX

Disassembly
1. Remove the steering column assembly from the vehicle. Notice: Be careful so that the steering column/ steering column shaft is not gotten the impact. If being gotten the impact, in case of the frontal collision, the plastic sleeve may be broken.
YAD6E300
2. Remove the steering column shaft from the steering column. Remove the retainer ring. Push the steering column shaft strongly downward.
YAD6E310
YAD6E320
Assembly
1. Assemble in reverse order of disassembly.
YAD6E330
SSANGYONG Y200

SPECIAL TOOLS TABLE
SteeringWheel Remover
YAD6E340
SSANGYONG Y200
SECTION 7A
HEATING AND VENTILATION SYSTEM

TABLE OF CONTENTS
Description and Operation ................................... 7A-2 General ............................................................... 7A-2 Specifications ...................................................... 7A-3 Air Delivery and Function ..................................... 7A-4 Schematic and Routing Diagrams ........................ 7A-6 Diagnostic Information and Procedures .............. 7A-7 Insufficient Heating Or Defrosting ........................ 7A-7 Blower Electrical .................................................. 7A-9 Improper Air Delivery Or No Mode Shift .............. 7A-10 Too Much Heat .................................................. 7A-11 Heater Controls .................................................. 7A-12 Blower Noise ..................................................... 7A-13 Component Locator ........................................... 7A-14 Airflow Through Vents With Rear Heating Duct ... 7A-14 Repair Instructions .............................................. 7A-15 On-Vehicle Service ............................................... 7A-15 Air Duct Assembly ............................................ 7A-15 Rear Cooler Duct ............................................... 7A-16 Heater and Blower Module Assembly................. 7A-17 Heater Suction and Discharge Hose ................... 7A-18
7A-2 HEATING AND VENTILATION SYSTEM

GENERAL
Heater is the system that circulate the suction air through the heater core to deliver the heat of engine coolant to the suction air and designed for heating and defrosting in the passenger room. Heater system is consist of heater hose, heater module, blower motor and adjustment system. The control switch assembly (adjustment system) equipped with the instrument panel can control the temperature, the amount and the direction of the outlet. Also this system can use the suction air as separation between ambient air and intake air on the vehicle.
YAD7A010
SSANGYONG Y200
HEATING AND VENTILATION SYSTEM 7A-3
SPECIFICATIONS
Blower Motor Heater Core Engine Type Max. Capacity Fin Pitch Size (L x H x W) Heating Capacity Blower Motor Resistance 1st Mode 2nd Mode 3rd Mode 4th Mode Front A/C and Heater Unit Type Heating Capacity Cooling Capacity Expansion Valve Input Power Rear Cooler Type Cooling Capacity Expansion Valve Input Power GSL 7.425 - 9.075 kcal/h 1.52 mm 194.6 x180 x 35 mm 8,250 (Min. 4,700) kcal/h 3.25 1.45 0.35 GSL
Heater+Evaporator and Blower (2 pieces) Min. 4600 kcal/h (5.5 m3/Min) Min. 4700 kcal/h (7.5 m3/Min) Block Type Max. 250 W Evaporator and Blower (only Cooler) Min. 2700 kcal/h (5 m3/Min) ANGLE Type Max. 180 W
SSANGYONG Y200
AIR DELIVERY AND FUNCTION

Mode Door Motor
Installation Location Its located at the left side of heater case. Function It controls the open/close of the outlet at Vent, Foot or Def by the control command of automatic temperature control and then can set up the outlet mode of Vent, Bi-level, Foot, Foot/Def or Def.
Air Mix Door Motor

Installation Location Its located at the lower side of heater housing Function It controls the open/close of damper by the control command of automatic temperature control to adjust the temperature of outlet air.
Intake Door Motor

Installation Location Its located at the upper and right side of blower housing. Function It operates ambient/intake door motor by the control command of automatic temperature control to set up the inlet mode of ambient/intake door.
Airflow Through Vents
YAD7A020
SSANGYONG Y200

VENT BI-LEVEL FOOT FOOT/DEF DEF Recirculation Switch Temperature Control Lever REC FRE (A) (B) A B C
MODE CENTER VENT (1) SIDE VENT (2) Front FOOT (3) DEFROSTER (4) SIDE DEF (5) Rear VENT* (6) FOOT (7)
A A B
B B C C C
B B D D B
B C C D D
B B C
INTAKE Door AIR MIX Door
YAD7A030
SSANGYONG Y200
SCHEMATIC & ROUTING DIAGRAM
BLOWER MOTOR DIAGRAM
YAD7A040
SSANGYONG Y200

INSUFFICIENT HEATING OR DEFROSTING
Step 1 Action Check the coolant level, the serpentine accessory drive belt for tension or damage, coolant hoses for leaks or kinks, coolant reservoir cap. Is the repair complete? 1. Set the temperature control switch to full hot. 2. Set the blower motor switch on 4. 3. Turn the ignition ON. 4. Check for the airflow from the vent outlet. Is there a heavy airflow from the vent outlet? Recheck the Heater system and then repair as needed. Does the system operate properly? Check for change in the airflow at various blower speeds. Does the blower speed increase as the switch is turned from 1 to 4? With the engine idle, remove the coolant reservoir cap and watch the flow of the coolant. Is the coolant flow visible? 1. Check for a restriction in the cooling system, failed water pump impeller, faulty thermostat. 2. Make repairs to the cooling system, as needed. Is the repairs complete? Check the airflow from the Defrost and vent outlets. Is there a heavy airflow from there? 1. Check the vehicle for cold air leaks at the Instrument panel, Heater case and Vents. 2. Repair and replace any leaks or obstructions. Are the repairs complete? Set all the selection switches to Defrost. Is there a heavy airflow from any step? Check the vent outlets and repair as needed. Is the repair complete? Check for change in the airflow at various blower speeds and then repair as needed. Is the repair complete? Check for obstructions in the system at the blower inlet and repair as needed. Is the repair complete? 1. Set the blower motor switch on 4. 2. Slide the temperature control knob from full hot to full cold. 3. Listen for an airflow change. Does the airflow change? 1. Repair the temperature door travel, cables and linkage as required. 2. Verify the accuracy of the temperature controls at full hot. Is the repair complete? 1. Turn the ignition LOCK. 2. Turn the temperature control knob to full cold, then rapidly to full hot. 3. Listen for the sound of the temperature door slam. Did the door slam? Yes No
System OK
Go to Step 2
Go to Step 4 System OK Go to Step 5
Go to Step 3 Go to Step 7 Go to Blower Electrical
3 4 5
Go to Step 6
Go to Step 8
System OK System OK
Go to Step 9
Go to Step 15 Go to Step 11 Go to Blower Electrical
9 10 11
Go to Step 12
12
System OK
Go to Step 13
13
Go to Step 14
Go to Step 19
14
System OK
15
Go to Step 16
Go to Step 20
SSANGYONG Y200
7A-8 HEATING AND VENTILATION SYSTEM Insufficient Heating or Defrosting (Cont'd)

Step Action 1. Set the temperature switch to full hot. 2. Start the vehicle. 3. Check the temperature of the heater inlet and outlet hose by feel. Is the heater inlet hose hot and the heater outlet hose warm? Inspection the heater inlet and outlet hose for proper installation. Are the heater inlet and outlet hose reserved? 1. Back flush the heater core. 2. Drain the cooling system. 3. Replace the coolant. 4. Warm the engine to an average operating temperature. 5. Feel the heater inlet and outlet hose. Is the heater inlet hose hot and outlet hose warm? Check the system for any obstruction between blower, heater case and airflow delivery outlet and then repair or replace as required. Is the repair complete? 1. Repair the temperature door travel, cables and linkage as required. 2. Verify the accuracy of the temperature control at full hot and full cold, and then repair as required. Is the repair complete? Check thermostat and then repair or replace as required. Is the repair complete? Reinstall heater hose properly. Is the replace complete? Replace heater core. Is the replace complete? Yes No
16
17
18
System OK
Go to Step 23
19
System OK
20
System OK System OK System OK System OK
21 22 23
SSANGYONG Y200
BLOWER ELECTRICAL
Step Action 1. Disconnect the power connector from the blower motor. 2. Check the resistance between the 2 terminal of the blower motor connector and each step with the blower switch place each position. Is the resistance within the specified value? Replace the blower motor. Is the repair complete? Check the fuse SB7 (30A) in the engine compartment fuse block. Is the fuse blown? Replace the fuse. Is the repair complete? 1. Turn the ignition ON. 2. Use the short detector to locate the following possible short: From the fuse SB7 (30A) in engine compartment fuse block to the blower motor. From the blower motor to the blower resister block. From the blower resister block to the blower speed switch. Is there any short in the above positions? Repair any short. Is the repair complete? 1. Disconnect the power connector from the blower motor. 2. Use the test lamp to locate a possible short between the terminal 1 of the blower switch connectors and the terminals 6, 3, 5, 4 of the blower switch connectors sequentially. Does the test lamp light on at any terminal? Replace the A/C controller switch. Is the repair complete? Replace the blower resistor. Is the repair complete? Check the ground of the blower motor and then repair as needed. Is the repair complete? Yes No
Go to Step 2 System OK Go to Step 4 System OK
2 3 4
Go to Step 7 -
Go to Step 8 System OK System OK System OK
8 9 10
SSANGYONG Y200
IMPROPER AIR DELIVERY OR NO MODE SHIFT

This procedure provides a test of all functions of the heater/defroster unit. 1. Warm the vehicle and keep the engine running. 2. Perform the following diagnostic procedure. Check Is the cable connected and retained properly? Action Check the range of the door travel and the effort required to move it. Connect and attach the cable properly. Check the operation of the temperature control switch. If required, repair. Recheck the system using Control setting/Correct Results test. Repair or replace the temperature control switch or the cable. System OK Check the airflow from the defroster or the vent outlets. System OK Switch the mode knob to defrost. Remove the heater outlet and then remove any obstructions in the heater outlet. Check the blower speed for change in the airflow as the control is turned 1 to 4. Repair or replace any obstructions at heater and air delivery case. Go to Blower Electrical System OK Set the blower switch to 4th. Rotate the temperature control from full cold to full hot. Listen to an airflow change. Repair or replace any obstruction between the blower and the system outlets. Check and repair the door adjustments, the cables, the linkage and the control.
Check connection and the attachment of the door cable
Yes No
Does the door operate properly? Is there a problem with the temperature control switch or wiring? Is the system OK after the repair complete? Is the heavy airflow?
Yes No Yes No Yes No Yes No
Is the airflow proper?
Yes No
Does the blower motor speed increase? Is the system OK after the repair complete? Does the airflow change?
Yes No Yes No Yes No
SSANGYONG Y200
TOO MUCH HEAT

Mode switch to the floor position Check Is there too much heat when the mode switch is in the floor position? Is the airflow proper? Yes No Yes Action Set the temperature control switch to defrost position. Set the mode switch to the vent position. Set the blower speed to 4th. Set the temperature control switch to full hot. Turn the ignition ON. Check the airflow and attachment at the foolr outlet. Check the door travel, the cables, the controls and the linkage for the defrost position and then repair or replace as needed. Check the door travel, the cables, the controls and the linkage for the full hot, full cold position and then adjust as needed. Check for a change in the airflow at different blower speed. Check the change. System OK Go to Blower Electrical Turn the ignition OFF. Turn the temperature control knob to full hot, then rapidly to full cold. Check the system case for leaks and check the floor outlet attachment. Adjust the vent door to vent mode. Check the door travel, the cables, the controls and the linkage for the full hot, full cold position and then adjust as needed.
No
Is the heavy airflow?
Yes
No Does the airflow change? Is the airflow proper? Yes No Yes
No Can you hear the sound of the temperature door slam? Yes No
SSANGYONG Y200
HEATER CONTROLS
Turn the temperature control switch Check Is excessive effort required to move the control? Yes No Action Check the cable for improper routing, kinks, wiring interference or other instrument panel interference. Set the blower switch to 4th. Repeat to turn the temperature control knob to full hot, then rapidly to full cold Remove the cable from any door that binds on the cable. Cycle the door manually. Check the door binding. Repair or replace the problem. Check the door seal for proper installation. Check the control for binding. Reinstall the cable to the door. Repair the instrument panel interference with the cable. Remove the cable from the control. Check the control for binding. Replace the control switch. Replace the cable. Remove the cable from the control. Operate the control switch. System OK System OK Replace the control switch. Check a binding door for the shaft alignment, a bent shaft, a bent door or warped case and then repair as needed. Repair the door seal or replace as needed.
Does the control operate properly?
Yes
Is there any door binding? Does the control bind?
No Yes No Yes No
Does the control bind? Is excessive effort required to move the control? Does the control operate properly without any interference? Is the installation good condition?
Yes No Yes No Yes No Yes No
SSANGYONG Y200
BLOWER NOISE
Cycle through the blower speeds, the modes and the temperature settings in order to find the noise. -Close all of the doors and windows. -Turn the ignition ON . -Set the blower switch to 4th. -Set the control switch to full hot position. Check Is the blower noise constant at high blower speeds or certain modes, but absent at lower speeds or in other modes? Yes Action Remove any obstruction or foreign material of the duct. Check floor/defroster door seals. Repair or replace as needed. Check for the vibration from the blower motor and fan assembly at each blower speed by feeling the blower motor housing. Check for the foreign materials at the opening of the blower inlet. Remove all foreign materials and repair or replace the blower motor and fan assembly. Set the blower switch to 4th. Check any noise from full hot to full cold temperature positions in the defroster, floor and vent modes. Remove any obstruction or foreign material of the duct. Check the floor/defroster door seals. Repair or replace as needed. Check any noise in the floor mode. Remove any obstruction or foreign material of the duct. Check the floor/defroster door seals. Repair or replace as needed. Check any noise in the vent mode. Remove any obstruction or foreign material of the duct. Check the vent door seals. Repair or replace as needed. Check the temperature door seals Check the system for obstructions, foreign materials between the fan and the temperature door and then repair or replace the fan as required.
No
Did you find the excessive vibration and any foreign material?
Yes No
Is the noise constant?
Yes
No Yes
No Yes
Is the blower noise constant at any modes but absent at all modes of temperature control lever?
Yes No
SSANGYONG Y200
COMPONENT LOCATOR
AIRFLOW THROUGH VENTS WITH REAR HEATING DUCT
YAD7A050
1 2 3 4 5 6 7
Blower and Evaporator Assembly Heater Assembly Side Defroster Duct (LH) Main Defroster Nozzle Side Defroster Duct (RH) Side Defroster Joint Console Front Ventilation Duct
8 9 10 11 12 13 14
A/C Controller Console Middle Ventilation Duct Console FOOT Duct Console Rear Ventilation Duct Rear cooler Duct Rear cooler Assembly Rear cooler Controller
SSANGYONG Y200

AIR DUCT ASSEMBLY
1. Remove the instrument assembly. 2. Remove the defroster nozzle retaining screws and the defroster nozzle assembly.
YAD7A060
3. Remove the ventilation duct.
YAD7A070
4. Remove the air distributor at console side. Remove the center console. Remove the parking brake lever assembly. Remove the middle duct retaining bolt. 5. Remove the middle duct and the lower duct.
YAD7A080
SSANGYONG Y200

6. Installation should follow the removal procedure in the reverse order. Install the nozzle and the ventilation duct to the instrument panel.
YAD7A090
Install the duct at console side with air duct.
YAD7A100
REAR COOLER DUCT

1. Remove the rear quarter inner panel. 2. Remove the tapping screw and hex screw at the duct. 3. Remove the duct.
YAD7A110
YAD7A120
SSANGYONG Y200
HEATER AND BLOWER MODULE ASSEMBLY

1. Disconnect the blower motor connecter.
YAD7A130
2. Remove the retaining bolts of the blower module and evaporator and then remove the blower module. Notice: A/C pipe should be removed previously.
YAD7A140
3. Remove the heater module retaining bolts and heater module assembly. Notice: Note that it is possible to remove the heater module only when you remove the heater hose previously.
YAD7A150
4. Installation should follow the removal procedure in the reverse order. Tighten the heater module with the retaining bolts. Retaining Bolt 5 N m (44 lb-in)
YAD7A160
SSANGYONG Y200
Tighten the blower module assembly with retaining nuts. Retaining Bolt 5 N m (44 lb-in)
YAD7A170
Connect the blower motor connector and install the heater hose and A/C pipe.
YAD7A180
HEATER SUCTION AND DISCHARGE HOSE

1. Drain the coolant. 2. Remove the clips and push back the suction heater hose clamp near the fire wall. 3. Twist the hose slowly from the left side to the right side to loosen the connection between the hose and the tube. 4. Remove the hose end from the tube.
YAD7A190
5. Remove the clip and push back the heater suction hose at engine block side. 6. Remove the heater suction hose and discharge hose on the vehicle. 7. Installation should follow the removal procedure in the reverse order.
YAD7A200
SSANGYONG Y200
SECTION 7B
GENERAL HVAC (HEATING, VENTILATION AND AIR CONDITIONING) SYSTEM

TABLE OF CONTENTS
Description and Operation ................................... 7B-2 Specifications ...................................................... 7B-2 Repair Instructions ............................................... 7B-3 Basic A/C System Function .................................. 7B-5 Component Locator ............................................. 7B-7 A/C System Component ...................................... 7B-7 A/C System Pipe Line .......................................... 7B-8 Compressor Location ........................................... 7B-9 Diagnostic Information and Procedures ............ 7B-10 General Diagnosis ............................................. 7B-10 Diagnosis Using The Manifold Gauge ................ 7B-11 Maintenance and Repair ................................... 7B-13 Refrigerant Charging .......................................... 7B-13 Compressor Oil Replacement ............................ 7B-17 Replacement of Refrigerant Connection .............. 7B-18 Repair Instructions .............................................. 7B-19 On-Vehicle Service ............................................... 7B-19 Air Filter (Auto A/C) ............................................ 7B-19 Receiver-Dryer ................................................... 7B-20 Condenser ......................................................... 7B-21 Compressor....................................................... 7B-23 A/C High/Low Pressure Line ............................... 7B-23 A/C Module Assembly ....................................... 7B-24 Unit Repair ........................................................... 7B-25 Compressor....................................................... 7B-25 Special Tools and Equipment ............................ 7B-27 Special Tools Table ............................................ 7B-27
7B-2 GENERAL HVAC SYSTEM

SPECIFICATIONS
Component Compressor Application Model Type Displacement PCD Cylinder Oil (Synthetic Oil) Condenser Receiver-Dryer Type Size Capacity Desiccant Pressure Switch Refrigerant Type Refrigerant Capacity V5 Variable Displacement 9.8 - 151 cc/rev 130 5 265 ml MFC (6-PASS) 620 w x 479 h x 20 t 250 cc XH-9 (35 g) DSL : Dual Pressure, GSL: Triple Pressure R-134a Single: 850 50 g, Dual: 1200 50 g Specifications V7 9.8 - 179 cc/rev 7
SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-3
REPAIR INSTRUCTIONS
Air Conditioning
Vehicle air conditioning is the cooling (refrigerant), heating and ventilation of the air in the passenger compartment. Refrigerant is accomplished by making practical use of the three laws of nature. These laws of nature and their practical application are as follows: Heat transfer Latent heat of vaporization Effect of pressure on boiling or condensation
3. Check the operation of the blower fan. 4. Check all the air ducts for leaks or restrictions. Low airflow rate may indicate a restricted evaporator core. 5. Check for slippage of the compressor clutch. 6. Check the drive belt tension.
Handling O-Ring
1. Even though O-rings may look identical, it is extremely important that only recommended service replacement air conditioning O-rings be used, or excessive leakage of the refrigerant may occur. 2. Always O-ring and installation area should be kept clean. Any foreign material and dust may result in excessive refrigerant leakage. 3. Before installation, verify that both O-ring and fittings have not been nicked or deformed. Deformed or nicked parts must be replaced. 4. Failure to use the proper service replacement parts and procedures may result in excessive refrigerant leakage.
Heat Transfer
The principle of heat transfer are that the heat always flow from hot to cold, the rate of heat transfer will increase as the difference in temperature between two objects increases, and the mass of an object remains the same regardless of its heat contents.
Latent Heat of Vaporization

Everything in the world is composed of matter and the matter exists in one of following states; Solid Liquid Vapor When a liquid boils, it changes to vapor and absorbs heat without raising the temperature of the resulting vapor. When the vapor condenses, it changes back to a liquid and gives off heat without lowing the temperature of the resulting liquid.
Handling Refrigerant
1. Always work in a well-ventilated area. 2. If you have difficulty breathing, seek medical attention immediately. If refrigerant comes in contact with any part of your body, flush the exposed area with water. If a rush or pain develops seek medical attention.
Handling of Refrigerant Lines and Fittings

1. Using too low or too high a torque when tightening a fitting can result in loose joints or deformed joint parts. 2. Back up the opposing fitting to prevent the distortion of the connecting lines or the components. Back up both the swaged fitting on the flexible hose connections and the coupling to which it is attached two wrenches to prevent turning the fitting and damaging the ground seat.
Effect of Pressure on Boiling or Condensing

When the pressure on the liquid or vapor changes, the boiling point changes. Increasing the pressure increases the boiling point, while the boiling point decreased by decreasing the pressure on the liquid or vapor. Another effect of the compression is an increase in temperature even through heat has not been added. For example, if you compress the refrigerant R-134a from 206kPa (30 psi) to 1206kPa (175 psi) the temperature of vapor will increase from 0 C (32 F) to 54 C (130 F) and boiling point increase. Condensing point also will increase.
Maintaining Chemical Stability In the Refrigeration System

The efficient operation and life of the air conditioning system is dependent upon the chemical stability of the refrigeration system. When foreign materials, such as dirt, air or moisture, contaminate the refrigeration system, they will change the stability of the refrigeration and the polyalkalene glycol (PAG) compressor oil. They will also affect the pressure-temperature relationship, reduce efficient operation and can possibly cause interior corrosion and abnormal wear of moving parts.
Testing the refrigerant system

1. Check the outer surfaces of the radiator and the condenser cores to be sure that the airflow is not blocked by dirt leaves or other foreign material. Check between the condenser and the radiator as well as all outer surfaces. 2. Check for any restrictions or kinks inthe condenser core, the hoses and the pipes.
SSANGYONG Y200

Observe the following practices to ensure chemical stability in the system: 1. Wipe away dirt or oil at and near any connection before opening that connection. This will reduce the chance of dirt entering the system. 2. Cap, plug or tape both sides of a connection as soon as possible after opening the connection. This will prevent the entry of dirt, foreign material and moisture. 3. Keep all tools clean and dry including the manifold gauge set and all replacement parts. 4. Use a clean and dry transfer device and container to add PAG refrigerant oil. This will ensure that the oil remains as moisture-free as possible. 5. When opening an A/C system, have everything needed to perform all operations ready. Do not leave the A/C system open any longer than necessary. 6. Evacuate and recharge any A/C system that has been opened.
SSANGYONG Y200
BASIC A/C SYSTEM FUNCTION

A/C System consists of the following component basically. The refrigerant continues to change the phase, liquid gas liquid to maximize the cooling effect.
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YAD7B010
SSANGYONG Y200
7B-6 GENERAL HVAC SYSTEM Airflow - Typical
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YAD7B020
A/C System - Typical
YAD7B030
SSANGYONG Y200
COMPONENT LOCATOR
A/C SYSTEM COMPONENT
YAD7B040
1 2 3 4 5 6
Condenser Receiver-Drier Compressor A/C & Heater (Blower) Module Defrost Nozzle/Duct Front A/C Controller
7 8 9 10 11 12
Rear Duct Rear Cooler Assembly Rear Cooler Duct Suction Rear Pipe Line Liquid Rear Pipe Line Rear Cooler Controller
SSANGYONG Y200
A/C SYSTEM PIPE LINE
YAD7B330
1 2 3 4 5
High Pressure Pipe Low Pressure Pipe Heater Hose High Pressure Hose And Pipe High Pressure Hose
6 7 8 9
Receiver-Drier Condenser Liquid Hose Compressor
SSANGYONG Y200
COMPRESSOR LOCATION
Gasoline Engine
YAD7B050
Diesel Engine
YAD7B060
SSANGYONG Y200

GENERAL DIAGNOSIS
Symptom Airflow not cold. Magnetic clutch switch dont turn ON. Check the fuse Check the A/C switch Check the triple switch (DSL: Dual switch) Check the thermo switch (GSL) Check the compressor relay Check the magnetic clutch Check the A/C control unit Insufficient refrigerant Faulty receiver-drier Abnormal rotating of compressor Abnormal compression of compressor Faulty expansion valve Airflow is cold but insufficient. Duct joint leak Evaporator frozen Faulty blower motor Blower 1th - 3th inoperative, 4th operative There is air in the refrigerant Faulty expansion valve Insufficient refrigerant Faulty receiver-drier Faulty condenser Excessive refrigerant in the system Abnormal rotating of compressor Insufficient compression of compressor There is air in the unit. Faulty expansion valve Check the refrigerant capacity Check the receiver-drier Check the drive belts tension, slip of the compressor and clutch Check the compressor Check the expansion valve Check the Duct joint Check the intake air temperature switch Check the blower motor Check the resistor, connector Measure the pressure Check the expansion valve Check the refrigerant capacity Check the receiver-drier Check the fins surface and crack of the tube, tank Check the refrigerant capacity (Verify the capacity higher than high pressure) Check the drive belts tension Check the compressor Check the pressure Check the expansion valve Check Action Replace Replace Replace Replace Replace Replace Replace Adding refrigerant Replace Adjusting belt Replace Replace Replace Replace Replace Replace Evacuating and charging refrigerant Replace Adding refrigerant Replace Cleaning surface, Replace Recharging refrigerant Adjusting belt Replace Evacuating and charging refrigerant Replace
Airflow is not continuous. Insufficient cooling.
SSANGYONG Y200
DIAGNOSIS USING THE MANIFOLD GAUGE

On normal operation during the cooling cycle, the manifold gauge must indicate approximately 1.5 - 2.0 kg/cm 2 at low pressure side and 14.5 - 15 kg/cm2 at high pressure side, on condition that the temperature at the cooler inlet, 30 C - 35 C, 2,000 rpm of the engine rpm , full cold and maximum blower speed.
YAD7B070
Symptom 1. High and low pressure are abnormally low. 2. Air at cooler outlet is not cold.
Cause
Action
There is a gas leak in the cooling system.
Check the oil leak, repair Add the refrigerant
YAD7B080
1. High and low pressure are abnormally high.
Insufficient cooling and faulty condenser cooling by excessive refrigerant.
Keep the specified amount of the refrigerant, Clean the condenser Repair the belt
YAD7B090
1. High and low pressure are abnormally high. 2. Connection at the low pressure is not cold.
Belt is slipped There is an air in the cooling system
Clean and repair the receiver-drier Check the oil contamination etc.
YAD7B100
SSANGYONG Y200

Symptom 1. The low-pressure side indicates excessive high and high-pressure indicates excessive low. 2. There is a moisture in the connection of the receiver-drier and the front/back of the expansion valve. Cause Action
The dust and moisture etc. are frozen at the expansion valve A gas leak in the heat reducer
Repair the receiver-drier Replace the expansion valve for the faulty heat reducer
YAD7B110
1. The low-side pressure is high or normal intermittently.
The mixed moisture is frozen at the expansion valve
Repair the receiver-drier and perform the bleeding
YAD7B120
1. The low-pressure and high-pressure are excessive high. 2. There are a lot of moistures in the connection of the low-side pressure
The faulty expansion valve, the improper installation of the heat reducer Fail to control the flow rate
Repair the receiver-drier Check the oil contamination etc.
YAD7B130
1. The low-pressure is excessive high and highpressure is excessive low.
There is an oil leak in the compressor
Replace the compressor
YAD7B140
SSANGYONG Y200
MAINTENANCE AND REPAIR

REFRIGERANT CHARGING
Installation of Manifold Gauge
1. Close both high/low pressure hand valves of manifold gauge before installation of gauge to the charging valve. 2. Both high/low pressure hand valves of manifold gauge connect the appropriate charging valve. Tighten the hose nuts by hand. high pressure hand valve high pressure charging valve
YAD7B150
low pressure hand valve low pressure charging valve
Discharging Refrigerant
1. Connect the manifold gauge to the charging valve. 2. Place the free end of the center hose in a shop towel. 3. Slowly open the high pressure hand valve and discharge refrigerant. Notice: If refrigerant is allowed to escape too fast, compressor oil will be drawn out of the system. 4. Check whether the shop towel gets wet in oil and if wet, close the hand valve. 5. After the high pressure gauge reading drops below 3.5 kg/cm 2, slowly open the low pressure valve. 6. When both high and low pressure gauges reading drops to 0 kg/cm2, discharging is completed.
YAD7B160
Evacuating Refrigeration System

Notice: The unit tank must contain a sufficient amount of R-134a refrigerant for charging. Check the amount of refrigerant in the tank. If there is less than 3.6 kg (8 pounds) of refrigerant, add new refrigerant to the tank. 1. Verify that the high-side and the low-side hoses are connected to the A/C system. Open both the high-side and the low-side valves on the units control panel. 2. Open both the gas and the liquid valves on the tank.
YAD7B170
SSANGYONG Y200

Important: R e f e r t o t h e m a n u f a c t u r e r s instructions for the charging station in use. It is necessary to evacuate the system before recharging it with new or recycled refrigerant. 3. Start the vacuum pump and begin the evacuation process. Non-condensable gases (mostly air) are vented from the tank automatically during the recycling process. The pressure being released may be heard. 4. Check for leaks in the system. Refer to the manufacturer s instructions for the charging station in use.
YAD7B180
Important: Change the vacuum pump oil frequently. Refer to the manufacturers instructions for the charging station in use.
Check for Refrigerant Leaks

1. Connect the center hose of the gauge to the refrigerant tank. 2. Open the high pressure valve of the gauge to charge with refrigerant gas. 3. Charge until the low pressure gauge reads 1.0 kg/cm2 and close the valve. 4. Using a gas leak detector, check the system for leaks. 5. If any leak is found, replace O-ring or repair the faulty connection.
YAD7B190
How to Use the Tap Valve

1. Rotate the handle counterclockwise fully before connecting the valve to the refrigerant tank. 2. Rotate the disk counterclockwise fully. 3. Connect the center hose to the valve fitting and then rotate the disk clockwise fully by hand. 4. Rotate the handle clockwise to drill the sealed hole. 5. Remove the hose nut securing the center fitting of the manifold gauge and then tighten the nut again in a few seconds.
YAD7B200
SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-15 Charging Refrigerant

Charging for Gas 1. Connect the tap valve to the refrigerant tank. 2. Open the low pressure and adjust the low-side reading below 4.2 kg/cm 2. 3. Place the refrigerant tank in the warm water (40 C) and keep the gas pressure in the refrigerant tank higher than the gas pressure in the charging valve. 4. Run the engine at high speed and operate A/C system.
YAD7B210
Notice: Place the refrigerant tank on the flat floor to protect the liquid refrigerant from coming through the suction inlet resulting in the compressor s damage. 5. Charge the specified amount to the charging valve and close the low pressure valve. Specified amount Single: 850 50 g Dual: 1200 50 g
YAD7B220
Notice: If the charging speed is low, its more efficient to place the refrigerant tank in the warm water (40 C). But the temperature should keep below (52 C) at any situation. Be careful not to contact the heating device or material.
Charging for Liquid Notice: Do not operate when charging the system through the high-side rpessure. Do not open the low pressure valve when charging the system by the liquid refrigerant. 1. Tighten both high pressure and low pressure completely before evacuating the charging valve. 2. Connect the tap valve of the refrigerant tank. 3. Open the high pressure valve and turn the refrigerant tank upside down.
YAD7B230
SSANGYONG Y200

4. The discharging pressure increases when the charging valve charges excessively, so charge the charging valve to the specified amount with measuring the weight of the refrigerant before closing the high pressure valve. 5. Charge the specified amount of the refrigerant and then close the valve of the manifold gauge. Check the system for any leak.
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YAD7B240
Operation Check Notice: Operation Check is recommended before removing the manifold gauge. 1. Install the manifold gauge set. 2. Run the engine at 2,000 rpm and set the blower switch at HI and A/C switch ON . Set the temperature control lever at COOL . 3. Keep opening all of the window and door. 4. Place a dry bulb thermometer to the front duct. 5. Place a psychrometer close to the inlet of the cooling unit. 6. Check the high pressure gauge reading within 14 - 16 kg/cm2 If the reading indicates high excessively, spray the water to the condenser. If the reading indicates low excessively, cover the condenser with the towel. 7. Check the temperature of air inlet within 25 - 35 C. 8. Calculate the relative humidity from the psychrometic graph comparing the wet/dry temperature at the air inlet. 9. Measure the wet/dry temperature at the cold air outlet and calculate the temperature difference of the dry bulb between the inlet and the outlet. 10. Check the cross point of the relative humidity and check the temperature difference between the black line. If the cross point is located between the black line, the cooling performance is normal.
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COMPRESSOR OIL REPLACEMENT

Before Oil Replacement
When any part is replaced or there are a lot of gas leaks in the A/C system, you should add the specified amount of the oil to keep the approval oil capacity because the oil for lubricating the compressor circulates through the A/C system during operating the compressor. Total Oil Capacity 265 cc
Handling Oil Be careful that moistures, dusts etc. must not flow into the oil. Do not mix with any other material. If the oil leaves outside for long time, its possible to mix it with the moistures and so keep the oil sealed with a container. Circulating Oil For checking or adjusting the oil level, set the control unit to full cold and max blower speed with keeping the engine run at idle for 20 - 30 minutes in order to circulate the oil through the compressor.
Replacement Oil
1. Perform the oil circulation and stop the engine. Remove the compressor on the vehicle. 2. Drain the oil at the position of the system line connection. Notice: It may be difficult to discharge the oil when the compressor is cold. At this time warm the compressor (40 - 50 C) before discharging the oil.
YAD7B250
SSANGYONG Y200

3. Measure the amount of the discharged oil. If the the amount of the discharged oil is below 70 cc, it means the oil leak. Check the connections of the system and repair or replace as needed. 4. Check the oil contamination and add the oil or adjust the oil level. Notice: For contaminating the oil by the dust or the foreign material, charge the refrigerant in the system and clean the receiver-drier.
YAD7B260
REPLACEMENT OF REFRIGERANT CONNECTION

1. When connecting a O-ring type, apply compressor oil to portions shown in illustration. Be careful not to apply oil to threaded portion. Notice: Use the approval compressor oil.
YAD7B270
2. O-rings must be closely attached to inflated portion of pipe and always replace used O-rings.
YAD7B280
3. After inserting the pipe to the union, tighten the nut by hand as much as possible and tighten the nut with the specified torque.
YAD7B290
SSANGYONG Y200

AIR FILTER (AUTO A/C)
1. Remove the glove box. 2. Remove the lower bracket of crash pad. 3. Remove the air filter.
YAD7B300
4. For replacing the air filter, verify that the flowing direction mark of the air filter face toward the evaporator core.
YAD7B310
Notice: Installation should follow the removal procedure in the reverse order.
YAD7B320
SSANGYONG Y200
RECEIVER-DRIER
1. Discharge and recover the refrigerant from the system. 2. Remove the head lamp assembly.
YAD7B340
3. Disconnect refrigerant pressure sensor connector.
YAD7B350
4. Remove the receiver-drier. Remove two flange nuts. Remove the O-ring
YAD7B360
Remove the bracket bolt retaining the receiverdrier and then remove the receiver-drier.
YAD7B370
SSANGYONG Y200

5. Installation should follow the removal procedure in the reverse order. Tighten the two flange nuts. Evacuate and recharge the A/C system. Notice: Before installing, check the O-ring and apply the compressor oil.
YAD7B380
CONDENSER
1. Discharge and recover the refrigerant from the system. 2. Remove the radiator grill and front bumper.
YAD7B390
3. Remove the inlet pipe. Remove the O-ring at the same time.
YAD7B400
4. Remove the outlet pipe (at the bottom side) with O-ring.
YAD7B410
SSANGYONG Y200

5. Remove the radiator grill plate.
YAD7B420
6. Remove the fan bolts. 7. Disconnect the fan connector and then remove the condenser fan from the condenser.
GSL
YAD7B430
DSL
YAD7B440
8. Remove the bolts and nuts retaining condenser and then remove the condenser from the vehicle. 9. Installation should follow the removal procedure in the reverse order. Notice: The used O-ring must be replaced by the new part.
YAD7B450
SSANGYONG Y200
COMPRESSOR
1. Discharge and recover the refrigerant from the system. 2. Remove the fan belt. 3. Disconnect suction/discharge hose from the compressor. Remove the flange bolt retaining the hoses.

YAD7B460
Disconnect the hoses. Remove two sealing washer.
4. Lift the vehicle and support safely. 5. Remove the skid plate. 6. Remove the compressor.
Disconnect the connector of the compressor. Remove three front bracket bolts retaining compressor.
Notice: Discard the used sealing washer.
YAD7B470
7. Installation should follow the removal procedure in the reverse order. 1 Tighten the bolts with the specified torque. 2 Evacuate and recharge the A/C system.
A/C HIGH/LOW PRESSURE LINE

Removal Procedure
1. Discharge and recover the refrigerant from the system.
YAD7B480
SSANGYONG Y200

2. Remove the high/low pressure pipe lines. 3. Remove the high/low pressure pipe lines from the evaporator.
YAD7B490
Notice: Discard the used O-ring and sealing washer. 1. Installation should follow the removal procedure in the reverse order. 2. Tighten the flange nut securing the high pressure line with the specified torque. flange nut at compressor flange nut at evaporator 3. Evacuate and recharge the A/C system.
A/C MODULE ASSEMBLY

Removal Procedure
1. Discharge the coolant from the system. 2. Discharge and recover the refrigerant from the system. 3. Disconnect the inlet and outlet hose of the heater. 4. Disconnect the high/low pressure pipe from the evaporator core. 5. Remove five bolts securing the A/C module. two bolts at evaporator two bolts at heater core a bolt at I/P 6. Remove the instrument panel. 7. Remove the fiber panel. 8. Remove the A/C module assembly.
YAD7B500
1. Installation should follow the removal procedure in the reverse order. 2. Tighten five bolts securing A/C module with the specified torque. 3. Recharging the coolant. 4. Evacuate and recharge the A/C system.
SSANGYONG Y200
UNIT REPAIR
COMPRESSOR
Disassembly and Assembly Procedure
1. Remove the compressor. 2. Remove the clutch driver. Install the compressor holding fixture to the compressor and hold the compressor holding fixture using a bench vise. Use the clutch hub holding tool to keep the clutch drive plate and the hub assembly from turning to remove the shaft nut. Remove the snap ring using the ring plier. Remove the clutch drive using the special tool.
YAD7B510
YAD7B520
Remove the clutch shaft key and spring.
YAD7B530
SSANGYONG Y200

3. Remove the compressor pulley. Remove the snap ring using the ring plier. Remove the compressor pulley using the special tool.
YAD7B540
4. Remove the clutch coil. Mark the location of the clutch coil connector at the clutch housing. Remove the clutch coil using the special tool.
YAD7B550
5. Assembly should follow the disassembly procedure in the reverse order.
YAD7B560
SSANGYONG Y200

SPECIAL TOOLS TABLE
DW 100-010 Spring Clamp Remover & Installer
YAD7B570
SSANGYONG Y200
SECTION 7C
MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

TABLE OF CONTENTS
Description and Operation ................................... 7C-2 System Components-Functional ........................... 7C-2 Specifications ...................................................... 7C-4 Diagnostic Information and Procedures .............. 7C-5 Insufficient Cooling Diagnosis .............................. 7C-5 Abnormal Refrigerant Pressure ............................ 7C-7 Repair Instructions ................................................ 7C-8 On-Vehicle Service ................................................. 7C-8 Control Switch Assembly ..................................... 7C-8
7C-2 MANUAL CONTROL HVAC SYSTEM

SYSTEM COMPONENTSFUNCTIONAL
Compressor
All compressor are belt-driven from the engine crankshaft through the compressor clutch pulley. The compressor pulley rotates without driving the compressor shaft until an electromagnetic clutch coil is energized. When voltage is applied to energize the clutch coil, the clutch plate and hub assembly is drawn rearward toward the pulley. The magnetic force locks the clutch plate and pulley together as one unit to drive the compressor shaft. As the compressor shaft driven, it compresses the low pressure refrigerant vapor from evaporator into high pressure, high temperature vapor. The refrigerant oil that is used to lubricate the compressor is carried with the refrigerant. The operations described are based on bench overhaul with the compressor removed from the vehicle, except as noted. They have been prepared in the order of accessibility of the components. When a compressor is removed from the vehicle for servicing, the amount of oil remaining the compressor should be drained, measured and recorded. This should then be discarded and new polyalkaline glycol (PAG) refrigerant oil added to the compressor. Important: The oil drain plug must be removed and the oil drained through the plug opening to insure complete draining of oil from the compressor.
V-5 Compressor-Operation
The V5 is a variable displacement compressor that can match the automotive air conditioning demand under all conditions without cycling. The basic compressor mechanism is a variable angle wobble-plate with seven axially oriented cylinders. The center of the control of the compressor displacement is a billows-actuated control valve located in the rear head of the compressor that senses compressor suction pressure. The wobble-plate angle and the compressor displacement are controlled by the crankcase suction pressure differential. When the A/C capacity demand is high, the suction pressure will be above the control point. The valve will maintain a bleed from crankcase to suction. With no crankcase suction pressure differential, the compressor will have maximum displacement. When the A/C capacity demand is lower and the suction pressure reaches the control point, the valve will bleed discharge gas in the crankcase and close off a passage from the crankcase to suction plenum. The angle of the wobble-plate is controlled by a force balance of seven pistons. A slight elevation of the crankcase suction pressure differential creates total force on the piston resulting in a movement about the wobble-plate pivot pin that reduces the plate angle. The compressor has a unique lubrication system. The crankcase suction bleed is routed through the rotating wobble-plate for lubrication of wobble-plate bearing. The rotation acts as an oil separator that removes some of the oil from the crankcase where it can lubricate the compressor mechanism.
Magnetic Clutch
The magnetic clutch is assembled in front of the compressor and controls to stop or operate the compressor. The center piece is inserted to the compressor crankshaft and rotate the only the pulley when it doesnt operate the compressor. When the A/C switch is turned ON, the current flows into the wrapped coil of the stator and the stator is converted to the powerful electromagnet. Therefore, the compressor can rotate with the pulley together because the stator can pull the center piece tightly.
V-5 Compressor-General
Description Vehicle using the V5 compressor may have differences between installations in the mounting brackets, the drive system, the pulleys, the connections and the system capacities. Basic overhaul procedures are similar between the compressors used on different vehicles. When serving the compressor, keep dirt and foreign material from getting on or into the compressor parts and the system. Clean tools and a clean work area are important for proper service. The compressor connections and outside of the compressor should be cleaned before performance of any on-vehicle repairs and before removal of the compressor. The parts must be kept clean at all times and any parts that are to be reassembled should be cleaned with trichloroethane, naphtha, stoddard solvent, kerosene or equivalent solvents and dried with dry air. Use only lint-free cloths to wipe the parts.
Condenser Core
The condenser assembly in front of the radiator consists of coils, which carry the refrigerant and cooling fins that provide the rapid transfer of heat. The air passing through the condenser cools the high-pressure refrigerant vapor and causes it to condense it to condense into a liquid.
SSANGYONG Y200
MANUAL CONTROL HVAC SYSTEM 7C-3 Receiver-Drier

The sealed receiver-drier assembly is connected between the condenser and evaporator. It acts as a refrigerant storing container, receiving liquid and some vapor and refrigerant oil from the condenser. At the bottom of the receiver-drier is the desiccant, which acts as drying agent for the moisture that may have entered the system. An oil bleed hole is located near the bottom of the receiver-drier outlet pipe to provide an oil return path to the compressor. The receiver drier is serviceable as an assembly.
Pressure Relief Valve

The compressor is equipped with a pressure relies valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure at approximately at 3,171 to 4,137 kPa (460 to 600 psi) in an R-134a system. Conditions that might cause this valve to open, such as a defective pressure transducer, an inoperative cooling fan, etc., should be corrected. The refrigerant oil and the refrigerant should be replaced as necessary.
Expansion Valve
The expansion valve can fall in three different positions: open, closed or restricted. An expansion valve that fails in open position will result in a noisy A/C compressor or no cooling. The cause can be a broken spring, a broken ball or excessive moisture in the A/C system. If the spring or the ball are found to be defective, replace the expansion valve. If excessive moisture is found in the A/C system recycle the refrigerant. A restricted expansion valve will result in low suction pressure and no cooling. This may be caused by debris in the refrigerant system. If debris is believed to be the cause, recycle the refrigerant, replace the expansion valve and replace the receiver-drier.
Controller
The operation of the A/C system is controlled by the switches and knob on the control head. This consolemounted controller contains following control knobs.
Rotary Temperature Control Knob
Actuates by cable. Raise the temperature of the air entering the vehicle by sliding to the right or the red portion of the knob. Varies the mix of the fresh air from outside the vehicle with the heated air from inside the vehicle to suit individual performance.
Rotary Mode Control Knob
Evaporator
The evaporator is a device which cools and dehumidifies the air before it enters the vehicle. High pressure liquid refrigerant flows through the expansion tube (orifice) and becomes a low pressure gas in the evaporator. The heat in the air passing through the evaporator core is transferred to the cooler surface or the core, which cools the air. As the process of heat transfer from the air the evaporator core surface is taking place, any moisture (humidity) in the air condenses on the outside surface of the evaporator core and is drained off as water.
Actuates by cable. Regulates the air distribution between the windshield, the instrument panel and the floor vents.
Rotary Blower Control Knob
Turn on to operate the blower motor at four speeds. Turn OFF to stop the blower. Operates completely independently from both the mode control knob and temperature control knob. Changes the fan speed in any mode and at any speed.
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SPECIFICATIONS
Component Compressor Type Model Description Variable Displacement Single V-5 Compressor Dual Gasoline Displacement Single Dual Gasoline Max. RPM Refrigerant Type Capacity Oil Receiver-Drier A/C Condenser Evaporator A/C Pressure Sensor A/C Cutoff Pressure High Pressure Low Pressure Type Capacity Material Capacity Max. Capacity Size Capacity A/C ON/OFF A/C ON/OFF High Pressure Low Pressure Single Dual V-7 Compressor 10PAIRC 9.8 - 151 cc/rev 179 cc/rev 170.5 cc/rev 6,000 - 7,500 rpm R-134a 850 50 g 1200 50 g Synthetic PAG Oil 260 cc Aluminum 260 cc 11,400 Kcal/h 263.0 x 228.6 x 88.9 mm 6,500 Kcal/h 305/425 psi 39/30 psi 32 Kgf/cm2 4 Kgf/cm2
SSANGYONG Y200
MANUAL CONTROL HVAC SYSTEM 7C-5

INSUFFICIENT COOLING DIAGNOSIS
Step Action 1. Check the A/C fuse. 2. Check the operation of the blower motor and cooling fan. 3. Check the accessory belt. 4. Check the A/C condenser for restricted air flow. 5. Check the engagement of the compressor clutch. 6. Check the discharge air temperature with the A/C turned ON. Are all above the operations normal? 1. Turn the ignition to LOCK. 2. Connect the high/low pressure gauges. Are both pressures within the specified value? 1. If its above the specified value, discharge the refrigerant. 2. If its below the specified value, add 0.45kg (1 pound) of the refrigerant and repair any leaks as needed. 3. Recover, evacuate and recharge the A/C system. Is the repair complete? 1. Start the engine and allow it to run at idle. 2. Turn the A/C switch to ON. 3. Set the blower motor switch to 4th. 4. Set the temperature control lever to full cold. Does the A/C compressor clutch engage? 1. Turn the ignition to LOCK. 2. Check the open or short in the compressor wiring. Is there any open or short in the wiring? Repair the faulty wiring as needed. Is the repair complete? Replace the compressor clutch coil. Is the replacement complete? Check for a knocking noise from the A/C compressor. Cycle the A/C compressor ON and OFF in order to verify the source of the noise. Do you hear a loud knocking noise? 1. Recover the A/C system refrigerant. 2. Replace the A/C compressor. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. Is the compressor running normally? 1. Close all of the windows and doors. 2. Set the A/C switch to ON position. 3. Set the intake air control switch to Fresh Air. 4. Set the blower motor switch to 4th. 5. Set the temperature control switch to full cold. 6. Keep it to run at idle for 5 minutes. 7. Check the temperature at the inlet/outlet of the evaporator. Is there a noticeable difference in the temperature of the evaporator inlet/outlet pipes? Yes No
System OK
Go to Step 2
Go to Step 4
Go to Step 3
System OK
Go to Step 8
Go to Step 5
Go to Step 7 -
6 7 8
Go to Step 9
Go to Step 10
System OK
10
Go to Step 11
Go to Step 13
SSANGYONG Y200
7C-6 MANUAL CONTROL HVAC SYSTEM Insufficient Cooling Diagnosis (Contd)

Step Action 1. Recover the A/C system refrigerant. 2. Replace the expansion valve as needed. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. 5. Operate the A/C system. Is the discharge temperature normal? 1. Recover the refrigerant of the A/C system. 2. Evacuate and recharge the A/C system. 3. Check the A/C system for leaks. Does the A/C system operate normally? Feel the liquid pipe between the condenser and the expansion valve. Is the pipe cold? 1. Repair any restriction in high pressure side. 2. Check the A/C system for leaks. Does the A/C system operate normally? 1. Run the engine at 3,000 rpm. 2. Close all of the windows and doors. 3. Set the A/C switch to ON. 4. Set the blower motor switch to 4th. 5. Set the temperature control switch to full cold. 6. Turn the A/C switch ON and OFF every 20 seconds for 3 minutes. 7. Measure the compressor high and low pressure. Are both pressures within the specified value? Add the specified amount of the refrigerant to the A/C system. Is the amount within the specified value? 1. Turn the ignition to LOCK. 2. Set the A/C switch to OFF position. Can you turn the compressor clutch freely by hand? 1. Check the A/C system for leaks. 2. Repair any leaks as needed. 3. Evacuate and recharge the A/C system. Does the A/C system operate normally? 1. Recover the refrigerant of the A/C system. 2. Evacuate and recharge the A/C system. 3. Check the A/C system for leaks. 4. Replace the compressor as needed. Is the repair complete? Yes No
11
Go to Step 13
Go to Step 12
12
Go to Step 14
13
14
System OK
15
Go to Step 16 -
16 17
Go to Step 18
Go to Step 19
18
System OK
19
System OK
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ABNORMAL REFRIGERANT PRESSURE

Step Action 1. Verify whether airflow and excessive refrigerant. 2. Check any restriction at the condenser or radiator. 3. Check the condenser or cooling fan for proper operation. 4. Check any restriction of the refrigerant lines. Is the high-side refrigerant pressure high abnormally? 1. Recover, evacuate and recharge the A/C system according to the specified value. 2. Clean the condenser or radiator core. 3. Check the voltage, rpm, direction of the cooling fan. 4. Repair or replace the appropriate parts as needed. Is the high-side pressure within the specified value? 1. Check the amount of the refrigerant. 2. Check the internal faulty of the compressor. 3. Check the faulty of the expansion valve. 4. Check the moisture mix into the system. Is the high-side refrigerant pressure low abnormally? 1. Replace the compressor and the expansion valve as needed. 2. Recover, evacuate and recharge the A/C system according to the specified value. 3. Repair any leaks as needed. Is the repair complete? 1. Check the freezing/clogging of the expansion valve. 2. Check the clogging of the receiver-drier. 3. Check the amount of the refrigerant. Is the low-side refrigerant pressure low abnormally? 1. Clean the expansion valve and replace it as needed. 2. Replace the receiver-drier as needed. Is the repair complete? 1. Check the expansion valve and the compressor for any faulty. 2. Check the excessive amount of the refrigerant. Is the low-side refrigerant pressure high abnormally? 1. Replace the expansion valve and the compressor as needed. 2. Add the specified amount of the refrigerant. Is the repair complete? 1. Check the tightening condition of the refrigerant line coupling and bolts. 2. Check the faulty O-ring. 3. Check the faulty gasket or seal of the compressor. Is there any refrigerant leak? 1. Tighten the bolts. 2. Replace the faulty O-ring. 3. Replace the faulty compressor. Is the repair complete? Yes No
Go to Step 2
Go to Step 3
System OK
Go to Step 4
Go to Step 5
System OK
Go to Step 6
Go to Step 7
System OK
Go to Step 8
Go to Step 9
System OK
Go to Step 10
System OK
10
System OK
SSANGYONG Y200

CONTROL SWITCH ASSEMBLY
1. Remove the center instrument panel.
YAD7C010
2. Remove four screws securing the A/C control switch assembly.
YAD7C020
3. Remove the A/C control switch assembly from the instrument panel.
YAD7C030
SSANGYONG Y200

4. Installation should follow the removal procedure in the reverse order. Notice: Insert connector to the switch and then assembly the
YAD7C040
SSANGYONG Y200
SECTION 7D
AUTOMATIC CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

TABLE OF CONTENTS
Description and Operation ................................... 7D-2 General ............................................................... 7D-2 FATC Control ....................................................... 7D-3 FATC Input/Output Routing Diagram .................... 7D-4 FATC System Characteristic................................. 7D-5 System Basic Function ........................................ 7D-6 System Components Control ............................. 7D-8 Specifications .................................................... 7D-13 Diagnostic Information and Procedures ............ 7D-14 General Diagnosis ............................................. 7D-14 Insufficient Cooling Diagnosis ............................ 7D-15 Full Automatic Temperature Control (FATC) Does Not Operate When The Ignition Is On .............. 7D-17 Controller Does Not Illuminate When Light Switch Is On ................................................... 7D-17 No Hot Air From Blower ...................................... 7D-18 Blower Motor Does Not Run At All ...................... 7D-19 No Cool Air From Blower .................................... 7D-21 Mode Controls Does Not Work ........................... 7D-22 Mode Controls Does Not Work ........................... 7D-22 Abnormal Refrigerant Pressure .......................... 7D-23 Compressor Magnetic Clutch Does not Engage .. 7D-24 Inside Air Temperature Sensor Error ................... 7D-24 Ambient Air Temperature Sensor Error ................ 7D-24 Coolant Temperature sensor Error ...................... 7D-25 Air Mix Door Error .............................................. 7D-25 Sun Sensor Error ................................................ 7D-27 Power Transistor Error ........................................ 7D-27 Max-High Relay Error ......................................... 7D-28 Repair Instructions .............................................. 7D-29 On-vehicle Service ................................................ 7D-29 Control Switch Assembly ................................... 7D-29 Blower Motor ..................................................... 7D-30 High Blower Relay ............................................. 7D-31 Blower Motor Resistance (Power Transistor) ....... 7D-31 Air Mix Door Actuator ......................................... 7D-31 Mode Control Door Actuator ............................... 7D-32 Sun Sensor ........................................................ 7D-32 Inside Air Temperature Sensor ........................... 7D-32 Ambient Air Temperature Sensor ........................ 7D-33 Coolant Temperature Sensor .............................. 7D-34
7D-2 AUTOMATIC CONTROL HVAC SYSTEM

GENERAL
THE V5 FULL AUTOMATIC TEMPERATURE CONTROL (FATC) SYSTEM The full automatic temperature control (FATC) uses the integrated control panel as the drivers interface to the system. The FATC receives drivers input signal and various input signal from sensors and controls the actuators to maintain drivers desired room temperature. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System for general Information details for the following: System Components Functional. The V5 A/C System. V5 Compressor Operation. Vacuum Fluorescent Display panel provides system operating information for the driver. With the system in OFF mode, the outside temperature is displayed continuously. The driver may display the current temperature setting by selecting any mode except OFF or adjusting the temperature control. Also, it provides the convenience to the driver by indicating the ambient air temperature. If it occurs the faulty in the FATC system, the MICOM informs the driver or mechanics of the results of the self-diagnostic check and controls the system by
V5 Compressor General Description.
SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-3
FATC CONTROL
YAD7D010
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FATC INPUT/OUTPUT ROUTING DIAGRAM
YAD7D020
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FATC SYSTEM CHARACTERISTIC

Display Performance Enhancement
It allows VFD (Vacuum Fluorescent Display) to develop the effect of the visible.
Airflow Control Enhancement

It allows MICOM to control the temperature and perform the control automatically of the heating operation, the cooling operation and the Mild operation. Also, MICOM enable to control the amount of the airflow and the direction of the vent outlet in order to keep the inside air fresh.
How to Verify Faulty Code When the temperature is set to 26 C and then within 3 second, push the AMB switch and the OFF switch simultaneously at three times, the FATC controller temperature display indicates the faulty code after performing the self-diagnosis by MICOM.
Self-Diagnostic Circuit Check

The full automatic temperature control (FATC) air conditioning controller contains a self-diagnosis function to aid in finding any problem with the system. If the FATC detects some errors it will blink the temperature display screen for 5 seconds when the ignition switch is ON. To enter the diagnostic mode, perform the following procedure. 1. Turn the ignition switch ON. 2. Set the temperature control to 26 C (79 F). 3. Within 3 seconds, push the AUTO and the OFF switches simultaneously, more than three times. 4. Check the diagnostic trouble code (DTC) in the temperature indicator screen blinks. If there are no diagnostic trouble code (DTC) set, the screen will display 00. 5. When the FATC controller indicates a DTC, proceed to the table for the DTC. 6. Push the OFF switch to return the controller to its normal function. DTC 0 1 2 3 4 5 6 7 Description Normal (No Error) Inside Air Temperature Sensor Error Ambient Air Temperature Sensor Error Coolant Temperature Sensor Error Air Mix Door Error Sun Sensor Error Power Transistor Error Ambient Temperature Sensor Error Coolant Temperature Sensor Error Sun Sensor Error
YAD7D030
Condition For Clearing the Faulty Code 1. When the vehicle restarts 2. When push the OFF switch after indicating the faulty code 3. When pass over 32 seconds after indicating the faulty code
Fault Safety Function

FATC air conditioner not only performs self-diagnosis but also has safety function against faults. If there is open or short in the sensors or potentiometer of temperature door some specific value will be substitute. Error Inside air Sensor Error Fault Safety Function 25 C will be substituted as temperature of inside of vehicle. 25 C will be substituted as ambient temperature. Sensor ON. 50 C will be substituted as coolant temperature. Zero (0) will be substituted as sun load.
Action Taken When the Faulty Occurred When any faulty is occurred in the automatic temperature control system, it s sign is informed to the driver by flashing the set temperature display for 5 seconds at initial starting.
SSANGYONG Y200
SYSTEM BASIC FUNCTION

Set Temperature Control
When you set the setting temperature using the temperature control switch, the FATC receives the various input signals from sensors including the information of inside air temperature, ambient temperature, coolant temperature and sun loads etc.. The FATC uses this signals to control automatically the A/C compressor, the mode door, the I/A door, air mix door and blower motor etc.
Automatic Control Td value can be determined by the set temperature value and Td value is set to the target voltage of the blower motor simultaneously. The blower motor can shift without step. Abbreviation: Td (Thermal Demand) : Td value is the default for automatic control of the automatic temperature control and allows it to control the set temperature calculating the differences between inside air temperature and ambient temperature.
Airflow Control
For setting at Full AUTO, it is possible to control the blower motor operation both manually and automatically in order to adjust the airflow according to the set temperature. Manual Control When you push the blower switch, you can control the blower motor manually and it increases or decreases each step by moving the switch to HI/LO. (with the ignition ON) Step 1 2 3 4 5 6 * Blower Voltage 4.5 V 6.0 V 7.5 V 9.0 V 11.0 V Max Hi Blower Step 1 2 3 4 5 6 Blower Motor Voltage 4.0 - 5.5 V 5.5 - 7.5 V 7.5 - 8.5 V 8.5 - 9.5 V 9.5 - 10.5 V 10.5 - 13.5 V
YAD7D040
The voltage of the blower motor may increase or decrease (0.5 V) according to power voltage.
Vent Rate Control By Heating Operation When the temperature of the engine coolant is low or its difficult to obtain the desired hot air in winter, the system controls to prevent the cold airflow from the outlet due to the cold air give a negative effect to the heating performance. Therefore vent step is fixed 1st on blower AUTO step until the coolant sensor detects above 20 C and also the blower step increases gradually according to going up the coolant temperature. When the coolant temperature goes up above 40 C, the heating operation stops. Vent Rate Control By Cooling Operation When the air inside the resonance duct is hot in summer, after the system keeps the low vent rate (1st) operating for 5 seconds and discharges the hot air to the windshield side (Def Mode), the system starts to control normally in order to avoid for the passengers contacting the hot air.
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Defroster Calibration On the blower AUTO step, when the passenger sets to Defroster (Def), the system increases the blower voltage by 2 V for some intervals comparing AUTO voltage. But it is excluded the condition when the blower voltage is above 11.0 V. Also, the voltage increasing by defroster calibration is limited up to 10.5 V. Vehicle Speed Calibration On the Ambient or the 1/3 Ambient and the blower AUTO, the blower decreases the voltage with the vehicle speed 100 Km/h such as 1.5 V for the Ambient, 1.0 V for the 1/3 Ambient. But it is the exception for the blower max.
Vent inlet Control

Manual Control When you push the I/A control switch, you can control the I/A door manually and the I/A door changes between the recirculation air and the fresh air flow alternately by the control switch. For changing the fresh air step (FRE) to the recirculation air step (REC), the blower voltage decrease 15% and for changing the recirculation air step (REC) to the fresh air step (FRE), the blower voltage return back. AUTO Control
YAD7D060
YAD7D050
Ambient Temperature Display It indicates the ambient temperature as 0.5 C increment in the set temperature digit by ambient temperature sensor. When you push the AMB key it indicates the ambient temperature for 5 seconds and return back the set temperature.
If you push the AMB key again during indicating in 5 seconds, it returns back. The ambient temperature sensor is securing in the front of radiator and may be influenced easily to the heat of the engine compartment in parking. Therefore the ambient temperature sensor indicates the ambient temperature accurately on the condition of above 40 km/h running.
Control by the Vehicle Speed The system controls the vent inlet according to the vehicle speed in order to prevent the exhaust gas of the preceding vehicle from flowing inside with the vehicle stopping or driving at low speed. The operation and control condition is following as; 1. When the vent inlet mode is AUTO and the A/C ON. 2. When the vehicle keeps to drive at below 10 km/h for 10 seconds and changes the REC mode at stop. 3. If 10 minutes passes after changing the REC mode, it returns back to the AUTO mode.
Delivery Condition
For the initial installation (the initial current draw), the initial mode follows; Actuator Condition Mode FOOT/ DEF Suction Air FRESH A/C OFF Blower OFF Mix Td Basic Control
YAD7D070
SSANGYONG Y200
Vent outlet Control

Manual Control For pushing the mode switch of AUTO temperature control, you can select four type of the vent outlets.
Wiper Calibration Control

It is possible to generate the frost on the windshield in the rainy days. At this time, FATC controller allows the mode to change the AUTO defroster mode. Operation Condition: When the passenger operates the wiper on AUTO mode, the system controls the wiper on the A/C AUTO mode after sending the wiper signal and controlling the delay for 1 minutes.
YAD7D080
When you push the Def switch, it keeps to change to the defroster mode regardless of the sequence.
YAD7D100
AUTO Control
FATC Controller Illumination Control

When the tail lamp is ON, ATC Controller illumination lamp turns on.
SYSTEM COMPONENTS CONTROL

Controller Assembly
The operation of the A/C system is controlled by the switched on the control head. This console-mounted controller consist of control knobs and a vacuum fluorescent display (VFD) indicating the status of the control settings selected.
YAD7D090
A/C Control
Manual Control When you pushed the A/C switch ON or the Def switch ON , A/C starts to operate. AUTO Control Basic Control: A/C ON has the priority for the initial operation.
Sensors and Motors
Inside air sensor, ambient sensor, coolant temperature and sun sensor Door mode motor, intake air control door motor, air mix door motor
Inside Air Sensor

Inside air sensor located in left side of full automatic temperature control (FATC) controller, is a sensor that detects the interior air temperature and a thermistor that decreases its resistance when temperature up and increases when temperature down. If there is open or short in the sensors, 25 C (77 F) will be substitute. Inspection When the inside air temperature sensor error displays, check the followings;
Full Cold/Hot Control

When you sets the set temperature to full cold (LO) or full hot (HI), the system controls the temperature to full cold or full hot regardless of sensors detection. For LO, it becomes A/C ON , front vent mode, recirculation air, max blower speed, air mix door close and for HI, A/C OFF, floor vent mode, ambient mode, air mix door open.
SSANGYONG Y200

1. Remove the inside air temperature sensor and measure the resistance between the sensor connectors. (approximately 2.2 K at 25 C) Replace the inside air temperature sensor when the resistance value is excessive low or high. 2. Replace the inside air temperature sensor for outside the specified value and check the followings for within the specified value; 3. Turn the ignition ON. 4. Measure the voltage between A13 and A16 terminal of the AUTO temperature control connector. (approximately 2.2 V at 25 C) 5. Verify the open circuit of the wiring harness when you can not measure the voltage value and replace the AUTO temperature control when its normal. Inspection When the coolant temperature sensor error displays, check the followings; 1. Measure the resistance between the sensor connectors. (approximately 2.2 K at 25 C) 2. Replace the coolant temperature sensor for outside the specified value and check the followings for within the specified value; 3. Turn the ignition ON. 4. Measure the voltage between A13 and B9 terminal of the AUTO temperature control connector. (approximately 2.2 V at 25 C) 5. Verify the open circuit of the wiring harness when you can not measure the voltage value and replace the AUTO temperature control when its normal.
Ambient Sensor
Ambient sensor is a thermistor (NTC resistance) that decreases its resistance when temperature up and increases when temperature down and it detects ambient air temperature. If there is open or short in the sensors, 25 C (77 F) will be substitute. The sensor is located in the left back side of front bumper. Inspection When the ambient temperature sensor error displays, check the followings; 1. Remove the ambient temperature sensor and then measure the resistance between the sensor connectors. (approximately 2.2 K at 25 C) Replace the ambient temperature sensor when the resistance value is excessive low or high. 2. Replace the ambient temperature sensor for outside the specified value and check the followings for within the specified value; 3. Turn the ignition ON. 4. Measure the voltage between A13 and B8 terminal of the AUTO temperature control connector. (approximately 2.2 V at 25 C) 5. Verify the open circuit of the wiring harness when you can not measure the voltage value and replace the AUTO temperature control when its normal.
Sun Sensor
Sun sensor is a photo diode that detects lights. Resistance of the diode can be measured as current by using voltmeter according to increasing sun loads. If the sun sensor is error, no sun load will be substitute. Photo Diode It is used to the circuit converting the sun light loads to the electric signals.
YAD7D110
Inspection When the sun sensor error displays, check the followings; 1. Remove the sensor to place it under the sun light and measure the current between the connector terminals. 2. Place the sun sensor under the shadow place and measure the current between the connector terminals. If the value is lower than the value under the sun light, it s normal. 3. Turn the ignition ON. 4. Measure the voltage between A13 and B10 terminal of the AUTO temperature control connector. (Sun light; 2.5 V, Shadow; 4.8 V) 5. Verify the open circuit of the wiring harness when you can not measure the voltage value and replace the AUTO temperature control when its normal.
Coolant Temperature Sensor

Coolant temperature sensor is a thermistor that decreases its resistance when temperature up and increases when temperature down. It detects coolant temperature to operate the blower speed at low when the coolant temperature is less than 50 C (122 F). If the coolant temperature sensor is open or short, 100 C (212 F) will be substitute.
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7D-10 AUTOMATIC CONTROL HVAC SYSTEM Intake Control Door Motor

The mode motor set the I/A mode by the control signal of the AUTO temperature control. When the mode displayed in the AUTO temperature control is different from the actual mode, check the followings; Inspection When the vent inlet mode displayed in the AUTO temperature control is different from the actual mode, check the followings; 1. Turn the ignition ON. 2. Measure the voltage between positive terminal and negative terminal of the Mtr-Act, AI connector. (Specified value; 12 V) 3. Measure the voltage between P1, P2, P3 and (+) terminal. (If it changes from 0V before the mode selection to 12 V after the mode selection, it s normal) 4. If the value is outside the specified value, check the open or short circuit. 5. If the wiring is normal, replace the AUTO temperature control. 6. If the value is the specified value, replace the MtrAct, AI. 7. Check the motor operation connecting the (+) terminal to No.4 of the motor connector and connecting No.5 and No.7 to (-) terminal sequentially using 12 V power.
Turn the ignition ON. Measure the voltage between the (+) terminals at each mode and verify that changes from 0V before the mode selection to 12V after the mode selection. If the value is the specified value, check the open or short circuit. If the wiring is normal, replace the AUTO temperature control. If the voltage value is outside the specified value, replace the I/A mode motor. Check the motor operation connecting the (+) terminal to No.4 of the motor connector and connecting No.5 and No.7 to (-) terminal sequentially using 12 V power.
Mode Control Motor

The control motor sets the mode of Vent, Bi-level, Foot, Foot/Def or Def by opening/closing the outlet damper at the outlet of Vent, Foot or Def according to control signal of the AUTO temperature control.
YAD7D120
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YAD7D130
YAD7D140
Inspection When the vent inlet mode displayed in the AUTO temperature control is different from the actual mode, check the followings; 1. Turn the ignition ON. 2. Measure the voltage between P1 - P5 and (+) terminal. (If it changes from 0V before the mode selection to 12 V after the mode selection, it s normal) 3. If the value is outside the specified value, check the open or short circuit. 4. If the wiring is normal, replace the AUTO temperature control. 5. If the value is the specified value, replace the MtrAct, AI. 6. Check the motor operation connecting the (+) (-) terminal to the Mtr-Act mode and each terminal P1 - P5 to (-) terminal sequentially using 12 V power.
Inspection When the air mix door motor error displays, check the followings; 1. Turn the ignition ON. 2. Measure the voltage within P1, P2 terminals (specified value; 12 V) and a,b (specified value; 5). 3. If the value is outside the specified value, check the open or short circuit. 4. If the wiring is normal, replace the Mtr-Act, Temp. 5. If the (+) (-) terminal connects to P1 and P2 of the Mtr-Act, Temp alternately, the output by the each mode is following; AMD Cool Hot Mode P1 (-), P2 (+) P1 (+), P2 (-) Bc Resistance Below 300 Above 2.4 K
Air Mix Door Motor

The air mix door motor is located on left side of heater module. The air mix door motor controls the exhaust air temperature by the signal of the FATC.
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7D-12 AUTOMATIC CONTROL HVAC SYSTEM Power Transistor

Power transistor controls the blower airflow and it receives the airflow control signal from the AUTO temperature control in order to for blower motor to shift the speed without step by adding the current to the power transistor basic current. Inspection When the power transistor error displays, check the followings. 1. Turn the ignition ON. 2. Measure the voltage between blower connectors by changing the step from 1st to 6th. 3. The voltage value by each step is the followings; (specified value; 0.5) 4. If the value is outside the specified value, check the open or short circuit. 1st 4.5 V 2nd 6.0 V 3rd 7.5 V 4th 9.0 V 5th 6th
11.0 V Relay Hi
5. When there is no problem in the wiring harness, replace the power transistor.
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SPECIFICATIONS
Component Compressor Type Model Displacement Max. RPM Receiver-Drier Refrigerant Oil Condenser A/C Pressure Sensor High (Gauge Pressure) Low (Gauge Pressure) Blower Motor Heater Core Material Capacity Type Capacity Type Capacity Max. Capacity A/C ON A/C OFF A/C ON A/C OFF Max. Capacity Fin Pitch Size Capacity Description Variable Displacement V-5 Compressor 9.8 - 151 cc/rev 6,000 - 6,500 rpm AL R/DRIER 210 cc R-134a 750 20 g Synthetic PAG Oil 220 cc 11,400 Kcal/h 305 psi 425 psi 39 psi 30 psi 7,475 - 9,075 Kcal/h 1.52 mm 200.5 x 168.2 x 25.0 mm 8,250 Kcal/h
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GENERAL DIAGNOSIS
The full automatic temperature control (FATC) air conditioning controller contains a self-diagnosis function to aid in finding any problem with the system.
General A/C Diagnosis

Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System for details of the following procedures:

YAD7D150
A/C Performance Test. Insufficient Cooling Quick Check Procedure. Insufficient Cooling Diagnosis. Leaking Testing the Refrigerant System. Low-and High-Side Pressure Relationship Chart. Pressure-Temperature Relationship of R-134a. Testing the refrigerant system. Pressure Test Chart (R-134a System).
If the FATC detects some errors it will blink the temperature display screen for 5 seconds when the ignition switch is ON. When there are some errors in the automatic temperature control system without displaying the faulty code, perform the diagnostic test using the applicable table.
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INSUFFICIENT COOLING DIAGNOSIS

Step Action 1. Check the A/C fuse. 2. Check the operation of the blower motor and cooling fan. 3. Check the accessory belt. 4. Check the A/C condenser for restricted air flow. 5. Check the engagement of the compressor clutch. 6. Check the discharge air temperature with the A/C turned ON. Are all above the operations normal? 1. Turn the ignition to LOCK. 2. Connect the high/low pressure gauges. Are both pressures within the specified value? 1. If its above the specified value, discharge the refrigerant. 2. If its below the specified value, add 0.45 kg (1 pound) of the refrigerant and repair any leaks as needed. 3. Recover, evacuate and recharge the A/C system. Is the repair complete? 1. Start the engine and allow it to run at idle. 2. Turn the A/C switch to ON. 3. Set the blower motor switch to 4th. 4. Set the temperature control lever to full cold. Does the A/C compressor clutch engage? 1. Turn the ignition to LOCK. 2. Check the open or short in the compressor wiring. Is there any open or short in the wiring? Repair the faulty wiring as needed. Is the repair complete? Replace the compressor clutch coil. Is the replacement complete? Check for a knocking noise from the A/C compressor. Cycle the A/C compressor ON and OFF in order to verify the source of the noise. Do you hear a loud knocking noise? 1. Recover the A/C system refrigerant. 2. Replace the A/C compressor. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. Is the compressor running normally? 1. Close all of the windows and doors. 2. Set the A/C switch to ON position. 3. Set the intake air control switch to Fresh Air. 4. Set the blower motor switch to 4th. 5. Set the temperature control switch to full cold. 6. Keep it to run at idle for 5 minutes. 7. Check the temperature at the inlet/outlet of the evaporator. Is there a noticeable difference in the temperature of the evaporator inlet/outlet pipes? Yes No
System OK
Go to Step 2
Go to Step 4
Go to Step 3
System OK
Go to Step 8
Go to Step 5
Go to Step 7 -
6 7 8
Go to Step 9
Go to Step 10
System OK
10
Go to Step 11
Go to Step 13
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7D-16 AUTOMATIC CONTROL HVAC SYSTEM Insufficient Cooling Diagnosis (Contd)

Step Action 1. Recover the A/C system refrigerant. 2. Replace the expansion valve as needed. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. 5. Operate the A/C system. Is the discharge temperature normal? 1. Recover the refrigerant of the A/C system. 2. Evacuate and recharge the A/C system. 3. Check the A/C system for leaks. Does the A/C system operate normally? Feel the liquid pipe between the condenser and the expansion valve. Is the pipe cold? 1. Repair any restriction in high pressure side. 2. Check the A/C system for leaks. Does the A/C system operate normally? 1. Run the engine at 3,000 rpm. 2. Close all of the windows and doors. 3. Set the A/C switch to ON. 4. Set the blower motor switch to 4th. 5. Set the temperature control switch to full cold. 6. Turn the A/C switch ON and OFF every 20 seconds for 3 minutes. 7. Measure the compressor high and low pressure. Are both pressures within the specified value? Add the specified amount of the refrigerant to the A/C system. Is the amount within the specified value? 1. Turn the ignition to LOCK. 2. Set the A/C switch to OFF position. Can you turn the compressor clutch freely by hand? 1. Check the A/C system for leaks. 2. Repair any leaks as needed. 3. Evacuate and recharge the A/C system. Does the A/C system operate normally? 1. Recover the refrigerant of the A/C system. 2. Evacuate and recharge the A/C system. 3. Check the A/C system for leaks. 4. Replace the compressor as needed. Is the repair complete? Yes No
11
Go to Step 13
Go to Step 12
12
Go to Step 14
13
14
System OK
15
Go to Step 16 -
16 17
Go to Step 18
Go to Step 19
18
System OK
19
System OK
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FULL AUTOMATIC TEMPERATURE CONTROL (FATC) DOES NOT OPERATE WHEN THE IGNITION IS ON
Step 1 2 Action Check the fuse F18. Are the fuses blown? Replace the fuse. Is the repair complete? 1. Remove the controller with connecting ATC wiring connector. 2. Turn the ignition switch to ON. 3. Measure the voltage between terminal A1 and A5 of the connectors Is the voltage within specified value? Replace the controller. Is the repair complete? Measure the voltage between terminal A5 of the connector and ground. Is the voltage within specified value? Repair the faulty circuit between fuse F18 and terminal A5 of the ATC wiring connector. Is the repair complete? Repair the faulty circuit between the ground G203 and terminal A1 of the ATC wiring connector. Is the repair complete? Yes Go to Step 3 System OK No Go to Step 2 -
Go to Step 15 11 - 14 V System OK Go to Step 6
4 5 6
System OK
System OK
CONTROLLER DOES NOT ILLUMINATE WHEN LIGHT SWITCH IS ON

Step Action 1. Remove the controller with connecting ATC wiring connector. 2. Turn the ignition switch to ON. 3. Measure the voltage between terminal A4 and A3 of the controller. Is the voltage within the specified value? Repair the wiring harness between splice S206 and terminal A3 of the controller connector or between splice S206 and terminal A4 of the controller connector. Is the repair complete? Check the illumination bulb. Is the bulb burned out? Check the illumination bulb. Is the repair complete? Replace the controller. Is the repair complete? Yes No
Go to Step 3 11 V - 14 V
Go to Step 2
System OK Go to Step 4 System OK System OK
Go to Step 5 -
3 4 5
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NO HOT AIR FROM BLOWER

Step 1 2 Action Check the coolant level. Is the coolant level within the specified value? Add coolant as needed. Is the repair complete? 1. Turn the ignition to ON. 2. Observe the temperature indication screen of the controller. Does the digit flash? Observe the blower motor operation. Is the blower motor functioning at all? Use the blower push switch to cycle the blower through its different speeds. Does the motor function at different speeds? Go to Step 7 6 Run a self diagnosis circuit check. Does the display indicate a defect code? Go to Step 7 7 8 Check the airflow of the ducts at each mode. Is the airflow normal? Check inside the heater duct for obstructions and repair as needed. Is the repair complete? Observe the air mix door motor while changing the temperature setting from LO to HI and then from HI to LO. Is the air mix door actuator functioning properly? Check the coolant hoses for leaks or kinks. Are the coolant hoses in good condition? Replace the coolant hoses. Is the repair complete? Check the coolant reservoir cap. Is the coolant tank cap in hood condition? Replace the coolant reservoir cap. Is the repair complete? 1. Turn the A/C switch to ON. 2. Set the temperature control to full hot (HI). 3. Set the blower motor speed to full high. 4. Remove the coolant reservoir cap (all segments illuminated on the display). 5. Start the vehicle and run the engine at idles. 6. Watch for the flow of the coolant when the thermostat opens. Does the coolant flow normally? 1. Check for faulty thermostat. failed coolant pump impeller. restriction in the cooling system. 2. Make repairs, as needed. Is the repair complete? Go to Step 9 System OK Yes Go to Step 3 System OK No Go to Step 2 -
Go to Step 6
Go to Step 4 Go to Blower Motor Does Not Run At All Go to the Applicable Diagnostic Table Go to the Applicable Diagnostic Table Go to Step 8 Go to the Applicable Diagnostic Table Go to Step 11 Go to Step 13 -
Go to Step 5 5
Go to Step 10 10 11 12 13 Go to Step 12 System OK Go to Step 14 System OK
14
Go to Step 16
Go to Step 15
15
System OK
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AUTOMATIC CONTROL HVAC SYSTEM 7D-19 No Hot Air From Blower (Contd)
Step 16 17 Action Check the temperature of the heater inlet and outlet hoses by feel. Is the heater inlet hose hot and the outlet hose warm? Back flush or replace the heater core. Is the repair complete? Check the vehicle for cold air leaks the Dash. Heater cases. Vents. Are any leaks found? Repair any cold air leaks. Is the repair complete? Check the coolant temperature sensor using the tests in DTC Coolant Temperature Sensor Error. Is there a problem indicated in the sensor, the sensor wiring or the controller? Repair, or replace the sensor, the wiring, or the controller as required. Is the repair complete? Replace the controller. Is the repair complete? Yes Go to Step 18 System OK No Go to Step 17 -
18
Go to Step 19 -
19
20
Go to Step 22 -
21 22
BLOWER MOTOR DOES NOT RUN AT ALL

Step Action 1. Turn the ignition switch to ON. 2. Observe the temperature indication screen of the controller. Dose the digit on and off? Check the fuses. Are the fuses blown? Replace the fuse. Is the repair complete? 1. Turn the ignition switch to ON. 2. Measure the voltage between ground and terminal 87 of blower relay. Is the voltage within the specified value? 1. Measure the voltage between ground and terminal 86 of blower relay. Is the voltage within the specified value? 1. Check the circuit between terminal 86 of the blower relay and fuse SB7 in the I/P fuse block. 2. Repair any problem found in the wiring or terminals at the relay socket or connectors. Is the repair complete? 1. Turn the ignition to OFF. 2. Disconnect the wiring connector of the blower motor. 3. Turn the ignition to ON. 4. Measure voltage between the wiring connector of the blower motor and ground. Is the voltage within the specified value? Yes Go to the Applicable Diagnostic Table Go to Step 3 System OK Go to Step 7 11 - 14 V Go to Step 9 11 - 14 V No
2 3
4 5
System OK
Go to Step 11 11 - 14 V
Go to Step 10
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7D-20 AUTOMATIC CONTROL HVAC SYSTEM Blower Motor Does Not Run At All (Contd)
Step 8 Action Repair the faulty circuit between the wiring connector of the blower relay, wiring, blower motor, connector C203, C107. Is the repair complete? Measure voltage between terminal 30 of the blower relay and ground. Is the voltage within the specified value? 1. Repair the circuit between terminal 86 of the blower relay and fuse SB7 in the I/P fuse block. 2. Repair the wiring connector of the blower relay, wiring, blower motor, connector C203, C107. Is the repair complete? 1. Turn the ignition switch to OFF. 2. Using an ohmmeter, measure the resistance between terminal 85 of the blower relay and ground. Does the measured resistance indicate 0 ? Repair the faulty circuit between terminal 85 of the blower relay, C104 and ground G101. Is the repair complete? Replace the blower motor relay. Is the repair complete? Measure the resistance of the blower motor. Does the measured resistance indicate 0.5 ? Replace the blower motor. Is the repair complete? Measure the open or short of the circuit between terminal 1 of the blower connector and terminal 30 of the blower high relay and terminal 6 of the power transistor. Is there any open or short circuit? Repair the problem in the circuit. Is the repair complete? Measure the resistance of the circuit from terminal 3 of the power transistor connector and ground. Does the measured resistance indicate 0 ? Replace the controller. Is the repair complete? 1. Repair the faulty circuit from terminal 3 of the power transistor connector and terminal 87 of the high blower relay to ground. 2. Repair the faulty in the wiring, connector, C109, C209, C104 or ground G104. Is the repair complete? Yes No
System OK Go to Step 9 11 - 14 V
Go to Step 10
10
System OK
11
Go to Step 13
Go to Step 12
12
System OK System OK Go to Step 15 System OK
Go to Step 16 -
13 14 15
16
Go to Step 18 -
17
18 19
Go to Step 20 -
20
System OK
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NO COOL AIR FROM BLOWER

Step 1 Action 1. Turn the ignition switch to ON. 2. Observe the temperature indication screen of the controller. Does the digit flash? Run a self-diagnosis circuit check. Does the display indicate a defect code? Yes No
Go to Step 2 Go to the Applicable Diagnostic Table
Go to Step 3
Go to Step 4 Go to Blower Motor Does Not Run At All Go to the Applicable Diagnostic Table Go to Step 6 Go to the Applicable Diagnostic Table Go to Step 9 Go to Step 10 -
Observe the blower motor operation. Is the blower motor functioning at all? Go to Step 4 Use the blower push switch to cycle the blower through its different speeds. Does the motor function at different speeds? Go to Step 5 Check the airflow of the ducts at each mode. Is the airflow normal? Check inside the heater duct for obstructions and repair as needed. Is the repair complete? Observe the air mix door motor while changing the temperature setting from LO to HI and then from HI to LO. Is the air mix door actuator functioning properly? Perform the checks found in Insufficient Cooling Diagnosis. Is the system operating normally now? Place the controller in the AUTO mode. Is smoke taken into the intake port of the inside air sensor? Replace the intake hose. Is the repair complete? Check the each sensor and sensor wiring using the Diagnostic Table. Is there a problem indicated in the sensor, the sensor wiring or the controller? Repair, or replace the sensor, the wiring, or the controller as required. Is the repair complete? Replace the controller. Is the repair complete?
5 6
Go to Step 8 8 9 10 11 12 13 System OK Go to Step 11 System OK
Go to Step 13 -
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MODE CONTROLS DOES NOT WORK

Step 1 2 Action Measure the voltage between terminal 4 of the blower motor and mode door motor ground. Is the voltage within the specified value? Repair the connector and the circuit for any wiring or terminal problems. Is the repair complete? 1. Using the Motor Control Table, measure the voltages at the specified terminals of the specified motor connectors. 2. Change the mode settings and observe the voltage changes. Is the voltage within the specified value? Repair or replace the wiring harness or the defective terminal. Is the repair complete? 1. Measure the voltages of the connector terminal. 2. Change the mode settings and observe the voltage changes. Is the voltage within the specified value? Replace the fuel filter or the fuel line. Check the connector at the controller. Is there a defective terminal? Repair the terminal and replace as needed. Is the repair complete? Replace the controller. Is the repair complete? Yes Go to Step 3 11 - 14 V System OK No
Go to Step 17 -
Go to Step 4 -
4 5 6 7 8 9
Go to Step 7 System OK Go to Step 8 System OK System OK
MODE CONTROLS DOES NOT WORK

Step 1 2 Action Measure the voltage between terminal 4 of the intake control door motor and ground. Is the voltage within the specified value? Repair the connector and the circuit for any wiring or terminal problems. Is the repair complete? 1. Measure the voltages at the specified terminals of the specified motor connectors. 2. Change the mode settings and observe the voltage changes Is the voltage within the specified value? 1. Repair the wiring harness or the defective terminal. 2. Replace the fuel filter or the fuel line as needed. Is the repair complete? Check the connector at the controller. Is there a defective terminal? Repair the terminal and replace as needed. Is the repair complete? Replace the controller. Is the repair complete? Yes Go to Step 3 11 - 14 V System OK No
Go to Step 2 -
Go to Step 5
Go to Step 4
4 5 6 7
System OK Go to Step 6 System OK System OK
Go to Step 7 -
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ABNORMAL REFRIGERANT PRESSURE

Step Action 1. Verify whether airflow and excessive refrigerant. 2. Check any restriction at the condenser or radiator. 3. Check the condenser or cooling fan for proper operation. 4. Check any restriction of the refrigerant lines. Is the high-side refrigerant pressure high abnormally? 1. Recover, evacuate and recharge the A/C system according to the specified value. 2. Clean the condenser or radiator core. 3. Check the voltage, rpm, direction of the cooling fan. 4. Repair or replace the applicable parts as needed. Is the high-side pressure within the specified value? 1. Check the amount of the refrigerant. 2. Check the internal faulty of the compressor. 3. Check the faulty of the expansion valve. 4. Check the moisture mix into the system. Is the high-side refrigerant pressure low abnormally? 1. Replace the compressor and the expansion valve as needed. 2. Recover, evacuate and recharge the A/C system according to the specified value. 3. Repair any leaks as needed. Is the repair complete? 1. Check the freezing/clogging of the expansion valve 2. Check the clogging of the receiver-drier. 3. Check the amount of the refrigerant. Is the low-side refrigerant pressure low abnormally? 1. Clean the expansion valve and replace it as needed. 2. Replace the receiver-drier as needed. Is the repair complete? 1. Check the expansion valve and the compressor for any faulty. 2. Check the excessive amount of the refrigerant. Is the low-side refrigerant pressure high abnormally? 1. Replace the expansion valve and the compressor as needed. 2. Add the specified amount of the refrigerant. Is the repair complete? 1. Check the tightening condition of the refrigerant line coupling and bolts. 2. Check the faulty O-ring. 3. Check the faulty gasket or seal of the compressor. Is there any refrigerant leak? 1. Tighten the bolts. 2. Replace the faulty O-ring. 3. Replace the faulty compressor. Is the repair complete? Yes No
Go to Step 2
Go to Step 3
System OK
Go to Step 4
Go to Step 5
System OK
Go to Step 6
Go to Step 7
System OK
Go to Step 8
Go to Step 9
System OK
Go to Step 10
System OK
10
System OK
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COMPRESSOR MAGNETIC CLUTCH DOES NOT ENGAGE

Step 1. 2. 3. 4. Action Remove the controller with connecting the connector. Turn the ignition switch to ON. Set the A/C switch to ON. Measure the voltage between the controller connector A12 (or all for GSL) and the ground. Is the voltage within the specified value? Replace the defective motor. Is the repair complete? Yes No
Go to Insufficient Cooling Diagnosis 11 - 14 V System OK
Go to Step 2 -
INSIDE AIR TEMPERATURE SENSOR ERROR

Step Action 1. Put the smoke of the cigarette near the air inlet and verify that the smoke come into the air inlet properly. 2. Remove the controller with connecting the connector. 3. Turn the ignition switch to ON. 4. Measure the voltage between the connector terminals of the inside air sensor. Does the measured voltage indicate 2 - 3 V at 25 C? Repair the open or short of the wiring harness. Is the repair complete? 1. Remove the inside air temperature sensor. 2. Measure the resistance between the inside air sensor connector terminals. Does the measured resistance indicate 2.2 k at 25 C? Replace the inside air sensor. Is the repair complete? Replace the controller. Is the repair complete? Yes No
Go to Step 2 -
Go to Step 4 -
4 5
AMBIENT AIR TEMPERATURE SENSOR ERROR

Step Action 1. Remove the ambient air temperature sensor. 2. Measure the resistance between the ambient air temperature sensor connector terminals. Does the measured resistance indicate 2.2 k at 25 C? Replace the ambient air temperature sensor. Is the repair complete? 1. Remove the controller with connecting the connector. 2. Turn the ignition switch to ON. 3. Measure the voltage between terminal B8 and connector A13. Does the measured voltage indicate 2.2 V at 25 C? Repair the open or short of the wiring harness. Is the repair complete? Replace the controller. Is the repair complete? Yes No
Go to Step 2 -
Go to Step 4 -
4 5
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COOLANT TEMPERATURE SENSOR ERROR

Step Action 1. Disconnect the coolant temperature sensor connector from the FATC harness. 2. Measure the resistance between the coolant temperature sensor connector terminals.. Does the measured resistance indicate 2.2 k at 25 C? Replace the coolant temperature sensor. Is the repair complete? 1. Remove the controller with connecting the connector. 2. Turn the ignition switch to ON. 3. Measure the voltage between terminal B9 and connector A13. Does the measured voltage indicate 2.2 V at 25 C? Repair the open or short of the wiring harness. Is the repair complete? Replace the controller. Is the repair complete? Yes No
Go to Step 2 -
Go to Step 4 -
4 5
AIR MIX DOOR ERROR

Step Action 1. Disconnect the I/P wiring harness connector form the air mix door motor. 2. Use an ohmmeter to measure the resistance between terminals 5 and 7 on the air mix door motor. Is the resistance within the specified value? Replace the air mix door motor. Is the repair complete? Use an ohmmeter to measure the resistance between terminals 2 and 3 on the air mix door motor. Does the measured resistance indicate approximately 3 k? Replace the air mix door motor. Is the repair complete? Use an ohmmeter to measure the resistance between terminals 6 and 3, 6 and 2 on the air mix door motor. Does the measured resistance indicate approximately 3 k? Replace the air mix door motor. Is the repair complete? Check the connector terminals at the air mix door motor and the wiring in the FATC harness. Is there a problem with any terminal on either the harness connector or the motor connector or the wiring? 1. Remove the FATC controller from the instrument panel. 2. Disconnect the harness connectors of the controller. 3. Examine the connector terminals on the harness connectors and the controller connectors and the harness wiring. Is there a problem with any of these connectors or the wiring? Repair the problem found with a connector terminal or wiring. Is the repair complete? Yes No
Go to step 3 open : short : 0 System OK
Go to Step 2 -
2 3 4
Go to Step 4 -
5 6
Go to Step 6 -
Go to Step 9
Go to Step 8
Go to Step 10 -
SSANGYONG Y200
7D-26 AUTOMATIC CONTROL HVAC SYSTEM Air Mix Door Error (Contd)
Step 10 Action Check continuity in the harness between the controller connectors and the air mix door motor connector. Is there a problem with the wiring? Repair the problem found with the wiring and replace as needed. Is the repair complete? 1. Reconnect the FATC harness connectors to the controller. 2. Reconnect the air mix door motor to the FATC harness. 3. Turn the ignition to ON. 4. Measure the voltage between ground and terminal B5 at the controller by backprobing the connector. Is the voltage within the specified value? Repair the problem found between the controller connector wiring and air mix door connector wiring. Is the repair complete? 1. Set the temperature controller to LO. 2. Measure the voltage between ground and terminal A15 at the controller by backprobing the connector. (Specified voltage : 12 V) 3. Raise the temperature setting on the controller to HI and measure the voltage. (Turn to 0V) 4. Measure the voltage between ground and terminal A9 at the controller. (Specified voltage : 12 V) 5. Change the temperature setting on the controller to LO and measure the voltage. (0 V) Is the voltage within the specified value? Recheck all wiring circuits between the controller and the air mix door motor with changing the temperature setting. Does the air mix door operate normally? Replace the air mix door motor. Is the repair complete? Recheck all wiring circuits between the controller and the air mix door motor. Is there a problem in the wiring or the connectors? Repair the problem in the wiring between the FATC controller and the air mix door motor. Is the repair complete? Recheck the air mix door motor. Is there a problem in the air mix door motor? Replace the air mix door motor. Is the repair complete? 1. Install the components. 2. Perform the diagnostic test of the controller. Does the DTC reset? Yes No
Go to Step 12 -
11
12
Go to Step 14 0-5V
Go to Step 13
13
System OK
14
Go to Step 15
Go to Step 17
15 16 17
System OK System OK
Go to Step 6 -
Go to Step 18
Go to Step 19
18 19 20
Go to Step 21 -
21
Go to Step 16
System OK
SSANGYONG Y200
SUN SENSOR ERROR

Step Action 1. Disconnect the Sun sensor connector. 2. Place the sun sensor under the sun light and measure the current between the connector terminals. 3. Place the sun sensor under the shadow place and measure the current between the connector terminals. Is the measured current lower at the shadow place? replace the sun sensor. Is the repair complete? 1. Remove the controller with connecting the connectors. 2. Turn the ignition switch to ON. 3. Measure the voltage terminal A13 and B10 by backprobing the connectors. (Sun light: 2.5 V, Shadow: 4.8 V) Is the voltage equal to the specified value? Repair open or short circuit. Is the repair complete? Replace the FATC controller. Is the repair complete? Yes No
Go to Step 2 -
Go to Step 4 -
4 5
POWER TRANSISTOR ERROR

Step Action 1. Remove the controller and disconnect the controller connector. 2. Disconnect power transistor connector. 3. Examine the open or short circuit between controller connector and power transistor connector. Is there a problem in the wiring or the connectors? Repair the faulty wiring and replace as needed. Is the repair complete? 1. Reconnect power transistor connector and FATC connectors. 2. Turn the ignition switch to ON. 3. Measure the voltage between ground and terminal B12 of the FATC controller while changing the blower speed from 1 to 6 manually. 1st : 4.5 V 4th : 9.0 V 2rd : 6.0 V 5th : 11.0 V 3th : 7.5 V 6th : 12.5 V Is the resistance equal to the specified value? Replace the power transistor. Is the repair complete? Replace the FATC controller. Is the repair complete? Yes No
Go to Step 3 -
Go to Step 4 -
4 5
SSANGYONG Y200
MAX-HIGH RELAY ERROR

Step Action 1. Remove the controller with connecting the connectors. 2. Turn the ignition switch to ON. 3. Set the blower speed for 5th speed manually. 4. Measure the voltage at terminal A10 and ground. Does the measured voltage indicate 0V? Replace the FATC controller. Is the repair complete? 1. Check the wiring harness associated with blower high relay and terminals. 2. Repair any defects found. 3. Install the component. Is DTC retrieved as a current DTC? Replace blower high relay. Is the repair complete? Yes No
Go to Step 2 -
System OK -
SSANGYONG Y200

CONTROL SWITCH ASSEMBLY
1. Remove the center instrument panel.
YAD7D160
2. Remove the four screws securing the control switch assembly.
YAD7D170
3. Remove the control switch assembly from the instrument panel.
YAD7D180
SSANGYONG Y200

4. Installation should follow the removal procedure in the reverse order. Notice: Insert the connectors to the switch and then assemble the control switch completely.
YAD7D190
BLOWER MOTOR
1. Remove the glove box and put the floor mat aside. 2. Disconnect the connectors connecting the blower motor.
YAD7D200
3. Remove four bolts securing the blower motor and remove the motor assembly.
YAD7D210
YAD7D220
SSANGYONG Y200
HIGH BLOWER RELAY

1. Remove the high relay connector of the blower motor. 2. Remove the bolt securing the high relay. 3. Installation should follow the removal procedure in the reverse order.
YAD7D230
BLOWER MOTOR RESISTANCE (POWER TRANSISTOR)

1. Remove the connector of the power transistor. 2. Remove two bolts securing the power transistor. 3. Remove the power transistor assembly.
YAD7D240
YAD7D250
AIR MIX DOOR ACTUATOR

1. Disconnect the negative battery cable. 2. Remove the glove box. 3. Disconnect the connectors of the air mix door actuator. 4. Remove three screws securing the mode control door actuator and heater/air distributor case. 5. Remove the mode control actuator slowly and then remove the air mix door actuator. 6. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
MODE CONTROL DOOR ACTUATOR

1. Disconnect the negative battery cable. 2. Remove the drivers knee bolster or lower cover. 3. Disconnect the connector to mode control door actuator. 4. Remove three screws securing the mode control door actuator and heater/air distributor case. 5. Remove the mode control actuator slowly and then remove the mode control door actuator.
YAD7D260
YAD7D270
SUN SENSOR
1. Remove the sun sensor from the instrument panel. 2. Disconnect the sensor connector and remove the sun sensor. 3. Installation should follow the removal procedure in the reverse order. Notice: For disconnecting the connector from the sun sensor, be careful that the wiring must not come into the instrument panel.
YAD7D280
INSIDE AIR TEMPERATURE SENSOR

1. Remove the instrument panel. 2. Disconnect the sensor connector, remove the inside air temperature sensor with the tube.
YAD7D290
SSANGYONG Y200

3. Remove the inside air temperature sensor sub from the instrument panel.
YAD7D300
YAD7D310
AMBIENT AIR TEMPERATURE SENSOR

1. Remove the left headlamp assembly.
YAD7D320
2. Disconnect the ambient air temperature sensor at the clip hole of the headlamp support outer panel and then disconnect the connector.
YAD7D330
SSANGYONG Y200

YAD7D340
COOLANT TEMPERATURE SENSOR

1. Disconnect the coolant temperature sensor at the side of the heater core (at left bottom of the glove box). 2. Installation should follow the removal procedure in the reverse order.
YAD7D350
SSANGYONG Y200
SECTION 8A
SEAT BELTS
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must be in B unless otherwise noted.
TABLE OF CONTENTS
Specifications ....................................................... 8A-2 Fastener Tightening Specifications ....................... 8A-2 Diagnosis .............................................................. 8A-3 Seat Belt Warning Lamp is Inoperative ................. 8A-3 Component Locator ............................................. 8A-4 Seat Belt Assembly ............................................. 8A-4 Maintenance and Repair ..................................... 8A-5 On-Vehicle Service ............................................... 8A-5 Front Seat Belt ..................................................... 8A-5 Front Seat Belt Buckle ......................................... 8A-6 2nd-Row Seat Belt ............................................... 8A-7 3rd-Row Seat Belt ................................................ 8A-8
8A-2 SEAT BELTS
SPECIFICATIONS
Application Front Seat Belt Adjuster Mounting Bolt Retractor Mounting Bolt Upper Bolt Lower Bolt Belt Buckle Bolt 2nd-Row Seat Belt 3rd-Row Seat Belt Retractor Mounting Bolt Upper Bolt Upper Bolt Lower Bolt Retractor Bolt Nm 30 - 40 30 - 45 30 - 45 30 - 45 30 - 45 30 - 45 30 - 45 30 - 45 30 - 45 30 - 45 Lb-Ft 22 - 30 22 - 33 22 - 33 22 - 33 22 - 33 22 - 33 22 - 33 22 - 33 22 - 33 22 - 33 Lb-In -
SSANGYONG Y200
SEAT BELTS 8A-3
DIAGNOSIS
SEAT BELT WARNING LAMP IS INOPERATIVE
Condition Seat belt warning lamp is inoperative Probable Cause Seat belt warning lamp wiring harness is open circuit or a short circuit. The continuity between the two terminals at the switch side of the connector is fail. The continuity between the terminal for the BLK wire and ground is fail. The warning lamp bulb in the instrument cluster is blown. Replace the warning lamp bulb. Repair the open ground. Replace the seat belt switch. Correction Repair the wiring harness.
SSANGYONG Y200
8A-4 SEAT BELTS
COMPONENT LOCATOR
SEAT BELT ASSEMBLY
YAD8A010
1 2 3 4
Upper anchor plate Seat Belt Retractor Buckle
5 Retractor 6 Rear Seat Belt 7 Seat Belt
SSANGYONG Y200
SEAT BELTS 8A-5

FRONT SEAT BELT
Removal Procedure
1. Push to slide the front seat toward and push down the seatback. 2. Pry off the bolt cap of the seat belt and remove the lower bolt.
YAD8A020
3. Pry off the upper bolt cap using the special tool and remove the upper bolt.
YAD8A030
4. Pry off the lower B-pillar trim. 5. Disconnect the connector in the front seat belt retractor and remove the mounting bolt. 6. Separate the front seat belt and the retractor assembly.
YAD8A040
SSANGYONG Y200
8A-6 SEAT BELTS

7. Remove the upper B-pillar trim and remove the bracket mounting bolt of the height adjuster to remove the adjuster assembly.
YAD8A050
1. Tighten the adjuster and the seat belt retractor bolt as specified torque. Installation Notice Adjuster Mounting Bolt (1) Retractor Mounting Bolt (2) 30 - 40 Nm (22 - 30 lb-ft) 30 - 45 Nm (22 - 33 lb-ft)
YAD8A060
2. Tighten the upper/lower bolt as specified torque. Installation Notice Upper Bolt (1) Lower Bolt (2) 30 - 45 Nm (22 - 33 lb-ft) 30 - 45 Nm (22 - 33 lb-ft)
YAD8A070
FRONT SEAT BELT BUCKLE

1. Remove the seat and seat belt buckle mounting bolt to remove the buckle assembly.
YAD8A080
SSANGYONG Y200
SEAT BELTS 8A-7

2. Installation should follow the removal procedure in the reverse order. Tighten the mounting bolt as specified torque. Installation Notice Tightening Torque 30 - 45 Nm (22 - 33 lb-ft)
YAD8A090
2ND-ROW SEAT BELT

1. Pry off the lower bolt cap of the seat belt and remove the lower bolt.
YAD8A100
2. Remove the lower quarter trim. 3. Remove the upper quarter trim.
YAD8A110
4. Remove the seat belt upper bolt. 5. Remove the retractor bolt and screw. Remove the seat belt assembly.
YAD8A120
SSANGYONG Y200
8A-8 SEAT BELTS

6. Installation should follow the removal procedure in the reverse order. Tighten the seat belt retractor bolt and the upper bolt as specified torque. Installation Notice Retractor Mounting Bolt (1) Upper Bolt (2) 30 - 45 Nm (22 - 33 lb-ft) 30 - 45 Nm (22 - 33 lb-ft)
YAD8A130
Tighten seat belt lower bolt as specified torque.
YAD8A140
3RD-ROW SEAT BELT

1. Remove the upper/lower bolt of the seat belt. Notice: Push the 3rd row seat down and perform the work with the upper quarter trim removed.
YAD8A150
2. Remove the retractor bolt and screw of the 3rd row seat and then remove the seat belt assembly.
YAD8A160
SSANGYONG Y200
SEAT BELTS 8A-9

3. Installation should follow the removal procedure in the reverse order. Tighten each bolt as specified torque. Installation Notice Upper Bolt (1) Lower Bolt (2) Retractor Bolt (3)
YAD8A170
30 - 45 Nm (22 - 33 lb-ft) 30 - 45 Nm (22 - 33 lb-ft) 30 - 45 Nm (22 - 33 lb-ft)
SSANGYONG Y200
SECTION 8B
RESTRAINTS
TABLE OF CONTENTS
General Description and Operation ..................... 8B-2 General Precautions ............................................. 8B-2 SIR System ......................................................... 8B-3 SIR System Operation ......................................... 8B-3 Airbag Module Discard ........................................ 8B-3 Component Function ............................................ 8B-5 Front Airbag ........................................................ 8B-7 Side Airbag ......................................................... 8B-8 Component Locator ............................................. 8B-9 Driver Airbag Assembly ....................................... 8B-9 Passenger Airbag Assembly ............................. 8B-10 Diagnostic Information and Procedures ............ 8B-11 General Diagnosis ............................................. 8B-11 Diagnosis .......................................................... 8B-12 Diagnostic Trouble Codes .................................. 8B-13 Maintenance and Repair ................................... 8B-16 On-Vehicle Service ............................................. 8B-16 Airbag Module (Driver) ....................................... 8B-16 Contact Coil ....................................................... 8B-17 Airbag Module (Passenger) ................................ 8B-18 Belt Pretensioner ............................................... 8B-19 Sensing and Diagnostic Module (SDM) .............. 8B-19 Special Tool and Equipment.............................. 8B-20 Special Tools Table ........................................... 8B-20
8B-2 RESTRAINTS

GENERAL PRECAUTIONS
When the ignition is switched ON, the supplemental inflatable restraints (SIR) warning lamp must blink at seven times for 7 seconds and then turn off. There is a fault in the airbag system if the warning lamp does not turn OFF or the warning lamp illuminates while the vehicle is in operation. If the warning lamp indicates there is a fault in the airbag system, assume that the SIR system may not be functional. Notice: Failure to follow all service procedures in the correct sequence can cause the airbag system to deploy unexpectedly and possibly cause a serious injury. Only trained personnel at franchised SsangYong dealers and authorized SsangYong service dealerships may service the airbag system.
SIR SYSTEM
SIR system consists of 6-Loop (DAB, PAB, 2*SAB, 2*PRET) fully and the block diagram is as shown below. On this diagram, SDM sends the output signal to DAB, PAB, 2*SAB, 2*PRET and receives the input of side impact from 2*SIS (Side Impact Seasor).
Never attempt to disassemble, repair or reuse the following component; - Airbag modules - Clock spring - Sensing and diagnostic module - Wiring harness When repairing SIR component, follow the service notice; - Inspect any SIR part before it is installed. - Use only new parts. - Do not install used SIR parts from other vehicles. - Do not install any part that has been dropped or that has dents, cracks or other defects. Before testing, disconnect the negative battery cable. Wait one minute for the SDM capacitor to discharge. The capacitor supplies reserve power to deploy the airbags, even if the battery is disconnected. Unintentional deployment of the airbags can cause injury.
YAD8B010
Abbreviation
1 2 3 4 5 6 SDM DAB PAB SAB PRET SIS Sensing and Diagnostic Module (SDM) Driver-side Airbag Module Passenger-side Airbag Module Side Airbag Module (Driver, Passenger) Seatbelt Pretensioner (Driver, Passenger) Side Impact Sensor (Driver, passenger)
SSANGYONG Y200
RESTRAINTS 8B-3
SIR SYSTEM OPERATION

The supplemental inflatable restraints (SIR) system is a safety device used in conjunction with the seat belts. The airbag does not replace the function of the seat belt. The driver and the passengers must always fasten their seat belts and adjust them for a proper fit.
AIRBAG MODULE DISCARD

Airbag Module Deployment (Inside Vehicle)
Deploy the airbag before disposing of them. If a vehicle to be scraped, the airbag may be deployed inside the vehicle.
Before deploying the airbags, remove all loose objects from the airbags expansion area. Deploy the airbags with the vehicle doors closed and the side windows open. Deploy the airbags only in an evacuated area. Service personnel who must be present during the deployment should be at least 10 meters (33 feet) in front of the vehicle. Do not connect the voltage source until after having completed all other preparations for the deployment of the airbags. Allow a deployed airbag module or pretensioner to cool for at least 30 minutes before handling. If the deployment fails, disconnect the voltage source and wait 5 minutes before approaching the vehicle.

YAD8B020
Deployment Condition
Airbag is designed to protect the driver and the front seat passenger in the event of a significant frontal impact to the vehicle. The airbags deploy if the force is applied from a direction within 30 degrees of the vehicles centerline and above 25 km/h (15 mph) speed. In case of the 0 degree frontal concrete barrier, airbag may deploy above 25 km/h (15 mph) speed. The side airbag deploys if the side impact is applied above 30 km/h.
Airbag Module Discard (Driver)

1. Disconnect the battery cable and place the vehicle battery at least 10 meters (33 feet) away from the airbag module. Notice: If the airbags are not disconnected, service cannot begin until one minute has passed after disconnecting power to the SDM. If the airbags are disconnected, service can begin immediately without waiting for one-minute time period to expire. Failure to temporarily disable the SRS during service result in unexpected deployment, personal injury and otherwise unneeded SRS repair. 2. Remove the lower cover of the steering column.
YAD8B030
Condition That Deployment may not be Occurred
Rear Impact Slight impact or partial impact Incline impact Overturn and fall accident Impact on the material that may be possible to absorb a lot of impact energy (styrofoam, empty drum can, etc.)
YAD8B040
3. Cut two wires between the airbag and the contact coil. 4. Strip 13 mm (0.5 inch) of the insulation from the end of the wires leading to the contact coil.
SSANGYONG Y200
8B-4 RESTRAINTS
5. Use two additional wires, each at least 10 meters (33 feet) long, to reach from the deployment battery to the airbag module. 6. Strip 13 mm (0.5 inch) of the insulation from the ends of these two additional wires. 7. Twist the two wires together at one end. 8. Place the twisted ends of the two wires near the deployment battery. Do not connect the wires to the battery at this time. 9. Using the free ends of the 10 meters (33 feet) wires leading to the airbag module, make two splices, one at each wires from the airbag module. 10. Wrap the splices with insulating tape. 11. Now that the free ends of the 10 meters (33 feet) wires are spliced to the airbag module wires and the ends that are twisted together are near the deployment battery, clear the area. 12. Untwist the wires that near the deployment battery. Observe following precaution if the airbag is deployed: Deploy the airbags only in an evacuated area. Service mechanics should be at least 10 meters (33 feet). Do not connect the voltage source until after having completed all other preparations for the deployment of the airbags.
Allow a deployed airbag module or pretensioner to cool for at least 30 minutes before handling. If the deployment fails, disconnect the voltage source and wait 5 minutes before approaching the vehicle. 1. Position the airbag module face up, on flat ground outdoors, at least 10 meters (33 feet) from any obstacle or people. 2. Place a vehicle battery at least 10 meters (33 feet) away from the airbag module. 3. Deploy the airbag module using the deployment tool. If you do not have deployment tool, cut the two additional wires to the airbag module and strip 13 mm (0.5 inch) of the insulation from the end of the wires leading to the airbag module. 4. Refer to DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURE in this section.
Deployed Airbag Module Disposal Procedure

After deployment, a powdery residue may be on the surface of the airbag. The powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by-products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by-product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate also known as baking soda}. Therefore, it is unlikely that sodium hydroxide will be present after deployment. Wear gloves and eye protection during the disposal procedure. After deployment, the metal surfaces of the airbag module will be hot. In order to avoid the risk of an injury or a fire, do not place the deployed airbag module near any flammable objects, and allow the airbag module to cool for 30 minutes before handling. Deploy an airbag or pretensioner before disposing of it. This includes those in a whole vehicle being scrapped. If the vehicle is still within the warranty period contact the SsangYong regional service manager for approval or special instructions before deploying an airbag module or pretensioner.
YAD8B050
13. Touch one wire to the positive battery terminal and touch the other wire to the negative battery terminal. The airbag module will deploy. 14. Refer to DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURE in this section.
Airbag Module Discard (Passenger)

The passenger airbag deployment is the same procedure of the drivers. Remove the glove box instead of the contact coil and cut two passenger airbag wires. Refer to AIRBAG MODULE DISCARD (DRIVER) in this section for more information.
Airbag Module Deployment (Outside Vehicle)

Deploy airbag modules in following situations: If the airbag module is removed in the discarded vehicle. If the airbag module is replaced due to any fault. If an airbag module is damaged during transfer, storage or servicing.
SSANGYONG Y200
RESTRAINTS 8B-5
COMPONENT FUNCTION
Back (Cushion)
The airbag system performance is influenced on the cushion size, shape and position. The cushion strength is a important parameter on the impact absorb effect. Therefore, the control of the airbag performance depends on cushion size, shape, inflator characteristic and vent hole size for the gas discharge. The cushions material and folding function to control the cushion deployment direction and the performance to protect passengers face. It is a type of a container that includes the cushion and the inflator. The module housing functions to deliver the reaction force between the body structure and the airbag (The airbag reaction is absorbed generally to the steering wheel or instrument panel). The module cover must be considered in a viewpoint of protection between exterior, internal units and cushion. Also the module cover should be designed not to cause any personal injury for deployment. The inflator is a type of the direct gas generated device. The inflator with initial low pressure provides negative restraint effect regarding passengers moving and time. On the contrary, the inflator with initial high pressure allows other components of the airbag to make a excessive impact resulting in any personal injury. Thus, the inflator output must be optimized according to the characteristic of the vehicle and passenger moving. The discharge gas has no toxicity or inflammability and also it is the important parameter to control the high temperature for gas firing.
YAD8B060
Module Cover/Housing
SDM (Sensing and Diagnostic Module)

1. The airbag system consists of the module section (driver, passenger and side), seat belt section and SDM. 2. The SDM has no user-serviceable parts and monitors the system components continuously. The SDM also records any faults which are discovered. 3. The SDM allows the fault codes to be retrieved with a scan tool and illuminates a warning lamp that alerts the driver to any faults. The SDM located on floor beneath the floor console assembly. The SDM performs the following functions: Impact decision processor function. Determine the airbag deployment through the impact signal of the accelerometer sensor and the safety sensor. Malfunction detection and recording any faults that are detected. Monitor the supplemental restrain system electrical components and set a diagnostic trouble code when malfunction is detected. Display airbag fault codes Display airbag fault codes and system status information when connected to a scan tool. Self-diagnosis function Illuminate the AIRBAG indicator to alert the driver to any fault. Power supply function Provide a reserve power source to deploy the airbags and pretensioners if an accident has disabled the normal power source.
Inflator
Airbag Module
The driver airbag module is under the center pad of the steering wheel. The passenger airbag module is installed in the instrument panel at passenger side. The driver and passenger side airbag is inside each seat. Notice: Do not disassemble the airbag module because unintentional deployment of the airbags resulting from any damage or interference of the module can cause injury.
Acceleromenter Sensor
The accelerometer sensor electronically represents the acceleration or deceleration of the vehicle during a frontal impact. In this electronic representation, the electrical signal is proportional to the acceleration or deceleration of the vehicle.
SSANGYONG Y200
8B-6 RESTRAINTS
Safety Sensor
The safety sensor is safety device made up of a dualcontact, electro-mechanical switch that: 1. Acts independently of the electronic components. 2. Connects the acceleration sensor in series in order to make up for the weak points in the current electronic sensor.
The SDM performs a turn-on test when the ignition is turned ON. The SDM flashes the AIRBAG indicator seven tomes by supplying an intermittent ground to the indicator lamp circuit. After flashing seven times, the AIRBAG indicator will turn off if no more malfunctions have been detected.
Micro Controller
This device receives the impact signal from the sensor for vehicle impact and identifies whether the current condition is necessary for airbag deployment or not. And then the controller sends the specified currents to the airbag ignition circuit as needed. This device always monitors the airbag system in conduction with the diagnostic circuit. When it is detected any problem, it illuminates the airbag warning indicator to inform driver of the fault and stores the fault information.
YAD8B080
Contact Coil
The contact coil is installed between the steering wheel and the steering column and contains a coil that enables to contact electrically between the airbag wiring harness, the driver airbag module and the horn switch. Notice: Turning the steering wheel more than three and one-quarter turns may damage the clock spring. The contact coil should never be disassembled and must be replaced if the airbag have been deployed. Warning lamp status Flash at seven times for 7 seconds and then turn off Warning lamp stays ON No turn on System fault Internal SDM fault Power supply circuit open and fuse open Warning lamp circuit open SDM fault System OK Fault contents
Wiring Harness Connectors

If the sensing and diagnostic module (SDM) electrical connector is not attached properly, a built in shorting bar will connect the wire from airbag warning lamp with the SDM ground wire. This turns on the AIRBAG indicator. To prevent deployment during servicing, additional shorting bars are located in following locations: Driver airbag module connector Passenger airbag module connector
YAD8B070
Notice: Turn the label of the clock spring clockwise to lock and turn the label of the clock spring counterclockwise approximately 2.9 0.2 turns to the neutral positions with the front wheels ahead. Align the pointed marks "! .
Airbag Warning Lamp

The instrument cluster contains an airbag warning indicator bulb to verify the operation of the AIRBAG indicator and sensing and diagnostic module (SDM).
Driver and passenger side airbag module connector SDM wiring harness connector
Contact coil connector to airbag wiring harness The shorting bar is only a backup safety device. Always disable the supplemental restraints system (SRS) before beginning any service procedure.
Belt Pretensioner
The belt pretensioner enables to retract the driver and the passenger seat belt webbing to reduce any personal impact when accounted a frontal collision.
SSANGYONG Y200
RESTRAINTS 8B-7
FRONT AIRBAG
General Description
The frontal airbag system is a safety device used in conjunction with the seat belts. The airbag does not replace the function of the seat belt. The driver and the passengers must always fasten their seat belts and adjust them for a proper fit. The front seat airbag is designed to protect the driver and the front seat passenger in the event of a significant frontal impact to the vehicle. The driver airbag is installed on the steering wheel and the passenger airbag is in the instrument panel.
Cushion Cushion is made mainly of nylon 66 material. It is made by assembling various panel pieces and sometimes, some surfaces of these panel pieces handled by coating. The coating material is used as silicon rubber generally. Inflator The inflator generates gas to fill the cushion with it. There are two type of ALL-PYRO TECHNIC TYPE and HYBRID TYPE according to gas generated type. Now, the driver airbag uses the all-pyro technic type and the passenger airbag uses both all-pyro technic type and hybrid type . The inflator has the ignitor at one side of the inflator. The ignitor receives a electrical signal from the sensor and ignites powders continuously. Housing It is a part of airbag steel plate structure.
Airbag Component
Cover It is a part of the airbag steering section and is made by injection molding. Door Assembly It is a part of the airbag steering and is made by vacuum bubble, PSM, injection.
SSANGYONG Y200
8B-8 RESTRAINTS
SIDE AIRBAG
The side airbag receives each of the side airbag sensor signal to deploy the airbag when the vehicle crashes at side impact. The side airbag module is installed inside the seat. When the airbag is deployed, replace the deployed front seat assembly.
System Structure
1 2 3 4 5 6 Related System Vehicle Structure and B/W Seat System Seat Belt System Door Trim and Door Structure B - Pillar Trim and Structure Airbag Wiring Harness Component 1 Side Airbag Module (LH/RH) 2 Side Airbag Sensor (LH/RH) 3 SDM (Common use the SDM for frontal airbag)
Side Airbag Module (SAB)
Side Airbag Module (SAB)
Chest, Head and Gas Airbag Installed on door or seatback
Chest, Head and Gas Airbag Installed on door or seatback
SDM
Operation Circuit Safety Sensor External Diagnosis
Side Airbag Sensor
Side Airbag Sensor
Side Impact Detection Deployment Decision Self-Diagnosis Installed on Inner B - Pillar or Side underbody
Side Impact Detection Deployment Decision Self-Diagnosis Installed on Inner B - Pillar or Side underbody
SSANGYONG Y200
RESTRAINTS 8B-9
FRONTAL AIRBAG CROSS SECTIONAL VIEW

DRIVER AIRBAG ASSEMBLY
YAD8B090
1 2 3 4 5
Cover Carrier Retainer cover assembly Retainer cushion assembly Cushion assembly
6 7 8 9 10
Inflator assembly Membrane switch assembly Reaction plate Steering wheel Remote control switch
SSANGYONG Y200
8B-10 RESTRAINTS
PASSENGER AIRBAG ASSEMBLY
YAD8B100
1 Cover assembly 2 Housing assembly 3 Upper Door Retainer
4 Lower Door Retainer 5 Cushion assembly 6 Inflator assembly
SSANGYONG Y200
RESTRAINTS 8B-11

GENERAL DIAGNOSIS
Warning Lamp Check
As soon as the opening voltage is applied to the sensing and diagnostic module (SDM) ignition input, the SDM activates the warning lamp for a bulb check. The SDM allows the lamp to blink at seven times for 7 seconds and then turn off. During the bulb check, the SDM is not ready to detect a crash or deploy the supplemental inflatable restraints.
Warning lamp stays ON : Connection fault between the SDM wiring harness connector and the SDM connector, or the airbag wiring harness fault. No the indicator turn ON : Power supply malfunction, indicator circuit open, bulb fault, SDM internal defect.
Diagnosis by Using Scan Tool Check the fault code by connecting the diagnostic (ALDL) connector.
Receive serial data from terminal 9 of the ALDL connector. Receive the ground signal from terminal 4 or 5 of the ALDL connector.
Clearing Fault Codes

When the sensing and diagnostic module (SDM) receives the CODE ERASE command from the scan tool, the SDM: Clears the entire fault memory. Turns OFF the warning lamp. When it is removed the scan tool after clearing the fault code, the SDM rechecks the airbag system to detect the SDM s fault.
YAD8B080
Fault Indication
The sensing and diagnostic module records the system s faults in two categories: Active Fault Current detected faults and the C appears the first digit of the fault code on the scan tool display (example: C16 ). History Fault These faults that were detected in the past, but are no longer active. The H appears the first digit of the fault code on the scan tool display (example: H17). Diagnosis by Using Warning Lamp The warning lamp flashes for 7 seconds at seven times and turn off : Normal Status - There is not any history or current fault code. The indicator turns on for 7 seconds and then turn off : Normal Status - A fault has been detected previously but now there is not any more of the same detected fault. Clear the fault using the scan tool. The indicator turns on for 7 seconds and turns off for 1 second and then turn on again: Abnormal Status - It has detected a current fault or has been occurred same fault more than five times, or has been occurred more than five types of faults. Perform the diagnosis using the scan tool.
External Fault Service personnel can reset the SDM and turn OFF the warning lamp if the fault is an external fault. Internal Fault An internal fault of the SDM or a CRASH RECORDED fault code cannot be reset. In the case of an internal fault of the SDM or a CRASH RECORDED fault code, the SDM must be replaced.
Microprocessor-Independent Lamp Activation

If the sensing and diagnostic module (SDM) electrical connector is not properly attached, the SDM cannot function and cannot control the warning lamp. If this fault is present, the warning lamp will operate independently from the SDM through the use of shorting bars that are built into the SDM connector. Notice: Do not measure the resistance of the airbag module because the multimeters battery may deploy the air bag causing any personal injury.
SSANGYONG Y200
8B-12 RESTRAINTS
DIAGNOSIS
Possible Cause Ignition ON Check warning lamp on I/P Does the warning lamp blink at seven times for 7 seconds and then turn off? Does the fault code display on the scan tool display? Is there any open in fuse? Yes No Replace fuse. Disconnect wiring connector. Check any wiring short between fuse and wiring connector. Is there any short in fuse? Yes No Repair wiring. Disconnect SDM wiring connector. Check wiring short between connector terminal and SDM connector terminal. Is there any short in wiring? Is there any open in wiring? Does the voltage indicate 11~14V? No Is there any open or short in wiring? Is there any open or short in wiring? Yes No Yes No Yes No Yes No Yes Replace airbag wiring. Check any open between ALDL connector No.4, No.5 terminal and ground. Repair wiring Ignition ON Measure voltage at the cigar lighter socket. Check any open or short between ALDL connector terminal and wiring connector terminal. Repair the wiring of the cigar lighter socket. Repair wiring Check any open or short between SDM connector terminal and wiring connector terminal. Replace the airbag wiring. Replace the SDM. Yes No Yes No System OK Connect the scan tool to diagnostic connector (ALDL). Select the fault code display menu and clear code menu. Perform Diagnostic System Check. Check any fuse open. Action
SSANGYONG Y200
RESTRAINTS 8B-13

Code 01h too high Fault Contents Driver airbag circuit, resistance Check Check the connection of the driver airbag connector. Check the wiring condition of the driver airbag. (including clock spring) Check the bending of the airbag terminal. 02h Driver airbag circuit, resistance too low Check the connection of the driver airbag connector. Check the wiring condition of the driver airbag. (including clock spring) Check the bending of the airbag terminal. 03h Driver airbag circuit, short to ground Check the connection of the driver airbag connector. Check the wiring condition of the driver airbag. (including clock spring) Check the bending of the airbag terminal. 04h Driver airbag circuit, short to battery voltage Check the connection of the driver airbag connector. Check the wiring condition of the driver airbag. (including clock spring) Check the bending of the airbag terminal. 05h Passenger airbag circuit, resistance too high 06h Passenger airbag circuit, resistance too low 07h Passenger airbag circuit, short to ground 08h Passenger airbag circuit, short to battery voltage 09h Driver pretensioner circuit, resistance too high 0Ah Driver pretensioner circuit, resistance too low 0Bh Driver pretensioner circuit, short to ground 0Ch Driver pretensioner circuit, short to battery voltage Check the connection of the passenger airbag connector. Check the wiring condition of the passenger airbag. Check the bending of the airbag terminal. Check the connection of the passenger airbag connector. Check the wiring condition of the passenger airbag. Check the bending of the airbag terminal. Check the connection of the passenger airbag connector. Check the wiring condition of the passenger airbag. Check the bending of the airbag terminal. Check the connection of the passenger airbag connector. Check the wiring condition of the passenger airbag. Check the bending of the airbag terminal. Check the connection of the driver pretensioner connector. Check the wiring condition of the driver pretensioner. Check the bending of the airbag terminal. Check the connection of the driver pretensioner connector. Check the wiring condition of the driver pretensioner. Check the bending of the airbag terminal. Check the connection of the driver pretensioner connector. Check the wiring condition of the driver pretensioner. Check the bending of the airbag terminal. Check the connection of the driver pretensioner connector. Check the wiring condition of the driver pretensioner. Check the bending of the airbag terminal.
SSANGYONG Y200
8B-14 RESTRAINTS
Code 0Dh Fault Contents Passenger pretensioner circuit, resistance too high 0Eh Passenger pretensioner circuit, resistance too low 0Fh Passenger pretensioner circuit, short to ground 10h Passenger pretensioner circuit, short to battery voltage 34h Driver side airbag circuit, resistance too high 35h Driver side airbag circuit, resistance too low 36h Driver side airbag circuit, short to ground 37h Driver side airbag circuit, short to battery voltage 38h Passenger side airbag circuit, resistance too high 39h Passenger side airbag circuit, resistance too low 3Ah Passenger side airbag circuit, short to ground 3Bh Passenger side airbag circuit, short to battery voltage 50h Driver side airbag sensor, open/ short to battery voltage Check Check the connection of the passenger pretensioner connector. Check the wiring condition of the passenger pretensioner. Check the bending of the airbag terminal. Check the connection of the passenger pretensioner connector. Check the wiring condition of the passenger pretensioner. Check the bending of the airbag terminal. Check the connection of the passenger pretensioner connector. Check the wiring condition of the passenger pretensioner. Check the bending of the airbag terminal. Check the connection of the passenger pretensioner connector. Check the wiring condition of the passenger pretensioner. Check the bending of the airbag terminal. Check the connection of the driver side airbag connector. Check the wiring condition of the driver side airbag. Check the bending of the airbag terminal. Check the connection of the driver side airbag connector. Check the wiring condition of the driver side airbag. Check the bending of the airbag terminal. Check the connection of the driver side airbag connector. Check the wiring condition of the driver side airbag. Check the bending of the airbag terminal. Check the connection of the driver side airbag connector. Check the wiring condition of the driver side airbag. Check the bending of the airbag terminal. Check the connection of the passenger side airbag connector. Check the wiring condition of the passenger side airbag. Check the bending of the airbag terminal. Check the connection of the passenger side airbag connector. Check the wiring condition of the passenger side airbag. Check the bending of the airbag terminal. Check the connection of the passenger side airbag connector. Check the wiring condition of the passenger side airbag. Check the bending of the airbag terminal. Check the connection of the passenger side airbag connector. Check the wiring condition of the passenger side airbag. Check the bending of the airbag terminal. Check the connection of the driver side airbag sensor connector. Check the wiring condition of the driver side airbag sensor. Check the bending of the airbag terminal.
SSANGYONG Y200
RESTRAINTS 8B-15
Code 51h Fault Contents Passenger side airbag circuit, short to ground 52h Communication malfunction of the driver side airbag 53h Internal fault of the driver side airbag sensor 54h Passenger side airbag sensor, open/short to battery voltage Check Check the connection of the driver side airbag sensor connector. Check the wiring condition of the driver side airbag sensor. Check the bending of the airbag terminal. Check the connection of the driver side airbag sensor connector. Check the wiring condition of the driver side airbag sensor. Check the bending of the airbag terminal. Check the connection of the driver side airbag sensor connector. Check the wiring condition of the driver side airbag sensor. Check the bending of the airbag terminal. Check the connection of the passenger side airbag sensor connector. Check the wiring condition of the passenger side airbag sensor. Check the bending of the airbag terminal. 55h Passenger side airbag sensor, short to ground Check the connection of the passenger side airbag sensor connector. Check the wiring condition of the passenger side airbag sensor. Check the bending of the airbag terminal. 56h Communication malfunction of the passenger side airbag Check the connection of the passenger side airbag sensor connector. Check the wiring condition of the passenger side airbag sensor. Check the bending of the airbag terminal. 57h Internal fault of the passenger side airbag sensor Check the connection of the passenger side airbag sensor connector. Check the wiring condition of the passenger side airbag sensor. Check the bending of the airbag terminal. 17h Battery voltage too high Check generator output voltage. Check the battery voltage. Check the bending of the airbag terminal. 18h Battery voltage too low Check generator output voltage. Check the battery voltage. Check the bending of the airbag terminal. 1Eh 1Fh SDM internal fault (Initialization fault) SDM internal fault Replace the SDM. Replace the SDM.
Caution: Use only the scan tool to check the airbag module and the sensing and diagnostic module (SDM). Never measure the resistance of an airbag module with an ohmmeter. An ohmmeters battery can deploy the airbag and cause injury. Before testing, disconnect the negative battery cable. Wait 1 minute for the SDM capacitor to discharge. The capacitor supplies reserve power to deploy the airbags, even if the battery is
disconnected. Unintentional deployment of the airbags can cause injury. Do not attempt to repair the supplemental inflatable restraints (SIR) wiring harness. An SIR repair can create a high-resistance connection which can keep the airbags from deploying when needed, resulting in injury.
SSANGYONG Y200
8B-16 RESTRAINTS

AIRBAG MODULE (DRIVER)
1. Disconnect the negative battery cable. 2. Place the steering wheel at the straight driving direction. 3. Remove the screw of the airbag module.
YAD8B110
4. Disconnect the airbag module connector, the horn connector and then remove the airbag module.
YAD8B120
5. Verify to tighten all of the module and each connector. Installation should follow the removal procedure in the reverse order.
YAD8B130
SSANGYONG Y200
RESTRAINTS 8B-17
CONTACT COIL
1. Remove the steering wheel, the lower panel at the driver side.
YAD8B140
2. Remove the upper and lower cover of the steering column.
YAD8B150
3. Disconnect the contact coil connector and remove the contact coil mounting screw. Remove the contact coil assembly.
YAD8B160
4. Tighten the contact coil mounting screw as the specified torque. Installation should follow the removal procedure in the reverse order. Installation Notice Tightening Torque 3 N m (27 lb-in)
YAD8B170
SSANGYONG Y200
8B-18 RESTRAINTS
5. Fix the contact coil to the center position. Notice: If the clock spring is not properly aligned, the steering wheel may not be able to rotate completely during a turn. Restricted turning ability can cause the vehicle to crash. Improper alignment of the clock spring also may make the supplemental inflatable restraints (SIR) system inoperative, preventing the airbags from deploying during a crash. Both of these outcomes can result in injury. Notice: Turn the label of the clock spring clockwise to lock and turn the label of the clock spring counterclockwise approximately 2.9 0.2 turns to the neutral positions with the front wheels ahead. And also Align the pointed marks "! .
YAD8B180
yyyy ;;;;
YAD8B190 YAD8B200
AIRBAG MODULE (PASSENGER)

1. Disconnect the negative battery cable. 2. Remove the glove box. 3. Disconnect the airbag module connector.
4. Remove the airbag module. 5. Installation should follow the removal procedure in the reverse order.
SSANGYONG Y200
RESTRAINTS 8B-19
BELT PRETENSIONER
1. Disconnect the negative battery cable. 2. Remove the upper belt bolt and disconnect the panel. 3. Disconnect the airbag wiring connector. 4. Remove the mounting bolt of the belt pretensioner and remove the belt assembly.
YAD8B210
5. Tighten the pretensioner mounting bolt as the specified torque. Installation should follow the removal procedure in the reverse order.
YAD8B220
SENSING AND DIAGNOSTIC MODULE (SDM)

1. Disconnect the negative battery cable. 2. Remove the I/P center panel and the console panel. 3. Remove the SDM connector.
YAD8B230
4. Remove the SDM mounting bolt and remove the SDM assembly. 5. Installation should follow the removal procedure in the reverse order.
YAD8B240
SSANGYONG Y200
8B-20 RESTRAINTS

SPECIAL TOOLS TABLE
Scan Tool
Wheel Wrench
YAD8B250
YAD8B260
SSANGYONG Y200
SECTION 9A
GENERAL BODY
TABLE OF CONTENTS
Specification ........................................................ 9A-2 Dignosis and Action Taken ................................... 9A-3 Diagnosis for Leaking Water ................................ 9A-3 Check and Repair ................................................. 9A-4 Check ................................................................. 9A-4 Repair ................................................................. 9A-7 Special Tool and Equipment................................ 9A-9 Special Tools Table .............................................. 9A-9
9A-2 GENERAL BODY
SPECIFICATION
Application Hood Front Door Type Structure Type of Regulator Lock System Rear Door Structure Type of Regulator Lock System Tail Gate Thickness of Glass Type Wind Shield Front Door Glass Rear Door Glass Rear Fix Glass Glass of Tail Gate Specification of Test Water Leaking Height of Nozzle Quantity of Injecting Pressure Position of a Piller Test Stand and Wing Shield Position of B Piller Test Stand Type of Nozzle Fixing Type Opening Type Specification Rear Hinge and Type of Front Opening, Gas Lifter Front Hinge and Frame Door Wire and Drum Pin and Fork Front Hinge and Frame Door Wire and Drum Pin and Fork Internal Hinge, Gas Lifter 5 mm 4.0 mm 4.0 mm 4.0 mm 4.0 mm 5.0 mm Spray Nozzle of #1/2 GG-25 or Nozzle with Sloping Angle 60 Equivalent Keep Distance 1,600 mm from Ground 14L Per Mir 155kPa(22.5 psi): Checking Pressure from nozzle Keep Injecting Water, 30 of Lower Direction and 45 of Backwards, Approximately at the corner of Windshield Keep Injecting Water, 30 of Lower Direction and 45 of Backwards, Approximately at the corner Line of Rear Door. Position of Rear Decklid Test and Tail Gate Glass Keep Injecting Water, 30 of Lower Direction and 45 of Forwards, Approximately at Distance of 60mm to the Corner of Rear Door
SSANGYONG Y200
GENERAL BODY 9A-3
DIGNOSIS AND ACTION TAKEN

Wind noise around door 1) 2) 3) 4) 5) Cause Not installed weather strip tightly Misinstalled of weather strip Not closed door accurately Misinstalled or door Not keep constant clearance between door glass and moulding Deformed of door Abnormal material build up on drain hose and pipe Drain hose or pipe is clogged up Misinstalled of drain hose or pipe, deformed or broken clip Deformed weather strip of roof-lid Not keep clearance constant between roof-lid and body or mis Installed weather strip Loose or deformed deflector Action Taken Adjust weather strip Adjust and replace weather strip Adjust Adjust Adjust Repair or replace 1) Remove abnormal material from drain hose or pipe 2) Abnormal material is removed from drain hose or pipe by compressor 3) Check the state of installing and connecting section in the drain hose or pipe 4) Replace 5) Adjust
6) Leaking water 1) from sun roof 2) 3) 4) 5)
Wind noise 1) around sun roof Failure of door 1) Misinstall of wind glass glass 2) Failure of motor 3) Failure of power window switch Not closed 1) Misinstalled of door door or not 2) Misoperated of door lock opened 3) Deformed of door checker completely. 4) Lack of grease at door hinge 1) Not fitted the position between Not closed striker and latch hood or not opened 2) Misinstalled of hood completely. 3) Inproper height of hood bumper Lack of sealing Leak from windshield or Damaged flange rear window
1) Retighten or replace
1) 2) 3) 1) 2) 3) 4) 1)
Adjust the position Replace Replace Adjust position Replace Repair or replace Grease Adjust
2) Adjust 3) Adjust Spread sealant Repair
DIAGNOSIS FOR LEAKING WATER

It is required for technician to inspect and diagnose accurately problems of leaking water. Problem of leaking water is repaired by adjusting of misaligned parts by using proper equipment, first of all check condition of leaking water. For example, condition caused leaking water to occur should be checked if vehicle is parked on the sloping road or spare tire in the trunk. Next step of checking leaking section of water is following as belows. If general leaking section of water is detected, check accurate leaking section of water, by using water hose or air hose. If general leaking
SSANGYONG Y200
section of water is not detected, check leaking section of water, by using the stand of tester of leaking water. It is required for technician to check accurate leaking section of water such as, removal of internal trim panel or component parts . Notice: Technician should detect cause of leaking water before leaking section of water is repaired. It is difficult for technician to do temporary solution of leaking water, but also this one will cause more difficult situation to solve problem of leaking water. To ensure detecting leaking section of water, keep test for leaking section of water.
9A-4 GENERAL BODY
CHECK AND REPAIR

CHECK
General Checking Leaking Water
1. Install checking equipment 2. Check leaking water. 3. If water pressure is getting below regulated water pressure, to inject water overlapping, technician keeps vehicle close to stand of each side.
YAD9A010
Check Local Section of Leaking Water

1. Test local section of leaking water by using water hose or air hose 2. First of all, test dubious section of leaking water by injecting water or air, until technician detect section of leaking water, point of checking is moving from the low of vehicle to the upper of vehicle.
YAD9A020
Check the Water Hose

1. In order to detect section of leaking water, another technician, is moving into the internal of vehicle. 2. Use water hose not having a nozzle. 3. First of all, test dubious section of leaking water by injecting water or air,until technician detect section of leaking water, point of checking is moving from the low of vehicle to the upper of vehicle.
YAD9A030
SSANGYONG Y200
GENERAL BODY 9A-5
Check Air Hose

1. Soap bubbles is fed on the dubious section of leaking water. 2. Inject air from the internal of the vehicle, not to keep compressing air, over 205 kPa ( 29.7 psi ). 3. Check whether bubble of soap is occurred on the dubious section of leaking water, or not and then make sure section of leaking water.
YAD9A040
Dignosis of Wind Noise

Notice: If technician diagnose the vehicle wind noise, another technician is driving the diagnosed vehicle for the prevention of vehicle unsafe. It is necessary for technician to drive vehicle in order to analyse position of wind noise, accurately, wind noise is occurred by first leaking and second, if all the leaking section is not repaired, wind noise will be reduced little bit, but wind noise will not be reduced completely For technician to diagnose position of wind nose with driving test, following description should be provided vacuum hose vinyl tape scrip cork pencil indicating screw driver Driving test should be observed as followings. 1. Select straight and even road which is available to East,West,South, and North. 2. Select road not preventing test which has no noise or traffic obstacle. 3. Drive the vehicle when wind noise is occurred Keep in mind within specified vehicle speed. 4. If following condition happen, each one is defined, as external wind noise. wind noise is occurred by wind wind noise happen on the lower side of door glass under vehicle is driving wind noise is removed by taping of moulding
SSANGYONG Y200
9A-6 GENERAL BODY

5. Internal wind noise is repaired following description Leaking section is detected by using stethoscope or vacuum hose is repaired by using vinyl tape temporarily. Keep driving test to check whether wind noise is removed or not if leaking section is checked. Wind noise will be completely repaired by proper equipment, tool of sealing.
YAD9A0650
Body
Periodically hood and locking system should be fed for operating smoothly, specially feeding oil to the section of closing and opening is depending on operation smooth and prevention of noise.
YAD9A060
Bolt and Nut

Notice: Contacting surface to the non-characteristic of each metal cause each metal to corrode so, for prevention of early corrosion, use specified bolt and nut Alloy of aluminium is using currently most vehicle Contacting between steel and aluminium cause to corrode if those are ,not hardening. Special bolt and nut are using for prevention of corrosion in the vehicle. If bolt and nut are replaced, same specification of bolt and nut should be, used or similar material of bolt and nut.
YAD9A070
The Prevention of Corrosion

In order not to corrode body, surface of internal panels of metal is added, material of anti-corrosion. If those panel are replaced, spread material of anti- corrosion on the panels with proper quantity
YAD9A080
SSANGYONG Y200
GENERAL BODY 9A-7
REPAIR
Repair Leaking Water
Leaking water on the section of glass can be repaired without removal of glass. Notice: Method to repair of following description is applied on the equipped glass of urethane sealing. 1. Remove leaking moulding and section of trim, to detect position of leaking water it is necessary for technician to remove trim and garnish moulding 2. During injecting water on the leaking section, to detect quantity of leaking water, carefully push the glass external area. 3. Mark accurate position of leaking water. 4. Wash section of leaking water and dry up air hose.
YAD9A090
5. Remove ununiform section of cohesive material on the distance of 75 - 100 mm to leaking section 6. Spread prima on the uniform section leaking
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YAD9A100
SSANGYONG Y200
9A-8 GENERAL BODY

7. Wait approximately 5 minutes, until drying up prima. 8. Spread cohisive material on the distance of 75 100 mm to leaking section. 9. After spreading cohisive material, using the flat stick and similar equipment, keep body and cohisive material uniform in order not to leak water. 10. To make sure to finish repairing leaking water, inject warm water or, hot water on the section of leaking water. 11. Install parts removed to repair leaking section.
YAD9A110
Notice: After repairing section of leaking water completely, using stand for leaking. test, check the section of leaking water again, if abnormal pressure is checked, repaired cohesive material may get out of position itself. So leaking water test should not check on local section of leaking .
Method to Repair Wind Noise

Method to repair wind noise is similar to method to repair leaking water. Wind noise of around door opening weather strip is not proper installed. Weather but depends on adjusting door and window.
Method to Repair Body Noise

Due to not properly installed parts of body, body noise is occurred, in order not to make a noise, proceed the following description. Install completely relative moving parts under vehicles moving. Repair clearance of moving parts under vehicles moving. In order not to cause body noise about moving parts, separate, moving parts, treat soundproof. Uniform surface of friction can prevent harding state.
SSANGYONG Y200
GENERAL BODY 9A-9

SPECIAL TOOLS TABLE
09793-21000 Adjusting Wrench of Door Wrench
09800-21000 Ornament Remover
YAD9A120
YAD9A130
09853-31000 Remover of Headlning Clip
09861-31100 Cutting Tool of Sealant
YAD9A140
YAD9A150
09861- 31200 Cuttibg Knife of Sealant
09861-31300 Sealant Gun
YAD9A160
YAD9A170
09861-31400 Glass Holder
09861-31000 Remover of Wind Shield Molding
YAD9A180
YAD9A190
SSANGYONG Y200
SECTION 9B
BODY INTERIOR
TABLE OF CONTENTS
Components Location ......................................... 9B-2 Instrument Assembly ........................................... 9B-2 Side Trim and Roof Assembly .............................. 9B-3 Seat .................................................................... 9B-4 Console ............................................................... 9B-5 Removal and Installation ..................................... 9B-6 Instrument ........................................................... 9B-6 Console Box ........................................................ 9B-9 Groove Box ....................................................... 9B-10 Trim and Roof .................................................... 9B-10 Handler ............................................................. 9B-15 Sunvisor ............................................................ 9B-15 Room Miror ........................................................ 9B-15 Seat .................................................................. 9B-16 Removal and Installation ................................... 9B-18 Front Seat .......................................................... 9B-18 Two Row Seat .................................................... 9B-19 Seat of Three Row.............................................. 9B-20
9B-2 BODY INTERIOR
COMPONENTS LOCATION
INSTRUMENTS ASSEMBLY
YAD9B010
1 2 3 4 5 6
Fuse Box Cover Side Facia Panel Instrument Panel Instrument Lower Main Panel Cluster Facia Panel Center Facia Lower Panel
7 8 9 10 11
Groove Box Side Facia Panel Duct Instrument Assembly Center Facia Upper Panel
SSANGYONG Y200
BODY INTERIOR 9B-3
SIDE TRIM AND ROOF ASSEMBLY
YAD9B020
1 2 3 4 5 6 7 8 9
Door Scuff Front Door Scuff Rear A-Pillar B-Upper Pillar B-Lower Pillar Side Cowl Side Cowl Out Side Step Front Out Side Step Rear
10 11 12 13 14 15 16 17 18
Upper Quarter Rear Aircon (Facia) Lower Quarter Jack Cover Lower Quarter (Cover) Lower Quarter Rear Transverse Trim Baggage Room Cover Roof Panel
SSANGYONG Y200
9B-4 BODY INTERIOR
SEAT
YAD9B030
1 Front Seat - Right Side 2 Rear Seat - Right Side 3 3 Row Seat
4 Rear Seat - Left Side 5 Front Seat - Left Side
SSANGYONG Y200
BODY INTERIOR 9B-5
CONSOLE
YAD9B040
SSANGYONG Y200
9B-6 BODY INTERIOR
REMOVAL AND INSTALLATION

INSTRUMENT
Removal / Installation
1. Remove negative terminal(-) from battery. 2. Remove seat of passenger to remove easily panel of instrument.
YAD9B050
3. Remove cover(1) of fuse box, switch panel(2) of side mirror, release lever(3) of fuel tank cover.
YAD9B060
4. Remove lower panel of driver seat in the instrument panel.
YAD9B070
SSANGYONG Y200
BODY INTERIOR 9B-7

5. Remove side cowl in the left side/ right side. 1) Remove front trim of door scuff in the left side / right side. 2) Removing screw of side of foot-board, side of door in the side cowl and then come to removal of side cowl.
YAD9B080
3) After driver put clearance between pillar and panel, remove side cowl.
YAD9B090
6. Separating connector and vacuum hose from steering column assembly, remove steering column shaft assembly.
YAD9B100
7. Removing center facia panel , remove Audio(1), Aircon controller Assembly(2).
YAD9B110
SSANGYONG Y200
9B-8 BODY INTERIOR

8. Remove the console box.
YAD9B120
9. Remove connector of main harness linking to center and right side /left in the instrument panel. 1) Connector linking to left side 2) Connector linking to right side 3) Connector linking to center
YAD9B130
YAD9B140
10. After releasing fixing bolt and nut in the instrument panel, remove panel assembly.
YAD9B150
SSANGYONG Y200
BODY INTERIOR 9B-9

11. Installing the reverse of removal, insert each connectors tightly.
YAD9B160
COSOLE BOX
1. Separate front console cover and console tray.
YAD9B170
2. After removing front console cover , separate fixing bolts( 2).
YAD9B180
3. Separate fixing bolts from console tray internal in the console box of rear side.
YAD9B190
SSANGYONG Y200
9B-10 BODY INTERIOR

4. Separate cigar lighter, connectors of seat warmer (right/ light). 5. Remove console assembly.
YAD9B200
GROOVE BOX
1. Remove hook of left/right side in the groove box from instrument. Notice: If excessive force is put on hook, hook may be broken.
YAD9B210
2. While the groove box is opened completely, release fixing bolt of bracket, and then remove groove box assembly.
YAD9B220
TRIM AND ROOF

Notice: Installation proceed reverse order of removal. A-pillar 1. Remove trim of A-pillar Pull key of A-pillar trim out of key home.
YAD9B230
SSANGYONG Y200
BODY INTERIOR 9B-11

Side cowl trim 1. Separate fixing screw of door side and fixing screw of foot board of side cowl-trim in the driver seat.
YAD9B240
2. Remove trim of side cowl ( right/left ).
YAD9B250
Upper / lower quarter 1. Remove rear window cover ,seat belt cover of upper quarter trim.
YAD9B260
2. Release fixing bolt of rear seat belt lower.
YAD9B270
SSANGYONG Y200
9B-12 BODY INTERIOR

3. After releasing fixing screw, separate upper quarter trim.
YAD9B280
4. Separate lower quarter trim, in order to make easy repair, cover of lower quarter trim ( right/left ) is separated in advance.
YAD9B290
Door scuff trim 1. Using special tool, separate door scuff trim of front and rear. Notice: First of all, remove door scuff trim of front and rear in advance while door scuff trim of front and rear is installed finally.
YAD9B300
SSANGYONG Y200
BODY INTERIOR 9B-13

Rear transverse trim of tail gate 1. After opening the tail gate, release fixing screw of rear transverse trim. 2. Separate rear transverse.
YAD9B310
Multi-purpose luggage box 1. Opening the cover of tool box, separate bolt and screw in the multi-purpose,box. 2. Separate multi-purpose box from luggage compartment.
YAD9B320
B - pillar trim 1. Release fixing bolt upper and lower of seat belt.
YAD9B330
2. After pulling trim of upper B-pillar trim by the hand, pick up key of trim from panel, and then separate trim.
YAD9B340
SSANGYONG Y200
9B-14 BODY INTERIOR

3. Separate trim of lower B-pillar trim with the same method to separate, upper trim.
YAD9B350
Roof ( Head lining ) 1. Separate sun-visor right and left. 2. Separate upper trim right and left. 3. Separate four handle. 4. Separate room lamp, sun roof, door opening weather strip. 5. After pulling clip bolt out of headlining, separate headlining.
YAD9B360
SSANGYONG Y200
BODY INTERIOR 9B-15
HANDLE
1. After downing handle, release screw. 2. Separate handle.
YAD9B370
SUNVISOR
1. Separate fixing hook of sun-visor.
YAD9B380
2. After separating fixing bracket, separate connector of mirror lamp. 3. Separate sun-visor.
YAD9B390
ROOM - MIRROR
1. Pulling room mirror, separate it.
YAD9B400
SSANGYONG Y200
9B-16 BODY INTERIOR
SEAT
Front seat 1. Remove plastic cap (3ea) of seat rail. 2. Separate fixing bolt (4ea: M10) of seat rail right and left.
YAD9B410
3. After separating connector of floor wiring, remove front seat. Position of connectors 1) Driver seat : 2 each , SAB : 3 each 2) Passenger seat : 1each, SAB : 2 each
YAD9B420
While the seat is installed, technician should tight the torque, as following. Tightening Torque 35 - 55 Nm (44 - 52 lb-ft)
YAD9B430
Two row seat 1. After separating cover fixing screw (2 each) of seat mounting in the seat right and left, remove cover of seat rail.
YAD9B440
SSANGYONG Y200
BODY INTERIOR 9B-17

2. After separating fixing bolt of mounting in the seat right and, left, remove seat. While the seat is installed, technician should tight fixing bolt, as following. Tightening Torque 60 - 70 N m (44 - 52 lb-ft)
YAD9B450
Three row seat 1. Pull seat cushion of three row seat forward 2. Separate fixing bolt of three row in the seat right and left.
YAD9B460
3. After separating fixing bolt of mounting in the rear seat right and, left, remove seat.
YAD9B470
While the seat is installed, technician should tight fixing bolt, as following. Torque fo front fixing bolt Torque fo front fixing bolt 35 - 55 N m 35 - 55 N m
YAD9B480
SSANGYONG Y200
9B-18 BODY INTERIOR
REMOVAL AND INSTALLATION

FRONT SEAT
1. Release fixing bolt ( 4 each ) of seat cushion from the separated seat. While the seat is installed, technician should tight the fixing bolt, as following Torque fo front fixing bolt Torque fo front fixing bolt 41.2 - 49 N m 41.2 - 49 N m
YAD9B490
2. Separate seat cushion from the seat rail, at this time, if seat warmer is equipped , separate connector.
YAD9B500
3. After separating connector of adjusting switch, remove external cover of seat. 4. Remove fixing bolt of seat rail ( M10 x P1.25. 2each ).
YAD9B510
SSANGYONG Y200
BODY INTERIOR 9B-19

5. After separating external cover(1) of seat and buckle assembly(2) the other side, separate fixing bolt of seat rail. 1) Remove the cover : screw, 2 each 2) Remove buckle assembly (7-1611-20) : After separate the connector. 3) Separate fixing bolt of seat rail : 2 each (M10 x P1.25)
YAD9B520
6. Install reverse order of removal.
YAD9B530
TWO ROW SEAT

1. After releasing fixing bolt of bracket in the two row seat of two person, separate seat cushion. 1) Remove nob of recliner 2) Remove cover of recliner ( External cover of seat ) : screw : one ) 3) Separate fixing bolt of seat and remove cable ( M10 x P 1.25 : 2 each )
YAD9B540
2. Position of fixing bolt differs in the left and right each other in the seat of one person ( see picture ), after checking the position, remove seat cushion. 1) seat of two person : after removing external cover ( screw : one ), separate fixing bolt and remove cable(M10Xp1.25) 2) seat of one person : after removing external cover ( screw : one ), remove bolt of hinge.
YAD9B550
SSANGYONG Y200
9B-20 BODY INTERIOR
YAD9B560
3. Install reverse order of removal.
YAD9B570
YAD9B580
SSANGYONG Y200
BODY INTERIOR 9B-21
SEAT OF THREE ROW

1. After releasing bolt of seat socket at the bracket of the seat right and left, remove seat.
YAD9B590
Replacing Seat Motor In The Guide Rail Of Seat

1. Separate seat cushion.
YAD9B600
2. After releasing A of part of seat motor, separate wire. 3. After releasing fixing nut of seat motor, separate motor assembly.
YAD9B610
SSANGYONG Y200
SECTION 9C
BODY EXTERIOR
TABLE OF CONTENTS
Parts Components ................................................ 9C-2 Front Bumper ...................................................... 9C-2 Tail Gate .............................................................. 9C-3 Hood ................................................................... 9C-6 Sun Roof And Roof Rack ..................................... 9C-7 Moulding ............................................................. 9C-8 Repair Procedure ................................................. 9C-9 Hood Assembly ................................................. .9C-9 Cowl Grill ......................................................... ..9C-12 Radiator. Grill .................................................... 9C-13 Front Bumper Assembly .................................... 9C-14 Rear Bumper Assembly ..................................... 9C-17 Back Beam ....................................................... 9C-17 Fender ............................................................... 9C-18 Fuel Filler Opening System ................................ 9C-20 Roof Carrier ....................................................... 9C-21 Side Step .......................................................... 9C-21 Side Moulding .................................................. 9C-22 Out Side Mirror ................................................. 9C-22 Door Assembly ................................................. 9C-23 Door Hinge ....................................................... 9C-24 Door Check Link ............................................... 9C-24 Door Lock Assembly ........................................ 9C-25 Door Handle ..................................................... 9C-26 Door Trim .......................................................... 9C-27 Door Opening Weathr Strip ............................... 9C-28 Fork Striker ....................................................... 9C-29 Tail Gate Crank .................................................. 9C-31 Tail Gate ............................................................ 9C-32 Tail Gate Flip Up System ................................... 9C-33 Tail Gate Air Spoiler ........................................... 9C-34 Check and Adjust Tail Gate ............................... 9C-35 Front Door Window ............................................ 9C-37 Front Door Glass Run And Regulator .................. 9C-38 Rear Window ..................................................... 9C-39 Rear Glass Run / Regulator / Channel ................ 9C-40 Wind Shield Glass ............................................. 9C-42 Front Quarter Glass ............................................ 9C-45 Rear Quarter Glass ............................................ 9C-48 Tail Gate Glass .................................................. 9C-49 Sun Roof ........................................................... 9C-53 Motor And Relay Box ......................................... 9C-54 Glass Panel ....................................................... 9C-56 Sun Shade ......................................................... 9C-57
9C-2 BODY EXTERIOR
PARTS COMPONENTS
FRONT BUMPER
YAD9C010
1 Front Bumper Facia Assembly 2 Energy Absorber
3 Front Nudge Bar Assembly 4 Bumper
SSANGYONG Y200
BODY EXTERIOR 9C-3
TAIL GATE
Mechanism
YAD9C020
1 2 3 4 5 6 7 8
Hinge Key Tail Gate Release Handle Garnish Glass Handle Guide Bumper Body Side Guide Bumper Tail Gate Latch
9 10 11 12 13 14 15 16
Door Safety Rod Box Crank Safety Nob Glass Open Latch Key Rod Over Slam Bumper Ball Stud Lifter Ball Stud
SSANGYONG Y200
9C-4 BODY EXTERIOR
FLIP- UP SYSTEM
YAD9C030
SSANGYONG Y200
BODY EXTERIOR 9C-5

1 2 3 4 5 6 7 8 Glass Lifter Ball Stud Bracket Bolt Pad Spoiler Glass Open Hinge Glass Handle Glass Weather Strip Glass Release Handle 9 10 11 12 13 14 15 Over Slam Bumper Latch Striker Panel Glass (Standard : 4.0 T Flip-Up : 5.0 T) Bracket Cover Of Ball Stud Bolt
SSANGYONG Y200
9C-6 BODY EXTERIOR HOOD
YAD9C040
1 Bolt 2 Shock Absorber 3 Hood Hinge
4 Hood 5 Hood Striker
SSANGYONG Y200
BODY EXTERIOR 9C-7
SUN-ROOF AND ROOF RACK
YAD9C050
1 2 3 4
Sun-Roof Glass Glass Moulding Head-Lining Assembly Roof Channel
5 6 7 8
Sun-Roof Glass Panel Roof Carrier Nut Motor And Relay Box
SSANGYONG Y200
9C-8 BODY EXTERIOR
MOULDING
YAD9C060
1 2 3 4
Nut (M5) Wheel Arch Front Moulding Front Door Garnish Rear Door Garnish
5 Wheel Arch Rear Moulding 6 Moulding 7 Side Step
SSANGYONG Y200
BODY EXTERIOR 9C-9
REPAIR PROCEDURE
HOOD ASSEMBLY
Removal and Installation
1. Release bolt of fixing bracket of shock absorber in the hood. Notice: While fixing bracket of shock absorber is removed, back up hood, to prevent closing of hood or use another supporting bar to prevent closing of hood.
YAD9C070
2. Remove shock absorber. (Method to remove shock absorber ; refer to replacement shock absorber of hood)
YAD9C080
3. Remove hose of wiper washer. 4. After releasing fixing bolt of hood hinge, remove hood assembly.
YAD9C090
5. After releasing fixing bolt of hood hinge, remove hood hinge.
YAD9C100
SSANGYONG Y200
9C-10 BODY EXTERIOR

6. Remove hood latch and cable. 1) Remove cable and hood latch lever in the lower main panel.
YAD9C110
2) Push cable removed through groove of body into direction of engine room. 3) After releasing fixing bolt of hood latch, remove latch and cable.
YAD9C120
4) Remove cable of hood latch.
YAD9C130
7. Install the reverse order of removal . 1) After installing hood hinge into body and hood, tighten fixing bolt with the torque of specification. Tightening Torque 29 - 39 Nm (21 - 29 lb-ft)
YAD9C140
SSANGYONG Y200
BODY EXTERIOR 9C-11

2) Install the shock absorber.
YAD9C150
Adjusting Hood Hinge

1. Release little bit fixing bolt of hood hinge. 2. After adjusting hood hinge to forward and backward, left and right, check whether right position of hood is installed or not.
YAD9C160
3. After adjusting over slam bumper, adjust height of front end of hood.
YAD9C170
Adjusting Hood Latch

1. Install hood latch on the right position, if hood latch is not installed on the right position, while hood is installed, hood may distort and be unbalanced.
Bolt of Hood Latch 8 - 11 Nm (44 - 52 lb-ft)
YAD9C180
SSANGYONG Y200
9C-12 BODY EXTERIOR

2. Release a little bit fixing bolt of striker. 3. After adjusting position of striker to forward and backward, left and right, put center of latch.
YAD9C190
Replacement Shock Absorber of Hood

1 . After inserting driver on the upper of bending equipped both end of shock absorber, get the bending out of shock absorber, and then, remove shock absorber. 2. Insert shock absorber, until is sounded like a kind of equipped sound.
YAD9C200
COWL GRILL
1. Remove wiper arm and fixing nut of wiper in the right and left. (M8)
YAD9C210
2. Remove weather strip.
YAD9C220
SSANGYONG Y200
BODY EXTERIOR 9C-13

3. Separate fixing clip of cowl. (4 EA)
YAD9C230
4. Remove cowl of left / right. (first, cowl of right is removed, and then cowl of left is removed) 5. Install reverse order of removal. Wiper Fixing Nut 14 - 17 N m (44 - 52 lb-ft)
YAD9C240
RADIATOR GRILL
1. Remove fixing screw (2 ea) of radiator grill and rivet (3 ea).
YAD9C250
2. Remove radiator grill and fixing rubber of grill.
YAD9C260
SSANGYONG Y200
9C-14 BODY EXTERIOR

3. Install reverse order of removal. Notice: Check damage of fixing rubber and damage of grill.
YAD9C270
FRONT BUMPER ASSEMBLY

1. After releasing screw of radiator grill and screw rivet, remove grill assembly.
YAD9C280
2. After releasing fixing bolt, remove connector of headlamp and remove headlamp. (first, after removing cap of wheel house cover, remove fixing nut of headlamp)
YAD9C290
3. After releasing fixing bolt (4 ea) of bumper guide, remove bumper guide from bumper. - After releasing fixing bolt of bumper guide support, remove bumper guide support.
YAD9C300
SSANGYONG Y200
BODY EXTERIOR 9C-15

4. Remove fog lamp. (After releasing nut (2 ea) of internal section of bumper facia)
YAD9C310
5. Remove bumper cover 1) Separate rivet (6 ea) of the upper of bumper facia. - Remove screw (2 ea) and nut (2 ea) of fender.
YAD9C320
2) Separate screw of the lower of bumper facia. (2 ea)
YAD9C330
3) Separate screw of bumper facia in the wheel house. - Side section : 4 ea - Rivet of lower section : 1 ea
YAD9C340
SSANGYONG Y200
9C-16 BODY EXTERIOR

4) After releasing fixing bolt of center of bumper facia, remove bumper facia. - Left : 1 ea - Right: 1 ea
YAD9C350
6. Remove energy absorber.
YAD9C360
7. After releasing fixing bolt of bumper in the frame, remove bumper.
YAD9C370
8. Install reverse order of removal. Fixing Bolt of Bumper Bolt of Bumper cover Bolt of Bumper Guide 76 - 114 Nm 2.8 - 5.2 Nm 16.8 - 31.2 Nm
SSANGYONG Y200
BODY EXTERIOR 9C-17
REAR BUMPER ASSEMBLY

Facia
1. Remove rear combi - lamp. 2. Separate screw of section of combi - lamp. (left: 1 ea, right: 2 ea) 3. Separate screw of the upper of the bumper. (left: 1 ea, right: 1 ea)
YAD9C380
4. Separate rivet of the upper of bumper facia. (5 ea) 5. Separate fixing screw of bumper facia in the rear wheel house. (left: 4 ea, right: 4 ea) 6. Install reverse order of removal.
YAD9C390
YAD9C380
BACK BEAM
1. After releasing fixing bolt of rear bumper, remove back beam assembly. 2. Install reverse order of removal. Tightening Torque 41.6 - 62.4 N m (44 - 52 lb-ft)
YAD9C400
SSANGYONG Y200
9C-18 BODY EXTERIOR
FENDER
1. Vehicle is fixing safely, and then lift up the vehicle. Notice: Before the fender is removed, adjust and check the gap and clearance between front door, side sill, and front bumper.
YAD9C410
2. Remove front bumper facia (1 ea), head lamp (2 ea), head lamp guide bracket, side repeater.
YAD9C420
3. Separate wheel guard, mud guard, and spring nut.
YAD9C430
4. Using driver, special service tool, remove fender garnish. Notice: Be careful about damage paint of body, not to make blemishes.
YAD9C440
SSANGYONG Y200
BODY EXTERIOR 9C-19

5. Release fixing bolt (2 ea) of mud guard in the lower vehicle. (the section of wheel rear) 6. After opening the door, release fixing bolt of fender. (1ea)
YAD9C450
7. Release bolt (2ea) of the section of bumper facia.
YAD9C460
8. Separate fixing bolt (1ea) of rear section of hood hinge and separate fixing bolt (3ea)of the upper section of fender and then remove fender.
YAD9C470
9. Install reverse order of removal. Notice: 1) Paint internal section of fender and installed section of fender. 2) After installing fender, tighten temporarily bolt (2 ea) the upper section of hood, in the back and front, adjust the gap and clearance of door, hood, and lamp.
YAD9C480
SSANGYONG Y200
9C-20 BODY EXTERIOR

3) After spread water-proof materials on the section of tightening, tighten the bolt with the torque of specification. Fender Bolt 6.9 - 8.8 N m (44 - 52 lb-ft)
4) After painting, check connection of electrical parts and operation.
FUEL FILLER OPENING SYSTEM

1. After opening the door of fuel filler, separate fixing bolt of door.
YAD9C490
2. Separate release handle of fuel filler in the lower main panel of driver seat.
YAD9C500
3. Remove the cable of fuel filler in the vehicle.
YAD9C510
SSANGYONG Y200
BODY EXTERIOR 9C-21

4. Install the reverse order of removal
YAD9C520
ROOF CARRIER
1. In order to remove roof carrier , first remove headlining 2. After releasing fixing nut of roof carrier, remove roof carrier, assembly. 3. Install reverse order of removal. Roof Carrier Nut 7 - 10 N m (44 - 52 lb-ft)
YAD9C530
Notice: Maximum load of roof carrier is approximately 45 kg, all the load should equivalently distribute on the roof carrier.
YAD9C540
SIDE STEP
1. After releasing bolt and nut of side step , remove side step assembly. 2. Install reverse order of removal. Bolt and Nut of Side Step 16.8 - 31.2 N m (44 - 52 lb-ft)
YAD9C550
SSANGYONG Y200
9C-22 BODY EXTERIOR
SIDE MOULDING
1. After releasing fixing screw of wheel housing moulding in the front and rear, remove moulding.
YAD9C560
2. Using special service tool, remove door moulding of front and rear. Notice: While door moulding and moulding of wheel housing is removed, pay attention on the damage of painting section, in order not to make scratch of moulding.
YAD9C570
3. Install reverse order of removal . Notice: While moulding is installed, install moulding tightly, not to make the gap.
YAD9C580
OUTSIDE MIRROR
1. Remove trim cover of front door.
YAD9C590
SSANGYONG Y200
BODY EXTERIOR 9C-23

2. Remove inner cover of outside mirror or cover of speaker assembly.
YAD9C600
3. Separate fixing bolt (3 ea) of outside mirror. 4. Separate connector of outside mirror, remove outside mirror. 5. Install reverse order of removal.
YAD9C610
DOOR ASSEMBLY
1. remove the negative (-) terminal of battery. 2. After removing the trim of cowl side, separate connector of door(1). 3. Disassemble the bolt of check link(2ea) in the body. 4. Disassemble the fixing bolt(3ea) of hinge in the body. 5. Remove the door assembly.
YAD9C620
SSANGYONG Y200
9C-24 BODY EXTERIOR

6. Install reverse order of removal. Bolt of Door Hinge Bolt of Door Check Link 44 - 54 N m 20 - 30 N m
YAD9C630
YAD9C640
DOOR HINGE
1. After opening the door, remove hinge of door. 1) Release the bolt(2ea) of in the body side. 2) Release the bolt(2ea) of door. 3) Remove the hinge. 2. Install the reverse order of removal. Bolt of Door Hinge 16 - 29 N m (44 - 52 lb-ft)
YAD9C650
DOOR CHECK LINK

1. Remove vinyl seal of door trim. 2. Remove door check link. 1) Release bolt (3 ea). 2) Remove door check link. 3. Install reverse order of installation. Door Check Link Bolt 7 - 11 N m (44 - 52 lb-ft)
YAD9C660
SSANGYONG Y200
BODY EXTERIOR 9C-25
DOOR LOCK ASSEMBLY

1. Remove the negative (-) terminal of battery 2. Remove vinyl seal and internal trim of door 3. In case door lock of central locking system, separate connector of door actuator and then remove actuator.
YAD9C670
4. After releasing fixing bolt of door lock, separate glass panel. Door Lock Bolt 7 - 9 Nm (44 - 52 lb-ft)
YAD9C680
5. After removing rod and cable from the door lock assembly, remove door lock assembly. 1) Separate rod of the external door handle.
YAD9C690
2) Remove the connector. 3) After removing internal cable of handle, remove door lock assembly.
YAD9C700
SSANGYONG Y200
9C-26 BODY EXTERIOR
DOOR HANDLE
1. After removing door trim, separate internal handle cable of door trim.
YAD9C710
2. Remove door lock assembly Notice: After removing rod of key lock, separate fixing nut of front external door handle 3. Release external fixing nut of door.
YAD9C720
4. Remove external handle of door.
YAD9C730
5. Install reverse order of installation. Fixing Nut of Handle 4 - 5 Nm (44 - 52 lb-ft)
YAD9C740
SSANGYONG Y200
BODY EXTERIOR 9C-27
DOOR TRIM
1. Remove the negative (-) terminal of battery. 2. Separate power window switch assembly.
YAD9C750
3. After inserting special tool or driver, remove door trim.
YAD9C760
4. After removing door trim , remove connector of door lamp and, cable of internal door handle.
YAD9C770
5. Remove seal of door trim. Notice: Pay attention about damage of seal.
YAD9C780
SSANGYONG Y200
9C-28 BODY EXTERIOR

6. After fixing screw of door speaker, separate connector and then, remove speaker.
YAD9C790
7. After releasing nut of regulator and window motor, remove regulator and window assembly.
YAD9C800
8. Install reverse order of removal. Notice: Spread sealant on the seal of door trim, and then install the right position.
YAD9C810
DOOR OPENING WEATHER STRIP

1. Remove door checker in the body.
YAD9C820
SSANGYONG Y200
BODY EXTERIOR 9C-29

2. Remove the upper section from the rail. 3. After removing the clip, remove the lower section.
YAD9C830
Notice: As clip and door opening weather strip is removed, due to damage of those part, install the new one.
YAD9C840
YAD9C850
FORK STRIKER
Removal and Inatallation
1. Remove the striker of door lock. 1) Release screw (2 ea). 2) Remove the striker. 2. Install the striker of door lock. 1) Install temporarily striker of door lock . 2) After opening and closing the door, tighten screw in the proper position.
YAD9C860
Screw of Door Lock
20 - 28 N m (44 - 52 lb-ft)
SSANGYONG Y200
9C-30 BODY EXTERIOR Adjusting Striker of Door Lock

Notice: Striker of door lock consists of striker and plate of floating cage in the pillar body, plate of floating cage can easily adjust by controlling striker up and down, left and right. As fork snap of door lock is linking the striker, the door comes to position of closing.
YAD9C870
Adjusting Forward and Backward

1. Door keep on the one line between door lock fork and striker. 2. Handle of door is pushing fork of door lock into contact on striker. 3. After door is set on position of opening, to keep contact fork of door lock with striker, open and close the door slow repeatedly.
YAD9C880
4. Technician can see keeping fork of door lock alignment with striker. Fork of door lock is linking perpendicular to center of striker, is linking center of body pillar.
YAD9C890
5. As striker is required for adjusting to forward and backward, proceed following the descriptions. 1) Release fixing bolt of striker. 2) If striker move to backward of vehicle , spacer is removed. 3) If striker move to forward of vehicle, put addition spacer (2 mm). 4) Tighten fixing bolt of striker. 6. Proceed to repair adjusting up and down, forward and backward.
YAD9C900
SSANGYONG Y200
BODY EXTERIOR 9C-31

Adgusting Up and Down, Left and Right
Adjusting striker up and down, left and right is required in following case, such as damage of vehicle collision, installation of new weather strip , wind-noise, difficulty of opening and closing door, in case adjusting up and down, left and right, proceed to repair the following. 1. Door keep on the one line between door lock fork and striker. 2. Release fixing bolt of door striker. 3. Plate of plotting gauge moves little bit to end of striker screw, plate of plotting gauge is put to adjust the position which is wanted. Notice: To protect section of screw from damage, while plate of plotting gauge is adjusted, flat rotary pile is used for adjusting. 4. As adjusting is required beyond of limit of distance movable, in order to make big hall , electrical hand drill or flat rotary pile (3/8) is used. 5. According to direction adjusted, tighten fixing bolt of striker.
YAD9C910
TAIL GATE CRANK

1. Separate the negative (-) terminal of battery. 2. Remove inner panel trim cover of tail gate.
YAD9C920
3. 4. 5. 6. 7.
Remove inner panel trim vinyl seal of tail gate. Separate wiring connector of actuator. Separate outside handle, glass handle. Separate safety rod. Remove tail gate, glass latch rod.
YAD9C930
SSANGYONG Y200
9C-32 BODY EXTERIOR

8. After separating fixing bolt (3 ea) of crank of tail gate, remove crank. Notice: If rekes is installed, key road is removed. 9. Install reverse order of removal.
YAD9C940
YAD9C950
TAIL GATE
1. After separating grommet of tail gate and wiring connector (2 section), remove hose of nozzle washer.
YAD9C960
2. Using service tool, after opening up clip (4 ea) at end of both gas lifter, remove gas lifter (right/left).
YAD9C970
SSANGYONG Y200
BODY EXTERIOR 9C-33

3. After releasing nut (4 ea) of body of tail gate hinge, remove tail gate from the body (proceed to remove after removing head-lining). Notice: In order for tail gate not to deflect, staff technician should support tail gate.
YAD9C980
4. Install reverse order of removal. Notice: High pressing nitrogen gas and oil is filled in the gas lifter, as gas lifter is removed, to prevent damage of (body of technician) and explosion, make hole (diameter 3 mm) into gas lifter for removal gas.
YAD9C990
TAIL GATE FLIP UP SYSTEM

1. Remove the upper garnish. 2. Separate wiring (2 ea) in the connector of heating line of rear glass and wiring (1 ea) of stop lamp (section of left spoiler).
YAD9C0A0
3. Using service tool, after opening up clip (4 ea) at end of both gas lifter, remove gas lifter (right/left).
YAD9C0B0
SSANGYONG Y200
9C-34 BODY EXTERIOR
YAD9C0C0
4. After separating fixing bolt (2 ea) of hinge (right/ left) of glass, remove glass from tail gate. 5. Install reverse order of removal.
YAD9C0D0
TAIL GATE AIR SPOILER

1. Separate fixing bolt (2 ea)of hinge in the left / right.
YAD9C0E0
2. Remove air spoiler of tail gate. 3. Install reverse order of removal.
YAD9C0F0
SSANGYONG Y200
BODY EXTERIOR 9C-35
CHECK AND ADJUST TAIL GATE

Lock striker of back door consists of striker and tail gate striker plate. Tail gate striker plate can be adjusted easily by fixing bolt of striker, up and down, forward and backwards. Lock of back door is linking striker and then turn to position of closing. Notice: As latch of tail gate and glass latch is installed, bolt of ground should be used.
YAD9C0G0
Adjust Striker Forward and Backward, Left and Right

Adjusting of striker of tail gate to forward and backward, left and right is required in, case of damage of frame due to collision, wind-noise, difficulty of opening and closing. If striker is adjusted to forward and backward, left and right, proceed to repair as following. 1. Tail gate keep on the one line. 2. Release fixing bolt of striker of tail gate. 3. Plate of plotting gauge moves little bit to end of striker screw, tail gate striker plate is put to adjust the position which is wanted. Notice: To protect section of screw from damage, while tail gate striker plate is adjusted, flat rotary pile is used for adjusting.
YAD9C0H0
4. As adjusting is required beyond of limit of distance movable, in order to make big hall, electrical hand drill or flat rotary pile (3/8) is used. 5. According to direction adjusted, tighten fixing bolt of striker. 6. Proceed to adjust up and down.
YAD9C0J0
SSANGYONG Y200
9C-36 BODY EXTERIOR Adjust Up and Down

1. Door of tail gate keep on the one line around parts. 2. Back door keep closing until door lock fork of tail gate into contacting to striker. 3. After door is set on position of opening, to keep contact fork of door lock with striker, open and close the door repeatedly.
YAD9C0K0
4. Technician can see and keep fork of door lock alignment with striker, fork of door lock is linking perpendicular to center of striker, is linking center of body pillar.
YAD9C0L0
5. As striker is required for adjusting to up and down, proceed to repair, following the descriptions. 1) Release fixing bolt of striker. 2) If striker move to upward, put addition spacer (2 mm). 3) Tighten fixing bolt of striker. Torque of Tightening 10 - 14 N m (44 - 52 lb-ft)
YAD9C0M0
Adjust Flip Up
1. After removing the upper garnish, release little bit mounting bolt of flip up glass.
YAD9C0N0
SSANGYONG Y200
BODY EXTERIOR 9C-37

2. After adjusting glass left and right, fit gap with quarter glass. Torque of Tightening 9 - 10 N m (44 - 52 lb-ft)
YAD9C0P0
Check the Deflection

As tail gate is pushed from the external, not to occur the deflection, adjust overlap. Standard 18 mm
YAD9C0Q0
Adjust Gap of Fitting

(mm) Section Gap A 11 B 5 C 5 D 5.7 E 4.2
YAD9C0R0
FRONT DOOR WINDOW

1. Remove seal and door trim.
YAD9C0S0
SSANGYONG Y200
9C-38 BODY EXTERIOR

2. Remove glass of front door. 1) Release fixing screw (2 ea) of glass, at this time, position of plate of regulator carrier should be position of installation. 2) Remove glass. Notice: If glass interfere to the body, damage of section of body painting may happen, so glass should not interfere body.
YAD9C0T0
3. Install reverse order of removal. Fixing Bolt of Glass 3 N m (26 lb-ft)
Notice: If water of soap spread on contacting section between glass run and glass, so that, can be installed easily.
YAD9C0U0
FRONT DOOR GLASS RUN AND REGULATOR

1. Remove door trim, seal, and window glass. 2. Remove door glass run from door .
YAD9C0V0
3. After releasing fixing nut of door regulator, and then remove motor connector of power window.
YAD9C0W0
SSANGYONG Y200
BODY EXTERIOR 9C-39

4. Remove door regulator assembly. Notice: After separating door glass run and regulator, remove and install them .
YAD9C0X0
5. As door glass run is installed, water of soap spead on section of glass run so door glass run can be installed easily.
YAD9C0Y0
6. Install reverse order of removal. Fixing Nut of Regulator 8 N m (26 lb-ft)
YAD9C0Z0
REAR WINDOW
1. Remove external weather strip of door window 2. Remove front garnish of rear door.
YAD9C1A0
SSANGYONG Y200
9C-40 BODY EXTERIOR

3. Remove seal and door trim.
YAD9C1B0
4. Remove rear door glass. 1) Release screw (move up carrier plate of regulator). 2) Extract glass upwards. Notice: If glass interfere to the body, damage of section of body painting may happen, so glass should not interfere body.
YAD9C1C0
5. Install reverse order of removal. Fixing Nut of Glass 3 N m (26 lb-ft)
Notice: As door glass run is installed, water of soap spead on section of glass run so door glass run can be installed easily.
YAD9C1D0
REAR GLASS RUN/ REGULATOR/ CHANNEL

1. Remove door trim, seal, and glass 2. Remove glass run. Pull door glass run internally, and then extract glass run. Notice: As door glass run is installed, water of soap spead on section of glass run so door glass run can be installed easily.
YAD9C1E0
SSANGYONG Y200
BODY EXTERIOR 9C-41

3. Remove door regulator assembly. 1) Separate connector of window motor. 2) After separating fixing nut (7 ea) of window regulator, remove regulator assembly.
YAD9C1F0
3) Remove regulator assembly.
YAD9C1G0
Installation Fixing Nut of Regulator 8 N m (26 lb-ft)
YAD9C1H0
4. Remove glass channel. 1) Remove internal (1) panel of rear door.
YAD9C1J0
SSANGYONG Y200
9C-42 BODY EXTERIOR

2) After releasing fixing nut of glass channel, remove glass channel.
YAD9C1K0
3) As glass channel is installed, in order for glass channel not to change up and down, should be installed right position, tighten fixing bolt.
YAD9C1L0
WIND SHIELD GLASS

Removal 1. Remove cowl grill. 2. Remove room back mirror. 3. Remove moulding (a) of wind shield glass.
YAD9C1M0
4. Using special tool, cut sealant of wind shield glass.
YAD9C1N0
SSANGYONG Y200
BODY EXTERIOR 9C-43

5. Remove wind shield glass 6. Using knife, remove sealant of wind shield glass and frame. Notice: In order to prevent damage of painting, approximately 1mm of sealant should not be removed from body.
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YAD9C1P0
Installation
1. Clean up section to spread primer of wind shield glass by washing. 1) Section of washing keep distance 15 mm from the end of glass. 2) After using gauze 20 times, gauze is thrown away. 3) Gauze is a solvent (isopropyl alcohol), gauze keep wet completely. 4) Keep an eye on the washed section of glass not to be touched by any thing polluted. 5) After washed glass, spread primer on the glass section of wet state. 2. Install new wind shield moulding on wind shield glass. Notice: After spreading sealant on the glass, glass should be installed within 5 minutes.
YAD9C1Q0
YAD9C1R0
3. Spread sealant on the wind shield. Notice: 1) If shape of spreading is not uniform, thickness of spreading is not uniform after installing wind shield, leaking of water may occur. 2) As sealant is spreading, due to interfering of nozzle, keep eye on for glass moulding, glass dam not to drop.
YAD9C1S0
SSANGYONG Y200
9C-44 BODY EXTERIOR
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YAD9C1T0
4. Wash up flange of wind shield glass. After using gauze 20 times, gauze is thrown away Gauze is a solvent (isopropyl alcohol), gauze keep wet completely Keep an eye on the washed section of glass not to be touched by any thing polluted. After washed body flange, spread primer on the glass section of wet state. If oil is stuck on the body flange, primer does not spread on the body flange. After spreading, is available time for use : from 3 hours to 8 hours As the body is polluted by primer, as soon as possible mixing with ethil alcohol and ethil asetate (as a volume 50 : 50) and with this wet cloth is wiping solvent. Term of validity of primer (90 days) which is passed is thrown away. As spreading primer, flowing into other sections, pay attention not to pollute other sections.
5. Insert spacer of wind shield. Insert spacer until kind of sound occur. After spacer insert body, no clearance.
YAD9C1U0
6. After install glass of wind shield, check the following description. Notice: If the section (b) of glass corner happen clearance between moulding and body, spacer can adjust this clearance.
YAD9C1V0
SSANGYONG Y200
BODY EXTERIOR 9C-45

7. For the right position installed of glass which wind shield is fixed, stick tape on moulding, and frame of wind shield. 8. To keep sealant dry, park the vehicle for 24 hours. 9. Remove tape1.
YAD9C1W0
10. Spread water on the wind shield glass, and then check leaking of water. If leaking of water happen, after keep wind shield glass dry, fill sealant on the section of leaking, if leaking of water goes on, wind shield glass is removed, the above descriptive work proceed to repair once again.
YAD9C1X0
FRONT QUARTER GLASS

Removal
1. After releasing fixing nut of quarter glass, remove cover of glass moulding. 2. After removing quarter glass, using knife, remove sealant of quarter and frame.
YAD9C1Y0
SSANGYONG Y200
9C-46 BODY EXTERIOR
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YAD9C1Z0
Installation
1. Wash up body frame (section of glass installed). 2. As keeping distance like the left picture, spread primer on the section of frame of installed glass.
3. Spread primer on the moulding of quarter glass of new quarter glass.
YAD9C2A0
SSANGYONG Y200
BODY EXTERIOR 9C-47

4. As keep distance like left picture, spread sealant on the glass.
YAD9C2B0
5. After Install glass of front quarter on the body frame, tighten nut on the bolt of mounting.
YAD9C2C0
6. After installing front quarter glass, proceed to check leaking of water.
SSANGYONG Y200
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9C-48 BODY EXTERIOR
REAR QUARTER GLASS

Removal
1. After using special tool, remove sealant around glass. 2. Remove rear quarter glass.
YAD9C2D0
Installation
1. Wash up the section of body frame. 2. As keep distance like the left picture, spread primer.
YAD9C2E0
3. After spread on the new rear quarter glass, install glass moulding.
YAD9C2F0
SSANGYONG Y200
BODY EXTERIOR 9C-49

4. Spread sealant on the rear quarter glass.
YAD9C2G0
5. After installing rear quarter glass on the body frame, tighten nut on the bolt of mounting. 6. After installing rear quarter glass, proceed to check leaking of water.
YAD9C2H0
TAIL GATE GLASS

Removal
1. Separate negative cable of battery. 2. Separate connector of heat line of back door glass.
YAD9C2J0
SSANGYONG Y200
9C-50 BODY EXTERIOR

3. Using special tool, remove sealant of door glass of tail gate.
YAD9C2K0
4. Remove door glass of tail gate from the vehicle. 5. Using the knife, remove sealant around door glass of tail gate and frame.
YAD9C2L0
Installation
1. Wash up outer panel of tail gate. After using gauze 20 times, gauze is thrown away. Gauze is a solvent (isopropyl alcohol), gauze keep wet completely. Keep an eye on the washing section of glass not to be touched by any thing polluted. After washing glass, spread primer on the glass section of wet state. Wash up on the section of spreading primer without being touched by any thing polluted. 2. After washing up outer panel of tail gate, and then spread primer. Keep primer in the refrigerator. Mix up primer. Opening vessel, use them within 2 hours. Opening vessel, immediately use them, if you reopen them, use them within 24 hours, as soon as possible. Spread uniformly primer on the surface of vehicle. Available hour for spreading primer to the vehicle : after 3 hour.
YAD9C2M0
YAD9C2N0
SSANGYONG Y200
BODY EXTERIOR 9C-51
If body of vehicle is polluted by primer : solvent is washed up to body of vehicle. Keep eye on section of spreading ,not to overflow other section to vehicle
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YAD9C2P0
3. Wash up glass tail gate. The section washed of glass keep distance 15 mm from the end of glass. After using gauze 20 times, gauze is thrown away. Gauze is a solvent (isopropyl alcohol), gauze keep wet completely. Keep an eye on the washing section of glass not to be touched by any thing polluted. After washing glass, spread primer on the glass section of wet state. Wash up on the section of spreading primer without being touched by any thing polluted. 4. Installing dual lock (1) on the glass (2), install the glass dam.
YAD9C2Q0
SSANGYONG Y200
;;; ;;; ;;;
9C-52 BODY EXTERIOR

5. Spread primer on the glass of tail gate. Mix up primer. Due to excessive spreading, keep eye on overflowing spreading other section. Available hour for spreading primer to the vehicle: after 3hour. Sealant is not available, if sealant has sludgematerial. If available date of sealant is passed, this sealant is throwing away. available date of sealant is 90 day for use. After using gauze 20 times, gauze is thrown away. Spread uniformly primer on the surface of glass.
YAD9C2R0
6. Spread sealant on the glass. Spread sealant point (200 mm) of lower section of right, like right picture. If shape of spreading, thickness is not uniform, leaking of water may occur.
YAD9C2S0
7. After spreading sealant, using compressor, install glass of tail gate within 5 minutes. After install glass, tape tail gate, two the point of glass and one point of the section of arm side.
YAD9C2T0
SSANGYONG Y200
BODY EXTERIOR 9C-53

8. After installing, check leaking of water as following procedure. In order to fix glass of back door, in the right position of installing, tape glass and frame of door glass. To keep sealant dry, wait for 24 hours. Remove taping(a).
YAD9C2U0
After spread water on the door of tail gate, check leaking of water. If leaking of water occur, keeping door glass of tail gate dry, fill sealant in the section of leaking. Leaking of water goes on, remove door glass of tail gate, and then proceed to repair above procedure. Connect connector of heating line to the door glass of tail gate. Connect negative cable of battery.
YAD9C2V0
SUN ROOF
1. Remove headlining, room lamp, and sun visor. 2. Separate hose clip of drain hose of sun roof (4 ea), pull hose slow, turning hoses to the left direction and to the right direction slow.
YAD9C2W0
3. Remove the power connector in the relay box.
YAD9C2X0
SSANGYONG Y200
9C-54 BODY EXTERIOR

4. Remove fixing bracket of sun roof.
YAD9C2Y0
5. After releasing mounting bolt of sun, remove sun roof assembly.
YAD9C2Z0
6. Install reverse order of removal. Bracket Bolt of Sun Roof Fixing Bolt of Sun Roof 25 - 35 N m 25 - 35 N m
YAD9C3A0
MOTOR AND RELAY BOX

1. Close sun roof. 2. Remove head lining, room lamp, and sun visor. 3. Cut tie wrap of relay box.
YAD9C3B0
SSANGYONG Y200
BODY EXTERIOR 9C-55

4. After releasing fixing bolt of motor, remove motor connector in the relay box, and then separate motor assembly.
YAD9C3C0
5. Separate power connector in the relay box. 6. After releasing fixing bolt of relay box, separate relay box from front beam (pushing hook of relay box of front beam by hand, remove it).
YAD9C3D0
7. Install reverse order of removal. 1) Assemble the closing state in the position of glass panel 2) Check the position of normal close: NORMAL CLOSE POSITION : After connecting between relay box and motor, connect the power and then touch on switch and then the motor stop. 3) Install the motor. 4) Tighten the fixing bolt of motor. Tightening Torque
YAD9C3E0
3 N m (26 lb-ft)
5) Insert hook of relay box into beam of front. 6) Fix relay box with tie wrap. 7) Check operation of sunroof.
YAD9C3F0
SSANGYONG Y200
9C-56 BODY EXTERIOR
GLASS PANEL
Removal
1. Turn on the switch, tilt glass.
YAD9C3G0
2. Remove side inner cover. 3. Separate fixing bolt (6 ea) glass.
YAD9C3H0
4. Extract panel of glass.
YAD9C3J0
Installstion
1. Install glass panel on internal panel of cover (check the tightening position in the vehicle). Notice: Install for marking glass indicator to put rear direction.
YAD9C3K0
SSANGYONG Y200
BODY EXTERIOR 9C-57

2. Tighten temporarily fixing bolt. 3. Using operation switch of sunroof, close glass panel slow. (Check motion of glass, up and down, forwards and backwards freely).
YAD9C3L0
4. Pulling the glass panel, adjust the height of glass and body. 5. After hight of front glass put the same of height of body and glass seal and 1 mm height to the rear is higher than height of body, and then tighten the bolt. Tightening Torque 5 N m (26 lb-ft)
6. Using switch of sunroof, check operation.
YAD9C3M0
7. Turn on the switch, up the glass. 8. Insert side cover (left/right). Notice: Check the state of installation between side inner cover and side outer cover.
YAD9C3N0
SUN SHADE
Removal
1. Remove glass panel.
YAD9C3P0
SSANGYONG Y200
9C-58 BODY EXTERIOR

2. After removing fixing bolt of drain channel, push hook of support drain channel by hand, remove drain channel.
YAD9C3Q0
3. Close panel of sun shade, using driver, extract slide block of sun shade panel from the guide rail (4 ea).
YAD9C3R0
4. Remove panel of sun shade.
YAD9C3S0
Installation
1. Put sun shade on the guide rail. 2. Using driver, pushing slide block of sun shade panel, and then insert guide rail.
YAD9C3T0
SSANGYONG Y200
BODY EXTERIOR 9C-59

3. After inserting drain channel into roof, and then insert drain channel into support drain channel and push front hook. Tightening Torque 12 N m (26 lb-ft)
4. Check operation of sun shade panel. 5. Install the glass panel.
YAD9C3U0
SSANGYONG Y200
GROUP 9D
BODY ELECTRICAL
TABLE OF CONTENTS
General Description ............................................. 9D-2 Notice : Repairing Electrical System ..................... 9D-2 Specification ........................................................ 9D-6 Diagnosis And Action Taken ................................ 9D-8 Check And Adjust ............................................. 9D-10 Repair Of Each System ...................................... 9D-13 Instrument Panel Assembly ............................... 9D-13 Check And Repair ............................................. 9D-17 Removal And Installation Of Instrument Panel .... 9D-20 Switch Of Multi - Function................................... 9D-22 Component Of Lighting ...................................... 9D-27 Location Of Lamp .............................................. 9D-31 Horn And Audio System .................................... 9D-39 Wiper And Washer ............................................ 9D-44 Power Window ................................................... 9D-61 Switch And Electrical System ............................. 9D-70 Function Of Operation And The Characteristic .... 9D-76 Self Diagnosis ................................................... 9D-84 Chart Of Diagnosis ............................................ 9D-85 Repair Of The System ........................................ 9D-86
9D-2 BODY ELECTRICAL
GENERAL DESCRIPTION
NOTICE: REPAIRING ELECTRICAL SYSTEM
1. While electrical parts is repaired, first of all separate negative terminal of battery. Notice: Before separate and link negative terminal, turn starting switch or all the switch of lamp off (if switches are not turned off, parts of semiconductor may be impaired). Notice: Memory values of electrical parts may be erased, so those value should be kept another place. 2. If harness is interfered by other sharp section, wrap them, and then, for protecting of harness.
YAD9D010
YAD9D020
3. While parts is instslled on the vehicle, keep in mind, in order not to tear or impair to the wiring harness.
YAD9D030
SSANGYONG Y200
BODY ELECTRICAL 9D-3

4. If fuse is damaged, fuse is replaced by rated capacity, if fuse is replaced by excessive rated capacity, parts may be impaired or fired.
YAD9D040
5. Sensors and relays should not be influenced by impact and should not be dropped on the floor.
YAD9D050
6. Electrical parts are impaired by heat, so if work of repair should be done excessive temperature of 8C, remove electrical parts before done this.
YAD9D060
7. If connector is connecting loose, this cause to repair, make sure connecting of connector.
YAD9D070
SSANGYONG Y200

8. While harness is separated, connector should be pulled, harness should not be pulled, like the picture.
YAD9D080
9. While connector is separated with the lock, pushing arrow indicated, remove the connector.
YAD9D090
10. While connector is linked, insert this until sounds like tack!, tack!
YAD9D100
11. If electric current is sent or check voltage through tester of circuit, probe is set from the harness, if connector is kind of sealing type, probe is set through hole of cap in the wiring rubber. At this time, keep in mind, not to damage isolation of wiring, insert probe until contact connector of terminal completely. Notice: Tester of circuit is not used on the air bag system, while this system is checked, scanner should be used.
YAD9D110
SSANGYONG Y200

Check Cable and Wire 1. Check looseness of the connecting and corrosion. 2. Check the corrosion of terminal and wire by the eletrolyte. 3. Check open circuit for terminal and wire. 4. Check isolation of wire, damage, deformation. 5. Check interference between parts of terminal and other metal parts.
YAD9D120
6. Check applying an electrical current complete between fixing bolt and body on the section of ground. 7. Check lay-out of wiring proper. 8. After fixing wiring completely, wiring should not be contacting by section of sharpness, section of high temp. (For example: exhaust manifold, exhaust pipe). 9. Keep the clearance between wiring and fan- pully, fan-belt, other parts. 10. After loosening wiring and fix, for vibration between section of body and the section of engine.
YAD9D130
SSANGYONG Y200
SPECIFICATION
Multi - function switch Description Rated voltage Range for operating temp Rated load Light switch Dimmer and passing switch Switch of turn signal Wiper switch Spec DC 12 V -30 C ~ +80 C Illumination: 1 A (Load of relay) High beam: 9.2 A Lower beam: 1 A Passing: 10 A 6.6 0.5 Lower: 5 A, High: 7 A Intermittemt: 0.22 0.05 A Fixing: MA X 28 A Washer switch Intermittent wiper switch Horn connector Instrument panel Turn signal lamp Seat belt Charging lamp Fuel indicator lamp High beam Oil pressure lamp Brake lamp Door open warning lamp ABS warning lamp Pre heating lamp Air bag warning lamp Hazard lamp 4WD check lamp 4WD high lamp 4WD low lamp Winter lamp Power lamp EBD lamp Engine check warning lamp TCS lamp Rear defogger lamp Lamp Head lamp High beam Low beam Position lamp Front combi lamp Side mounted lamp High mounted lamp Turn signal lamp Fog lamp :4A MAX: 25 mmA 1A 14 V,1.4 W 2.2 V, 20 mA 2.2 V, 20 mA 2.2 V, 20 mA 14 V, 3 W 2.2 V, 20mA 2.2 V, 20 mA 2.2 V, 20 mA 14 V, 1.4 W 2.2 V, 20 mA 14 V, 1.4 W 2.2 V, 20 mA 2.2 V, 20 mA 14 V, 1.4 W 2.2 V, 20 mA 14 V, 1.4 W 2.2 V, 20 mA 14 V, 1.4 W 2.2 V, 20 mA 14 V, 1.4 W 2.2 V, 20 mA Green Red Red Orange Blue Red Red Red Orange Orange Red Red Red Green Orange Green Orange Red Orange Orange Orange 55 W X 2 5WX2 28 W X 2 27 W X 2 5WX2 5WX1
55 W X 2
SSANGYONG Y200

Description Rear combi lamp Spec Tail/ Stop Tail lamp Stop lamp Turn signal lamp Brake lamp Licensee lamp Room lamp Front Center Rear Door lamp Glove box lamp 27 W X 2 8WX2 27 W X 2 27 W X 2 27 W X 2 5WX2 8WX2 10 W X 1 10 W X 1 5WX4 10 W
Lamp
SSANGYONG Y200
DIAGNOSIS AND ACTION TAKEN

Gauge Panel amd Warning System
Nature of Defect Tacometer is not operated Cause of Defect Cut of fuse Defective tacometer Defective wiring Gauge of fuel is not operated Cut of fuse Defective fuel gauge Defective fuel sender defective wiring Warning lamp of fuel is not operated Cut of fuse Failure of bulb Defective sensor of fuel Defective wiring or defective grounding Gauge of temperature is not operated Cut of fuse Defective gauge of coolant temp Defective coolant temp sender Defective wiring or defective grounding Warning lamp of oil pressure is not turned on Cut of fuse Failure of bulb Defective sensor of oil pressure Defective wiring,and grounding Warning lamp of brake is not turned on Cut of fuse Failure of bulb Defective warning switch of brake fluid Defective parking brake switch Defective wiring or defective grounding Warning lamp of opening door or tail gate is not turned on Cut of fuse Failure of bulb Defective door switch Defective wiring or defective grounding Warning lamp of seat belt is not turned on. Cut of fuse Failure of bulb Defective buckle switch Defective wiring or defective grounding If necessary, repair wiring or grounding Check short of fuse, replace fuse Replace bulb Check switch If necessary, repair wiring or grounding Check short of fuse Replace bulb Check switch If necessary, repair wiring or grounding Check switch Action Taken Check short of fuse, replace fuse Check tacometer If necessary, repair wiring Check short of fuse, replace fuse Check gauge Check fuel sender If necessary,repair wiring Check short of fuse replace fuse Replace bulb Check sensor If necessary, repair wiring or grounding Check short of fuse, replace fuse Check gauge Check sender If necessary, repair wiring or grounding Check short of fuse, replace fuse Replace bulb Check sensor If necessary, repair wiring or grounding Check short of fuse, replace fuse Replace bulb Check switch
SSANGYONG Y200
BODY ELECTRICAL 9D-9 Lighting System

Nature of Defect On side of lamp only is turned on (All the lamp of outdoors) Head lamp is not turned on Cause of Defect Failure of bulb Defective socket, wiring defective grounding Failure of bulb Defective fusible link Defective head lamp relay Defective lighting switch Defective wiring or grounding Lamp of tail or lamp of license plate is not turned on Cut of tail lamp fuse Defective fusible link Defective relay of tail lamp Defective lighting switch Defective wiring or grounding Stop lamp is not turned on Cut of fuse Defective switch of stop lamp Defective wiring or grounding Stop lamp continue to turn on Gauge lamp is not turned on One side of signal lamp is not turned on Malfunction of relay of stop lamp Malfunction of switch of stop lamp. Malfunction of connector Malfunction of wiring or grounding The burned of bulb Malfunction of switch of turn signal lamp Malfunction of wiring or grounding Turn signal lamp is not operated The burned of bulb Malfunction of flasher unit Malfunction of switch of turn signal Malfunction of wiring or grounding Hazard lamp is not turned on Cut of fuse Malfunction of flasher unit Malfunction of hazard lamp switch Malfunction of wiring or grounding Frequency of flash is too quick or delaying Lamp of back up is not turned on Standard of bulb is out of specification Cut of bulb, malfunction of connecting Malfunction of flasher unit Cut of fuse Malfunction of switch of back up lamp Malfunction of wiring or grounding Console lamp of over head is not turned on Cut of fusible link Malfunction of wiring or grounding If necessary, replair wiring or grounding Replace fuse, check short of fuse Check flasher unit Check switch of turn signal If necessary, replair wiring or grounding Check short of circuit replace fuse Check flasher unit Check switch If necessary, replair wiring or grounding Replace bulb Check cut of bulb or connecting Replace flasher unit Check short of circuit Check switch If necessary, replair wiring or grounding Replace fusible link If necessary, replair wiring or grounding Replace bulb Check switch Replace bulb Replace fusible link Check relay Check switch If necessary, replair wiring or grounding Replace fuse, check short of fuse Replace fusible link Check relay Check switch If necessary, replair wiring or grounding Replace fuse check short of fuse Adjust switch, or replace switch If necessary, replair wiring or grounding Replace relay Adjust switch or replace switch. Check the state of connecting Action Taken Replace bulb If necessary replace socket, wiring
SSANGYONG Y200
CHECK AND ADJUST

Adjust Focus of Head Lamp (Aiming)
Beam adjusting equipment approved can adjust accurately focus of head lamp. This equipment should be operated by manufacturers operation manual. While focus of head lamp is arranged, condition of vehicle keep air pressure of tire specified, except spare tire and tool of OVM, every thing is unloaded, and vehicle is parked on the even place. If beam adjusting is not installed, focus of head lamp can be arranged by using screen. Using Beam Adjusting Equipment 1. Beam adjusting equipment should be arranged with vehicle.
YAD9D140
2. Switch on control lever of up and down, left and right by the screw, arrange focus of head lamp.
YAD9D150
Arrange Focus of Head Lamp by Screen (Unit: mm) 1. After screen (2 m x 1.5 m) installs the verticalness position of 3m of distance from the front head lamp of vehicle, keep line of center between vehicle and screen such as the right below picture.
YAD9D160
SSANGYONG Y200

2. Keep line of center between through horizontal line of center of head lamp and center of screen.
YAD9D170
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YAD9D180
3. Keep engine R.P.M of 2000, and then switch head lamp on, at this time focus of head lamp should indicate position of A .
4. If focus of head lamp get out of specification, after switching control lever of up and down, left and right, arrange focus of head lamp.
YAD9D150
SSANGYONG Y200
YAD9D190
SSANGYONG Y200
REPAIR OF EACH SYSTEM

INSTRUMENT PANEL ASSEMBLY
YAD9D200
SSANGYONG Y200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Fuel Gauge Speed Gauge Turn Signal Lamp (Left) Lamp of Operating of Brake or Flude Lamp of Position And High Beam Turn Signal Lamp (Right) Speedometer Gauge Speed Gauge Temperature Gauge Lamp of High Speed of 4WD Lamp of Winter (Automatic Transmission) Lamp of Low Speed of 4WD Check Lamp of 4WD (Gasoline) Power Lamp (Automatic Transmission) Lamp of Engine Check (for Gasoline) Warning Lamp of Seat Belt Warning Lamp of Charge 18 Warning Lamp of Oil Pressure 19 Lamp of Pre Heating 20 Lamp of Selector Lever (Automatic Transmisson) 21 Button of Reset 22 Warning Lamp of Air Bag 23 Warning Lamp of ABS 24 Warning Lamp of EBD 25 Lamp of TCS 26 Warning Lamp of Door Opening 27 Lamp of Outside And Lamp of Heat Line of Rear Glass 28 Warning Lamp of fuel refilling 29 Warning Lamp of Hazard 30 Connector of White Color 31 Colorless Connector (Auto) 32 Gray Connector
SSANGYONG Y200

Component of Connector Pin
Layout of Connect Color of connect : gray color Number of Pin A1 A2 A3 A4 A5 A6 A7 A8 A9
YAD9D210
Description Opening of door Oil pressure Seat belt Charging ILL (-) EBD 1GN (+), B Ground2 ACC B (+) Checking of 4 WD (+) Checking of 4 WD (-) Low speed of 4 WD ILL (+) High speed of 4 WD Turn signal lamp (Left) High beam (Lamp of position) Lamp of position Turn signal lamp (Right) Brake Automatic transmission - D range Automatic transmission - 3 range Automatic transmission - 2 range Automatic transmission - 1 range Automatic transmission - R range Automatic transmission - N range Automatic transmission - NC Automatic transmission - P range Winter Power
A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20
Color of connect
C1 C2 C3 C4 C5 C6 C7 C8 C9
YAD9D220
C10 C11 C12
SSANGYONG Y200

Layout of Connect Color of connect Number of Pin B1 B2 B3 B4 B5 B6 B7 B8 B9
YAD9D230
Description Unit of tacometer Speed sensor Chime bell Signal out of speed ABS Air bag Engine check TCS Fuel sender Temp sender Gnd (ground1) IGN (+), A Emegency Rear defogger Pre - heat -
B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20
SSANGYONG Y200
CHECK AND REPAIR

Speed Meter
1. Using tester of speed meter, check error of allowance of speed meter and operation of tacometer. Standard of speed Error of allowance Standard of speed Error of allowance
YAD9D240
20 3 140
40 +4 0 160
60 +4 0 180 +6 +1
80 +5 0 200 +6 +1
100 120 +5 +5.5 0 220 +0.5 -
+5.5 +5.5 +0.5 +0.5
2. Check trembling of indicator of speed meter or noise of unusual 3. Tap speed meter, and then remove hysteresis. Notice: If tire is weared or out of specification of air pressure, error allowed increase.
Tacometer
1. Connect tacometer of testing, start engine. 2. Comparing value indicated between tester and tacometer, error is big enough, replace tacometer. 3. While tacometer is inspected, tap tacometer, and then remove magnetic power.
YAD9D250
Diesel vehicle Standard of speed Error of allowance 1000 +137 - 67 2000 +199 - 51 3000 +261 - 39 4000 +298 -2 5000 +335 +35 -
(rpm) 6000
Gasoline vehicle Standard of speed Error of allowance 1000 100 2000 125 3000 150 4000 150 5000 150 6000 180 7000 180
(rpm) 8000 -
SSANGYONG Y200

Fuel System
Gauge of fuel 1. Separate connector of fuel sender. 2. Ground connector (B11, B14) of direction of harness through bulb (12 V, 3.4 W). 3. Turn the start switch on. 4. See if bulb of testing turn on, and see if indicator of fuel gauge gradually move to position of F .
YAD9D260
Check resistence of fuel sender 1. Put float on the position of F and E , and check resistence between B11 and B14. 2. While float is moving from position of E to position of F , check if resistence change gradually. Position of float E 1/2 F Specified resistence approximately 285 approximately 101.5 approximately 40
Fuel sender 1. Connect testing bulb (12 V. 3.4 W) of fuel gauge terminal deepen thermister in the water. 2. See if thermister is deepened in the water, light is off, and see if thermister get out of water, light is on. Notice: If malfunction may happen, replace fuel sender assembly. After this testing have done, before fuel sender is installed, fuel sender should dry up completely.
YAD9D270
Gauge of Temp
1. Separate wiring connector of water coolant in the engine room. 2. Ground between testing bulb (12 V,3.4 W) and connector to harness in a series. 3. Turn ignition switch on. 4. See if testing light turns on or not, check if gauge of water temp operate or not.
YAD9D280
SSANGYONG Y200

Check resistence of sensor of water temp After checking resistence between terminal and ground with gage of resistence, if resistence get out of specification, replace it by new one. temp ( C) resistence() C (50) 254 C (50) 77 C (50) 42.2 C (50) 27.8
YAD9D290
YAD9D300
Switch of Oil Pressure

1. After stopping engine, check applying of electric current between terminal and ground. 2. After driving engine, check applying of electric current between terminal and ground. 3. Separate connector from terminal of ground and warning switch to wiring harness. 4. After ignition switch turn to on and then check if the light is on, if the light is not on test the bulb and check harness.
YAD9D310
SSANGYONG Y200
Brake
If the switch of starting turns on, the fluid of brake is under specified level, or while lever of parking brake is pulling, sensor of brake or switch of parking brake is on and then warning of brake turns on. Notice: Sensor of brake fluid is installed on the reservoir tank of master cylinder. 1. Separate gauge connector of brake fluid level. 2. While switch is turned off, check applying of electric current between terminal. 3. While switch is turned on, check applying of electric current between terminal. Switch of parking brake Switch of parking brake is located under lever of parking brake, if switch of parking brake is adjusted, after releasing parking brake, switch of parking brake is installed . 1. While switch is turned on (lever is pulling), check applying of electric current between terminal and switch. 2. While switch is turned off (lever is released), check applying of electric current between terminal and switch, applying of electric current get out of specification, replace switch, or check grounding.
YAD9D330
YAD9D320
Door Switch
1. Switch of door is removed, check applying of electric current between terminals. 2. If applying of electric current between terminals get out of specification, replace switch of door.
YAD9D340
REMOVAL AND INSTALLATION OF INSTRUMENT PANEL

1. Remove negative terminal of battery. 2. After releasing screw (2ea), remove housing of instrument panel .
YAD9D350
SSANGYONG Y200

3. After releasing fixing screw (4ea) of instrument panel, separate connector (3ea), and then remove instrument panel.
YAD9D360
4. Separate all the bulb from the instrument removed like the left picture.
YAD9D370
5. After separating the glass of instrument, and then release fixing screw (5ea), and separate instrument panel and housing.
YAD9D380
6. Install reverse order of removal, after installing, check operation of instrument panel.
YAD9D390
SSANGYONG Y200
SWITCH OF MULTI FUNCTION
YAD9D400
1 2 3 4
Multi - Function Switch Assembly Turn Signal Switch Assembly Turn Signal Switch Assembly Screw
5 6 7 8
Switch of Light Switch of Auto - Light Connector Switch of Wiper
SSANGYONG Y200

Components of Connector Pin
Layout of connect Number of pin 1 2 3 4 5 6 7 8
YAD9D410
Name of connector TL TB TR HU HS (2) W EW AUTO P ES A HS (1) TS EB LO HI ET INT HORN Switch of turn signal (LH) Power of flasher unit Switch of turn signal (RH) Power of head lamp upper beam Switch passing of head lamp Front washer switch Wiper and washer ground Auto wiper Wiper parking Ground of light switch Auto light switch Switch of head lamp Switch of tail lamp Ground of dimmer and passing switch Low speed of wiper High speed of wiper Ground of intermittent wiper Intermittent wiper Horn relay
9 10 11 12 13 14 15 16 17 18 19 20
SSANGYONG Y200

Check and Repair
Check applying of electric current below terminal at each position of multi-function switch, if each terminals are not applied of electric current, replace multi-function switch.
Light switch
Dimmer and passing
YAD9D420
YAD9D450
Auto - light switch
Washer
YAD9D430
YAD9D460
Turn signal lamp
Wiper switch
YAD9D440
YAD9D470
SSANGYONG Y200

Before multi-function switch is removed in the vehicle with air bag, keep in mind the following. Notice: Do not separate module of air bag or coil of contact, if malfunction of air bag or coil of contact happen, replace them. Do not drop down module of air bag or coil of contact, do not contact module of air bag or coil of contact over water, grease, and oil, if crack deformation and corrosion are detected, replace them, if module of air bag keep in the place, put this on the even place, set the surface of pad on the above, do not put anything on them, module of air bag is not kept in the room temp 93 C. After air-bag is exploded, coil of contact and module of air bag should be replaced. While exploded air bag is treated, wear glove and glasses of protection. In case for module of air bag not to explode, treat as the procedure described. While module of air bag and coil of contact are separated, do not force them to push excessively. Before coil of contact is not installed, after keep front tire forward in align, keep in line between mark of contact coil and mark of neutral and then install contact coil. If mark of contact coil does not keep in line properly, steering wheel does not revolve, flat cable can be damaged, air bag does not operate normally, so can cause driver to damage, if contact coil is inspected any situation, refer to the section of air bag. If module of air bag is not blown, module of air bag should be treated by procedure. If module of air bag and connector of contact coil are separated, excessive force does not be put in those one. Before contact coil is installed front wheel should be aligned to the forward, mark on the contact coil should keep on the one line with mark of NEUTRAL, and then contact coil should be installed. 1. Separate negative terminal of battery. 2. Put direction of wheel on the forward and moving direction of vehicle, after releasing screw (left and right), remove module of air bag.
YAD9D480
SSANGYONG Y200

3. Mark installing mark on the wheel nut, release wheel nut. 4. Using the special tool, remove steering wheel. Notice: Separate all the connector.
YAD9D490
5. Separate cover equipped in the steering column shaft.
YAD9D500
6. Separate vacuum hose of fuel cut and connector which is linked to switch of multi- function. 7. After separating coil connector of air bag contact, remove contact coil.
YAD9D510
8. Remove switch of multi- function. 9. Install reverse order of removal.
YAD9D520
SSANGYONG Y200
COMPONENTS OF LIGHTING
General Description
Head lamp Head lamp is controlled by light switch which is located in the left of steering column. If light switch is set on first stage, position lamp, lamp of license plate and lamp of instrument panel illumination is turned on, if light switch is set on two stage, head lamp is turned on. If light switch is off, all the lamp are turned off. High beam and low beam is controlled by operation of light switch. As light switch is pushed and pulled, is switched to high beam and low beam, if head lamp is turned on by high beam, high beam is displayed on the instrument panel. Aiming of head lamp is adjusted properly. If new head lamp is replaced, aiming of head lamp should be inspected. Front turn signal lamp / position lamp If light switch is set on the first stage, lamp of position is turned on, if light switch is off, lamp of position is turned off. Turn signal lamp is controlled by light switch which is located in the left of steering column, as light switch is operated by moving up and down, and then turn signal lamp is turned on and off. Change of vehicle direction is finished completely, light switch back to original position, turn signal lamp is turned off, operating of steering wheel is small in the narrow road or in the narrow turn signal lamp so, light switch does not turn back to original position automatically, at this time, as light switch is operated by hand, and then light switch back to normal position, and turn signal lamp is turned off. Fog lamp Switch of fog lamp is located on the instrument panel of left gauge panel of audio system, after position lamp and head lamp are turned on, in the result of this, turn switch of fog lamp on, so fog lamp is on, if switch of fog lamp is turned on, fog lamp is on , indicated lamp also is turned on,in the instrument panel, instead of head lamp, fog lamp should not be used, in case new fog lamp is replaced, adjustment of aiming to the fog lamp should be inspected.
Tail lamp Tail lamp consists of rear back lamp, tail lamp, back up lamp and turn signal lamp in the assembling part. If position lamp or head lamp are turned, rear back lamp is turned on. As rear back lamp and brake lamp consist of double lamp, if technician is put foot on the brake pedal, brake lamp is turned brighter. If lever of transmission is operated to backwards, back up lamp is turned on. Assistant brake lamp Assistant brake lamp is located on the upper section of back glass, if pedal of brake is operated, assistant brake lamp is turned on. Lamp of license plate If position lamp or head lamp is turned on, lamp of license is turned on, this lamp is attached rear deck lid of license plate. Lamp for reading and room lamp Lamp for reading and room lamp is attached on the head lining, if switch of lamp for reading is turned on, lamp for reading is on in the driver seat and passenger seat, if switch is touched one, lamp is on, if switch is touched twice, lamp is off . Switch of room lamp is the type of three point, if open door, in the state of pushing switch of door, room lamp is turned on, if door is closed, room lamp is gradually turned off. In the state of switch off , though door is opened, yet room lamp is not turned.
SSANGYONG Y200
9D-28 BODY ELECTRICAL Auto Light System

Summary Controlling of auto light cause tail lamp or position lamp to turn on or off, sensor unit of auto light is attached on the upper panel of instrument, this unit is sensing change of illumination to atmosphere, though driver does not operate light switch, yet if mode is set on AUTO, head lamp and tail lamp is automatically turned on and off, during the vehicle is driven on the time of day through tunnel area, foggy area, rainy day, or snowy day, due to the low of illumination around atmosphere, this system is operating.
Specification
Name of part Voltage of load Load Sensor unit of auto light Temp available Room temp for keeping Position of attaching Description 9 -16 V MAX 200 mA - 30 ~ +85 C - 40 ~ +120 C Upper right section of instrument panel
Input and Output of Diagram
YAD9D530
SSANGYONG Y200

Sensor Unit Terminal of Auto Light
1 2 3 4 5 6 Power Supply For System Auto Light Switch Non-Use Relay of Head Lamp Relay of Tail Lamp System Grounding
YAD9D540
Operation of Auto Light and Operating Condition

Operation of switch function 1. After turning ignition on, operate multi-function switch, OFF TAIL LAMP HEAD LAMP AUTO switch. 2. Turn tail lamp, head lamp on and off 3. Turn switch of AUTO ON, While sensor is sensing illumination of light, which is set on the diode of photo. As quantity of illumination of light is equivalent to voltage which is set on the internal CPU, tail lamp and head lamp is turned on and off automatically. 4. Switch of tail lamp and head lamp is operated by hand, tail lamp and head lamp are not turned, on and off by sensor. 5. If switch of ignition is turned off, tail lamp and head lamp is turned off.
Operation Condition
Lamp Illumination intensity
Condition of tail lamp 30.5 5 (LUX) 60.5 5 (LUX)
Condition of head lamp 8.9 3 (LUX) 17.2 3 (LUX)
Time of delaying 0.5 0.1 31
Illumination intensity of light on Illumination intensity of light off
SSANGYONG Y200
9D-30 BODY ELECTRICAL The Characteristic of Operation
YAD9D550
Operation condition should be under on and off range with tail lamp, head lamp T1 : 3 1.0 sec T2 : 500 100 msec
Check
After turn to position of AUTO, put black cloth on the section of sensor, check if head lamp, tail lamp are turned on or not.
YAD9D560
SSANGYONG Y200
LOCATION OF LAMP
YAD9D570
1 2 3 4 5 6 7
Head Lamp - Low Head Lamp - High Beam, Position Lamp Position Lamp Turn Signal Lamp Fog Lamp High Mounted Stop Lamp Plate Tail and Stop Lamp
8 9 10 11 12 13
Tail Lamp Stop Lamp Turn Signal Lamp Back up Lamp Rear Back Mirror Lamp of License
SSANGYONG Y200
YAD9D580
1 Lamp of Glove 2 Room Ramp 3 Lamp of Center Room
4 Door Lamp 5 Turn Signal Lamp of Side 6 Lamp of Cosmetic Mirror
SSANGYONG Y200
BODY ELECTRICAL 9D-33 Specification of Lamp

Item Head lamp Low beam High beam Position lamp Front combi lamp Turn signal lamp Rear Rear combi lamp Tail lamp Stop lamp Turn signal lamp High mounted stop lamp Tail/ stop (L, R) (1, 1) (L, R) (1, 1) (L, R) (1, 1) (L, R) (1, 1) 27 W 27 W Side combi 8W Cosmetic mirror lamp Turn signal lamp (L, R) (1, 1) (L, R) (1, 1) 5W 27/ 8 W Fog lamp Quantity (L, R) (1, 1) (L, R) (1, 1) (L, R) (2, 2) (L, R) (1, 1) (L, R) (1, 1) 4 EA 5W 28 W Front room lamp Lamp of center room Door lamp (4) 5W (2) 10 W (2) 8W 27/ 8 W 5W Lamp of license plate Room Lamp of license plate Glove box (1) 10 W 55 W Spe 55 W Rear combi lamp Back mirror Rear Item Back up lamp Quantity (L, R) (1, 1) (L, R) (1, 1) (2) 5W Spe 27 W
SSANGYONG Y200

Head Lamp 1. Remove negative terminal of battery. 2. Remove the grill of radiator. 3. Remove mounting bolt (3ea) of head lamp.
YAD9D590
4. After separating connector of head lamp, remove the head lamp.
YAD9D600
5. Separate cover of bulb, connector, and bulb orderly, from head lamp separated.
YAD9D610
6. Install the reverse order of removal.
YAD9D620
SSANGYONG Y200
After installing head lamp, proceed to arrange of focus.
YAD9D630
Turn signal lamp / fog lamp 1. Remove the negative terminal of battery and head lamp. 2. After releasing fixing bolt of lamp of front turn signal lamp and fog lamp, remove connector. 3. Remove lamp assembly from the bumper. 4. Install the reverse order of removal. Fix the left of lamp on the hook of bumper, and then tighten the right with fixing nut (2 ea).
YAD9D640
Rear combi - lamp 1. Remove the negative terminal from battery. 2. Separate fixing screw (2ea) of rear combi - lamp.
YAD9D650
3. After separating bulb from rear combi-lamp and then remove rear combi - lamp.
YAD9D660
SSANGYONG Y200

Side lamp 1. After pushing side lamp to front side, pulling rear of lamp, and then remove side lamp. 2. After removing the connector, remove side lamp.
YAD9D670
High mounted lamp 1. Remove spoiler from the tail gate.
YAD9D680
2. After separating fixing screw (2 ea) of lamp spoiler of tail gate, and then remove connector. 3. Remove lamp assembly. 4. Install the reverse order of removal.
YAD9D690
Lamp of glove box 1. Open up cover of glove box. 2. After pushing lamp as indicated mark, remove lamp of glove box. 3. After separating connector of lamp, remove lamp. 4. Install the reverse order of removal.
YAD9D700
SSANGYONG Y200

Door lamp 1. Remove the negative terminal of battery. 2. After removing door trim, and then separate connector of lamp.
YAD9D710
3. After releasing fixing screw of lamp, remove lamp. 4. Install the reverse order of removal.
YAD9D720
Lamp of license plate 1. Remove lamp of license plate. 2. Separate bulb from lamp. 3. After insert bulb into lamp, and then insert in the hole of mounting of tail gate.
YAD9D730
Room lamp Front lamp 1. After removing lense of lamp, remove bulb.
YAD9D740
SSANGYONG Y200

2. After releasing the housing fixing screw of lamp, and then separate housing. 3. After separating connector of lamp housing, remove lamp housing. 4. Install the reverse order of removal.
YAD9D750
Center / rear lamp 1. After removing lense of lamp, remove bulb.
YAD9D760
2. After releasing housing fixing screw of lamp, separate the housing. 3. After removing connector from the lamp housing, remove lamp housing. 4. Install the reverse order of removal.
YAD9D770
SSANGYONG Y200
HORN AND AUDIO SYSTEM

General Description
Horn Horn is located under the hood, is also installed near radiator in the front. Horn is operated by pushing pad of steering wheel which is linking to the electric circuit. Audio system Audio Radio and cassette are installed in the audio system by standard specification, changer of cd is applied option specification, which is installed on the room of trunk.
Front and rear speaker Eight of speaker is installed in the vehicle, two of speaker is installed on the front door, rear door, and tail gate and an speaker is installed each side mirror (left, right). Glass antenna Glass antenna is different from existing antenna, is not appeared external shape of antenna,this one is installed on the quarter glass, consists of module of glass antenna, harness, and connector. The sensitivity of reception are better than the existing antenna.
YAD9D780
SSANGYONG Y200
9D-40 BODY ELECTRICAL Removal and Installation

Horn 1. After releasing fixing bolt, remove horn. 2. Install the reverse order of removal.
YAD9D790
3. Adjust After operating the horn, and then adjust tone of horn proper (adjust screw of controlling). Notice: After adjusting screw, spread paint on the screw of adjusting, do not release screw of adjusting.
YAD9D800
Speaker 1. Remove front door speaker and rear. 1) Remove door trim and seal. 2) After separating connector of speaker, and then release fixing screw of speaker. 3) Remove speaker. 4) Install the reverse order of removal.
YAD9D810
2. Remove speaker of tail gate. 1) Remove trim of tail gate and seal. 2) After releasing fixing screw and connector of speaker, remove speaker. 3) Install the reverse order of removal.
YAD9D820
SSANGYONG Y200

3. Remove speaker of side. 1) Remove door trim. 2) After removing speaker assembly, remove connector of speaker. 3) Install the reverse order of removal.
YAD9D830
Accessory of audio system Audio 1. Separate the negative terminal of battery. 2. Remove center of instrument panel.
YAD9D840
3. Remove audio Release fixing screw of audio. Separate cable of antenna and connector. Remove audio. 4. Install the reverse order of removal.
YAD9D850
Controller of audio remote 1. Remove air bag module of steering wheel or horn pad on the driver seat. 2. After releasing connector and fixing screw, and then remove remote control. 3. Install the reverse order of removal.
YAD9D860
SSANGYONG Y200

Power antenna and module Power antenna 1. After separating the negative terminal, remove lower quarter panel of seat in the passenger seat. 2. Remove fixing cover of power antenna.
YAD9D870
3. After separating motor connector of power antenna, and then release fixing nut of motor. 4. Remove power antenna assembly.
YAD9D880
Module of glass antenna 1. Remove the upper quarter panel. 2. Remove module of glass antenna. Separate connector of glass antenna. Separate jack of antenna. Release bolt (2ea). Separate connector of rear heating line. Remove module of glass antenna.
YAD9D890
3. Install the reverse order of removal.
YAD9D900
SSANGYONG Y200

CD Changer 1. Remove the negative terminal of battery and AUDIO. 2. Separate cable of CD changer from the AUDIO.
YAD9D910
3. Remove rear lower quarter panel in the driver seat. 4. Remove cable from the changer of CD.
YAD9D920
5. After releasing bracket fixing bolt of changer of CD, remove changer of CD. 6. After Installing the reverse order of removal, check unusual noise or state of operation.
YAD9D930
SSANGYONG Y200
WIPER AND WASHER

General Description
Wiper system of sensing rain Summary Wiper motor of musso and korando is controlled by stics. In the case of this, time of operation of wiper is controlled by stics, driver should control time which is drived of stics. But wiper system of rexton is sensing quantity of rain by the unit of sensing rain which is installed on the upper center of windshield, this unit is controlling operation of wiper, low and high speed according to quantity of rain. Diagram Of System
Multifunction switch Control wiper mode and ON/OFF
Unit of sensing rain Quantity of rain Unit of sensing is sensing quantity of rain, according to quantity of rain, this unit is controlling operation of wiper,low and high speed. Wiper motor
SSANGYONG Y200

Principle of Rain Sensor
(Wave drop of rain is contacting, loss happen by transmitting electronic wave)
Wave which is transmitted reflects and reinput
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YAD9D940
1. Unit of sensing rain is sensing by the LED and the diode of photo. 2. As infrared ray is emitting from LED, diode of photo which is reflected by drop of rain is sensing the quantity of rain.
3. Unit of sensing rain is correcting itself, so regardless of transmitting of windshield, this unit is constantly sensing rain. 4. This unit is sensing the area between the LED and diode of photo.
Mode of operation Wiper control system consist of OFF, MIST, LOW, WASHER, plus AUTO mode, if turn to the position of AUTO, rain sensor is sensing drop of rain, and then, is controliing time of operation, speed of operation with LOW, HIGH.
YAD9D950
SSANGYONG Y200

1. OFF Mode If switch of wiper is turned off and switch of ignition is turned on, at this time, rain sensor is operating with OFF MODE, under this mode, wiper mode is stopped, during rain sensor is OFF MODE, rain sensor is sensing the state of windshield, so that turn switch to proper position. 2. Auto Mode If wiper switch is transferred OFF MODE into AUTO MODE, immediately wiper is operating once, that means wiper system is operating, after wiper is operating once, is calcurated the time of gap between drop of rain and speed of wiper operation. After stoppng time, rain sensor transfer signal into wiper motor, wipe out rain. 3. Automatic Intermittent Mode At the automatic intermittent mode, wiper is operating once with low speed, and then this mode has variable stopping time. 4. Automatic Low Speed This mode is operating beyond value of limit of automatic intermittent and automatic low speed. 5. Automatic High Speed As quantity of rain beyond value of automatic low speed and automatic high speed is operating. 6. Washer Mode (48Page) Rain sensor is sensing whether switch of wiper select function of washer or not. If switch of wiper is turned on more than 0.6 sec, wiper is operating for 2.5 - 3.8sec, under this value is operating only once. At washer mode, motor of wiper is operating with low speed. 7. Manual Mode Switch operation of driver turn motor of wiper to low speed, high speed, at this time, wiper is operated by not rain sensor by but wiper switch. Notice: As rain sensor is out of order, wiper is operating with low speed and high speed. Characteristic of rain sensor 1.Supply power Power is supplying to rain sensor and within 250 msec, rain sensor is emitting the signal OFF , until effective power is supplying, effective power is available for supplying power, after 2 second. 2. Speed of wiper and control frequency of revolution Main function of rain sensor is controlling wiper speed and delaying of time to between the driving time, due to sensing and the accumulation of rain, algorithm of rain sensor is deciding mode of motion, automatic intermittent, automatic low speed, and automatic high speed. If the stage is set, without the operation of driver, wiper is continuously operating. 3. Transfer between the modes Algorithm of rain sensor is transferred automatic intermittent,automatic low speed, and automatic high speed under low stage so doesnt make noise. 4. Performance of sensing Sensing of rain sensor is set 5 stage, due to accumulated drop of rain, driver can satisfy, range of adjusting can control from the short delaying time to thelong delaying time, but, due to heavy rain, regardless of sensing which is set, is continuously operating with high speed. 5. Responding characteristic of automatic low speed As wiper is operated from the zero state of dropping of rain to the automatic low mode. Time is needed within only 9 second for high required signal. 6. Responding characteristic of automatic high speed As wiper is operated from the zero state of dropping of rain to the automatic high mode. Time is needed within only 9 second for high required signal 7. Responding characteristic from the automatic low speed to the automatic high speed As wiper is operated from the automatic low speed to the automatic high speed mode, time is needed within only 6 second for high required signal. 8. Responding characteristic from the automatic high speed to the state of off (48 Page) As wiper is operated from the automatic high speed mode to the the zero state of dropping of rain mode, times of wiper motion is under 19 times. 9. The instant operating of wiper While system of wiper is operating by switch of wiper, before wiper back to the position of operating, wiper is operating once, such as once operating, is occurred at time from the lower stage to the high stage by operating of wiper switch, but if the high stage is moving to the low stage, once operating of wiper does not happen.
SSANGYONG Y200

If the ignition switch is off and if wiper switch is set on any position, turn ignition switch on, the instant operation of wiper is occurred, signal to driver beginning of wiper operating, due to lack of rain drop, if wiper is not operated, rain sensor stay on the automatic intermittent mode. Check unit of rain sensor Check selection of sensing (check position of nob of variable resistent) Check if variable resistent nob of multifunction switch is positioned in the middle of between S of position and F of position, if nob is positioned F (fast) or S (slow),sensing is much higher or much lower, so customer can complain this. Self - diagnosis 1. Rain sensor has two kind of self diagnosis test mode. 1) Self diagnosis of FAULT A In case operating point of rain sensor servo is beyond range of soft ware, that means sensor has a fault, if part of wind shield glass has a damage, or if sensor is removed from the coupler. 2) Self diagnosis of FAULT B While rain sensor does not reaction with signal of rain, that means FAULT B, if wind shield glass which is equipped coupler has a damage or sensor is out of order. 2. Value of cohesion While FAULT A is sensed, the cohesion is decided, the value of cohesion is 140,in this case, except heavily damage of wind shield glass, rain sensor is operating in the all conditions. 3. Failure which is occurred with adjustment of intermittent volume Due to adjustment of sensing and motion of wiper, self diagnosis is described as below. 1) Wiper switch is transferred the intermittent into 5 step stage, under the state of ignition on 2) Under this state, sensing is changed 5 step stage into 4 step stage. 3) At this time, wiper is moving once, that means self diagnosis of FAULT A, check if wind shield glass has a damage or not, also check if sensor is installed completely on the coupler. 4) After check 3) article, sensing is changed 4 step stage into 3 step stage. 5) If wiper is operating once, this means self diagnosis of FAULT OF B. Replace new rain sensor. Wiper blade Check the state of wear of wiper blade, due to excessive wear of wiper blade, if is not cleaned up over section of sensor, quantity of rain is not sensed accurately. Coupler Check if blister is shaped on the external section of coupler which is stuck on the wind shield. If there is a blister in the internal section of sensor, is not sensed accurately, check if coupler is installed the right position or not, specially check if section of coupler sensor is positioned on the section of ceramic coating or not, if the space of sensing is shielded, infrared of sensor is not passed so sensing is not available accurately. Wind shield glass Check if wind shield glass surface of the external sensor has excessive wear,damage, and scratch or not. Wear of sensor is compensated little bit, if there come to beyond constant value, sensor is not sensing, such a kind of diagnosis is used self diagnosis. Exterior cover Check the state of exterior cover of rain sensor, check that sensor is impacted by shaking, owing to releasing fixing section of cover, also check interference with wind shield glass or head lining. Spring clip Check if rain sensor release from coupler or not, after removing exterior cover, check the state of spring clip. Connector After check the state of tighting between terminal of connector and wiring, check that the terminal is inserted into connector as the state of locking. Check the state of combination between the connector of wiring and the connector of rain sensor, check interference between them. Relay Check if low relay of wiper and high relay of wiper is operating normally, as relay is damaged by fire so motor of wiper is not operated, at the auto mode, blade of wiper is not operated. Circuit Check circuit, specially check if the value of variable resistence of multifunction switch is feeding properly or not, this can see by moving nob of variable resistence step by step from the state of slow to the state of fast (This is called Instant Wipe ).
SSANGYONG Y200

If parking position of wipe motor is not feeding properly or not, if parking position of wipe motor is not feeding, wiper motor can be operated quickly rather than the state of normal, intermittent speed shifting time of wiper motor is not sensing, wiper motor is not operated normally. Notice: While unit of rain sensor is removed. 1. Remove exterior cover, at this time, if exterior cover is removed by compulsion, keep in mind not to break fixing hook of coupler, as exterior cover is removed, using hole of cover by driver, after section of fixing hook is pushing, and remove them. 2. As rain sensor is removed from coupler, using driver after open up spring clip, remove them. 3. Remove connector to the wiring from the sensor. 3. On the turning, Applying the current between contact point of W of CAM switch and contact point of C, relay 2 of CONT is OFF and relay 1 is ON and then, turn motor clock wise, wiper is operating between position of B and position of C by transfering pole of motor. Operation of parking mode 1. Parking on the operation with the clockwise : Under the wiper is operating,switch of wiper is off On the turning,applying the current between contact point of W of CAM switch and contact point C, after relay 1 is off, stopping the motor, within approximately 1 second, relay 2 of CONT is on, turning motor counter-clockwise, apply the current between P ground of CAM switch and C ground, and then relay 2 of CONT is OFF, motor can stop. Operation for washer mode Turn washer switch on above 0.5 second, after operation of wiper mode is operating twice, after operation of parking mode is operating and then motor is stopped, but if washer switch is on below 0.5 second, wiper motor is not operating. Mode operation of limit switch ON 1. Limit switch on: Under wiper is operating while wiper is operating, limit switch is ON, immediately back to the position of parking, and then stop the motor. 2. Limit switch on at the position of parking. Though turn wiper switch or intermittent switch on, motor is not operated. Description of system operation 1. Turn motor switch on, after relay 1 of controller is on, turn motor clockwise (operation order: (1) (2) (3) (4)) 2. On the turning, Applying the current between contact point of W of CAM switch and contact point of C, relay 2 of controller is OFF and relay 1 is ON and then, turn motor clock wise. CAM switch is operating between position of (2) and position of (4) by transfering pole of motor. (operation order :(2) (3) (4) (3) (2): motion of cycle) 3. Angle of DSP denote the angle between (1) and (2) or the angle between (1) and (4). 4. Turning motor from position of (3) to position of (4), stopping in the position of (1), turning from position of (3) to position of (2), stop in the position of (1), namely, as motor is parking, such as below the picture, contact point of W, C, and P are on the one line.
Rear Wiper System

Summary Controlling of existing rear wiper is controlled by relay which is operated with switch, but rear wiper of Rexton is controlled by ECU, in the existing vehicle, brush of rear wipe is installed on the rear glass, but rear glass can is opened up, brush of rear wiper can not be installed, so,this one is installed on the back panel, wiper motor is operating by second stage.
YAD9D960
Description of System Operation

Operation for wipping mode 1. Turn switch of wiper on, and then relay 1 of CONT is on, turn motor with clockwise 2. On the turning, Applying the current between contact point of W and contact point of C, after relay 2 of CONT is OFF relay 1 is ON , turn motor counter clock-wise.
SSANGYONG Y200
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YAD9D970 YAD9D990
Position of (1) : Position of soft contact Position of (2) and (4) : Reverse position
Function of rear wipe 1. While switch of ignition turns on, turning switch of wiper on, and then 1of relay is operated, so wiper motor is controlled. 2. While wiper motor is operating, after contact signal of W is feeding, so 2 of relay is operated, cause wiper motor to reverse direction (angle of revolution of wiper motor : 260 ) 3. As above the description, under the control of wiper motor, if wiper switch is off , turn power of wiper motor until position of P is feeding, and then back to the position of parking.
YAD9D980
SSANGYONG Y200
9D-50 BODY ELECTRICAL Trouble Shooting

Flow Chart Mode Of Wiper Operation
Turn wiper switch ON
1 of relay is ON,2 of relay is OFF (Motor is turning to clockwise)
Ground of W is ON ?
ON
YES
1 of relay is OFF 2 of relay is ON (Motor is turning to counter-clockwise)
Ground of W is ON?
ON
YES
SSANGYONG Y200

Parking Mode Parking is under operation of the clock wise. Parking is under operation of the counter clock wise. Motor is operating to the counterclock wise wiper switch is off or switch of intermittent is off
Motor is operating to the clock wise wiper switch is off or switch of intermittent is off
Ground of W is ON ?
NO
Ground of W is ON ?
NO
YES
YES
1 of relay is OFF, 2 of relay is OFF (motor : stop), wate for 1 minute
1 of relay is OFF, 2 of relay is OFF (motor : stop), wate for 1 minute
1 of relay is ON, 2 of relay is OFF (motor is turning to clock wise)
1 of relay is OFF, 2 of relay is ON (motor is turning to counter-clock wise)
Ground of P is ON ?
NO
Ground of P is ON ?
NO
YES
YES
1 of relay is OFF, 2 of relay is ON motor : stop
1 of relay is OFF, 2 of relay is OFF motor : stop
SSANGYONG Y200

Operation Of Washer Mode
Turn washer switch on
Is it passing time o.5 second
NO
YES 1 of relay is ON, 2 of relay is OFF motor is turning to clockwise 1 of relay is off, 2 of relay is off (motor : stop)
NO Ground of W is ON ?
YES
1 of relay is OFF, 2 of relay is ON
Ground of W is ON ?
NO
YES 1 of relay is ON, 2 of relay is OFF motor is turning to clockwise
Ground of W is ON ?
NO
YES Parking : is operating under the clockwise (motor : stop )
SSANGYONG Y200

Operation of Limit Switch
Motor is operating : limit switch is ON
Limit switch is ON
NO Ground of W is ON?
Wiper switch is ON, or Intermittent is ON
YES 1 of relay is OFF, 2 of relay is OFF (motor : stop) 1 of relay is OFF, 2 of relay is OFF (motor : stop)
1 of relay is ON, 2 of relay is OFF (motor : is turning clockwise)
Ground of P is ON ?
NO
YES 1 of relay is OFF, 2 of relay is OFF (motor : stop)
SSANGYONG Y200

Washer linked mode 1. As turn ignition switch on, wiper switch is ON more than 0.6 seconds, and then, power of washer linked mode is ON 2. After turning washer switch off, operation of wiper mode is operating twice, and then back to parking position. 3. Power of wiper motor is operating with the same mode of wiper operation.
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Operation of limit switch: ON/ OFF mode 1. As turn ignition switch on, if wiper motor turn limit on, without delay, back to parking position and then stop motor. 2. Being state of turning on, stop control power of wiper motor. (Namely, opening up rear glass, for wiper not to be interfered )
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SSANGYONG Y200
BODY ELECTRICAL 9D-55 Specification

Description Motor Rated voltage Test voltage Range of allowed voltage Minimum operating voltage Insulated resistence Restraint test
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Specification DC 12 V 0.3 V DC 13.5 0.3 V DC 10 - 15 V DC 8 V 500 V 1 M 1.1 Km 14 A - 40 c ~ + 80C DC 12 V DC 9 ~ 16 V - 30 C ~ + 80C - 40 C~ + 90C 1 M (500 V) 0.5 V 14.0 0.5 A 10 A
Torque
Current Range of atmosphere temp allowed Rated voltage Range of allowed voltage Range of allowed temperature Range of conserved temperature Insulated resistence Voltage dropping
Control
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Test voltage Load allowed current
Circuit diagram
; ;
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SSANGYONG Y200

Components
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1 Wiper Blade 2 Wiper Motor And Link 3 Washer Tank Assembly
4 Wiper Blade 5 Wiper Motor
SSANGYONG Y200

Removal and Installation Front wiper Assembly
1. After opening up front hood, remove wiper arm.
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2. After cowl left is removed, remove wiper linkage assembly. (At this time, separate connector of wiper motor)
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3. From linkage separated, releasing fixing bolt of wiper motor, separate linkage and motor.
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4. Install the reverse order of removal. Fixing bolt of motor Nut of linkage Nut of blade 7 -11 Nm 4 - 6 Nm 19 - 28 Nm
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SSANGYONG Y200

Rear wiper assembly 1. After cap of wiper arm, remove nut of wiper and blade of wiper.
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2. Remove trim of tail gate. 3. After connector of wiper motor is separated, release fixing nut. 4. Remove wiper motor assembly from the tail gate.
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5. Install the reverse order of removal. Wiper motor assembly Bolt of motor Bolt of motor bracket 7 - 11 Nm 7 - 9 Nm
Rear wiper blade Torque of Tightening 19 - 28 N m (44 - 52 lb-ft)
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SSANGYONG Y200
Check
Check speed of front wiper motor 1. Remove connector from the motor of wiper. 2. Connect positive terminal into 3 terminal and negative terminal into 6 terminal. 3. Check motor with low speed. 4. Connect positive terminal into 3 terminal and negative terminal into 5 terminal. 5. Check motor with high speed.
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Check operation of automatic stop of front 1. Operate motor with low speed 2. After separating 6 terminal, stop operation of motor except position of OFF 3. Connect 2 terminal and 6 terminal. 4. After connecting positive terminal into 3 terminal, and then 4 terminal turn to the ground. 5. Check motor at the OFF position.
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Check motor of rear wiper 1. Remove connector from the motor of rear wiper 2. Connect positive terminal into 4 terminal and negative terminal into 3 terminal. 3. Check motor is operating normally, if motor has a problem, replace motor.
Check washer motor 1. After installing washer motor into washer tank, and then fill fluid of washer 2. Connect 1 terminal into positive terminal of battery and 2 terminal into 3 negative terminal 3. Aftter motor of washer is operated, check the fluid of washer is operated.
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SSANGYONG Y200

Check position of wiper arm While installing wiper arm, check position of front wiper arm and rear wipe arm, and reinstall, to positioned original position. Front wiper arm: Distance from the end of cowl grill to the blade: 45 mm Rear wiper arm: Distance from the lower section of rear glass to the blade: 30 mm
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SSANGYONG Y200
POWER WINDOW
Components
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1 2 3 4
Power Window Switch Of Passenger Seat Power Window Switch Of Rr Seat (LH) Power Window Switch Of Rr Seat (RH) Power Window Switch Of Driver Seat
5 Window Regulator 6 Window Motor 7 Window
SSANGYONG Y200

1. After inserting switch of window in the door handle, separate grip of fixing hook.
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2. After connector of window switch is separated, remove window switch assembly.
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3. Remove trim of door and seal. 4. After window glass is removed, remove regulator assembly. 5. Remove motor of window from the regulator which is separated. 6. Install the reverse order of removal.
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SSANGYONG Y200

Check and Repair
Main switch of power window
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1. After main switch of power window is removed in the driver seat, check that applying an electric current of each terminal.
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2. Lockong system of window.
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SSANGYONG Y200

Serve switch of passenger set and rear seat 1. After switch is removed, check that applying an electric current of each terminal.
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Passenger seat
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Rear seat
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SSANGYONG Y200

Check motor of power window After terminal of motor is connected, check that motor is operating softly, and then change pole of current, motor is operating to the reverse direction softly, if motor is operating unnormal, and then replace motor.
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Check rear window and defogger of quarter glass Notice: It is prevention for the defogger not to have a impact, so after taping foil of tin at the end of tester, foil of tin is moving along with line of grid for checking the circuit open or not.
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1. At the state of idling, after switch of defogger is turned on, check the below description. 1) After turn switch of defogger on, measure voltage of defogger with voltmeter in the center of glass, if value of voltage is 6V, heater line of rear window is normal.
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2) If defogger is damaged by a fire between center and positive terminal, value of voltage is indicated 12 V.
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SSANGYONG Y200

3) If defogger is damaged by a fire between center and negative terminal, value of voltage is indicated 0 V.
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4) Lid of tester is moving into the section which is assumed circuit open, after measuring circuit open look for the section of 0 V, voltage which is changed in the section, which is open of circuit.
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2. After turn switch of defogger off, check the below description. Using voltmeter, measure resistence of each defogger in the center of grid line, resistence between the same terminal and defogger orderly. Broken section of defogger is 2 times rather than other the section of defogger, section which is impacted with the rapid change of resistence.
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Method to repair grid line of defogger After being prepared, repair section of defogger which is broken. 1) Paint of applying electric current 2) Thinner of paint 3) Masking tape 4) Alcohol
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SSANGYONG Y200

5) Slim brush Clean up the section of defogger which is broken, indicating like left picture, with the state which is sticking masking tape, clean up with alcohol. After mixing between paint of applying electric current and thinner per interval of 15 minutes, paint 3 times. Before power is supplying, pull tape out of the section broken, to finish up better, after drying up completely (approximately after one day), remove the edge painting unnecessary with knife. Notice: After repairing, clean up glass with the soft towel, grid line with the towel wet.
1. Disconnect cable of negative terminal of battery. 2. Disconnect defogger connector of tail gate.
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3. After checking grid line, scraping approximately 6 mm to both section from disconnection of a line with wooden spoon, clean up these section, a kind of cloth wet with alcohol.
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SSANGYONG Y200

4. Attach tape of repair of grid line properly. Attach tape to have a same width with grid line. 5. Spread material of repair with wooden spoon. 6. Remove tape carefully.
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7. Heat up the section which is repaired, keep distance 25 mm from this section, with drier below 149 for 1-2 minutes Notice: Repair material of grid line dry up with heating, while is heating repairing section trim which is linked should be protected from heating, pay attention to deformation of interior trim 8. If grid line of repairing is discolored, after spreading coating of paint of iodine on section discolored, if get spreading out of grid line, after half hour is passed, clean up grid line with soft wiper. 9. Check if grid line is repaired or not, operate glass defogger of back door. Notice: Until repair material is dried up completely, this is needed 24 hours at least, section repaired should be protected from unnormal material.
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Repair of defogger of tail gate Copper line of glass defogger have reinstallation available with soldering, soldering consists of 30 % silver solder and rosin solvent 1. Disconnect negative cable of battery. 2. Scrape the around section of repair with wooden spoon 3. After spreading on the copper line, clean up on the section which is repaired with brush.
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SSANGYONG Y200

4. Put soldering on the the end of soldering gun. 5. If copper line is repaired with soldering, for copper line not to overheat, this work should be repaired under limit of temperature which can melt solder.
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SSANGYONG Y200
SWITCH AND ELECTRICAL SYSTEM

Components
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Defogger Switch Front Switch of Fog Lamp Digital Watch Switch of Hazard Warning Lamp Sensing Unit of Auto Lighting Air Bag of Passenger Unit of EGR Unit of OVPR 8 ECM 9 SDM 10 Nevigation System
1 2 3 4 5 6 7
11 12 13 14 15 16 17 18 19 20
Switch of Seat Warmer Unit of Seat Position and Seat Warmer TCM Switch of Position Memory TOD, TCCU Internal Sensor of Temp Connector of Self Dignosis Stics / Rekes Fold Switch of Side Mirror Sensor of Sun
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Description of System
Unit of seat position and seat warmer This unit is located on the lower section of passenger which controls driver seat and out side mirror manual operation, put in memory, function of returning and also has a function which warm up seat and fold up outside mirror.
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Function of Operation Type SEAT Regardless of ignition switch Description Operating voltage Rang of operating temp Operating speed of Slide seat Operating distance of seat Operating current (at 13.5 V) Heater switch of seat Outside mirror Angle of up and down Angle of left and right Angle of folding Tilt Height Slide Recline Lift Slide Tilt and lift Rated load Range of operating temp Foce of switch operation Specification DC 11 - 15 V -30 C - 80C 20 7 mm/sec 10.6 5 mm/sec 7 2 mm/sec 228 3 mm 23 0 48 30 3 mm 7A 8A DC 12 V / 1A 35 c - 45 c 0.3 - 0.7 kgf -8 - 8 -8 - 8 67
SSANGYONG Y200

Seat and Out Side Mirror, With Memory Part of function Slide Recline Lift (front/rear) Warmer (driver/passenger) Outside mirror Up and down Left and right Set memory 1. Condition: If ignition is ON position of selector lever is P and N 2. Parking brake is O N 3. Switch of set is ON 4. Switch of 1/2/3 is operating within 5 seconds Release mory 1. After switch of set is ON time is passed more than 5 seconds. 2. While switch of seat or switch of outside mirror (manual operati on is set) 3. Ignition switch is OFF
Seat
The characteristic of operation.
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Function of Memory Return Item Operation condition Description Position of selector lever is P and N on condition that, ignition switch is ON Automatic vehicle: P/N or parking brake is ON Manual transmission : parking brake is ON Memory return is operating at the state of stop (vehicle speed : 0 km/h). If position button is operating while memory is returning, memory is returnng as memory is set on before. While memory is returning, button of stop is set, return operation is stoping immediately.
1. 2. 3. 4. 1. 2.
The state of operation: Another condition is set under function of memory is returning
SSANGYONG Y200

The characteristic of operation
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Function of outside mirror(folding /unfolding )
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Function of seat warmer
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SSANGYONG Y200

Power seat Connector and connected circuit NO. A1, A2 A3, A4 B1 B2 B3 B4
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Size / color BW BLACK WB Y GB RG BY GY BR GB
Connected circuit Battery Ground Slide Slide Tilt Tilt Recline Height Height Recline
B5 B6 B7 B11
1 Slide Adjusting Motor 5 Driver Power Seat 2 Height Adjusting Recline Switch Motor 6 Driver Power Seat 3 Tilt Adjusting Motor Switch 4 Recline Adjusting (Slide, Height, Tilt) Motor 7 Seat Heater Control Unit
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SSANGYONG Y200

Seat warmer switch Connected circuit
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Stics Summary Stics which is electron control unit, has the function of sixteen, if stics is unnormal at the sensor or load, unit of stics has self diagnosis.
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SSANGYONG Y200
FUNCTION OF OPERATION AND THE CHARACTERISTIC

Intermittent Wiper of Velocity Induction Type
1. Intermittent wiper of velocity induction type which is linked according to velocity of vehicle, intermittent time is changed automatically a kind of wiper system, this one is controlled by below switch of control. - Auto switch : which is selected to the intermittent mode. - Time control switch of the intermittent : this one control the intermittent time - Intermittent time is set (at 0 km/h ) : 2.6 0.5 sec ~ 18 sec 2 sec 2. After IGN 2 switch is ON , turn auto switch on, or after turn auto switch is ON , turn IGN2 on, immediately, velocity linking mode is operating.
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Washer linking wiper 1. As ignition switch is turning on, if washer switch is ON, after 0.6 second, wiper is operating, after washer switch is OFF, wiper is operating 3 times and then wiper is turned OFF
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2. While the intermittent wiper is operating, washer switch is turned on more than 0.6 seconds and then washer linked wiper is operating, if washer switch is turned between 0.2 and 0.6, such as MIST wiper, wiper is operating only once
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SSANGYONG Y200

Room lamp of light sensitive type 1. As switch of room lamp is set on the position of door is linked operation, release lock switch of driver or lock switch of passenger, turn the switch of ignition (IGN2) OFF , and then open up door, lamp of room is turned on, after door is closed, after 2 seconds, light is ON and then gradually is sensing light, after 3 seconds approximately, should be turned off completely. 2. If switch of ignition (IGN2) is turned ON or lock switch of driver seat or passenger is set free, open up door and then the light is turned on and if door driver seat and passenger are closed, and then,immediately should be turned off (Disregard time of turning on which is less than 0.2 seconds). 3. Capacity of time resolving is more than 32 stem per 1 seconds.
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Power window of time delaying After turn ignition switch (IGN1) OFF, during 30 seconds, switch of power window is operating available and within this time (30 seconds) if door is opened up, from at that time, time is extending for 30 minutes,if door is closed within a time extended, power is OFF.
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Function of defogger timer 1. At state of engine which is operated, if switch of defogger is operated, defogger is operated (12 minutes). 2. Under defogger is operating, if switch of defogger is reoperated, operating is stopped. 3. After operation of defogger is finished, within 10 minutes, again switch of defogger is turned on only once this one is operated for 6 minutes. (except that switch of defogger is turned off ) 4. If ignition switch (IGN2) is OFF or if the VOLT of L terminal of alternator is less than 10 V, operating of defogger is stopped.
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Warning lamp of no wearing seat belt 1. If switch of ignition is turned on, warning lamp of seat belt is lighting on for 6 seconds with 0.6 seconds of frequency duty 50 %, chime bell is sounding for 6 seconds with 0.6 seconds of frequency duty 50 %. 2. Within 6 seconds, if switch of ignition is OFF , chime bell is not operated immediately. Within 6 seconds, if switch of seat belt is OFF , chime bell is not operated immediately, and warning lamp of seat belt is sounding for 6 seconds. 3. After seat belt is worn under ignition is ON , on the every time that seat belt is taken off, chime bell is always operating.
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Warning lamp of parking breake 1. Parking brake is pulling under vehicles stopping, warning lamp is turned ON, under this situation vehicle is running and then speed of vehicle goes up to 3 - 5 km/h or after speed of vehicle goes up more than 5 km/h if parking brake is pulled, lamp of warning should be turned off (After switch of ignition is turned on, after time is passed more than 1.5 seconds, speed of vehicle should be sensed. 2. While switch of IGN 1 is off in the above number 1, warning lamp of brake is OFF 3. While switch of parking brake under the state of OFF , after key of ING 1 is OFF, as switch of ignition is ON, after lighting is four times, and then OFF (During lighting of 4 seconds, if key of ignition is OFF , immediately is turned OFF )
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The waring of operating tail lamp 1. If switch of key reminder is OFF under the state of operating switch of tail lamp, rekes is also not operating. If there is no the vigilance of robbery or the condition of alarm, under this situation, open up door of passenger seat or driver seat, buzzer is ON/OFF repeatedly by the frequency of 0.3 seconds. 2. If one of them is getting out of above 1 description, buzzer should be OFF immediately. At this time, if lock switch of driver seat or passenger seat is locked, unlock relay is operating for 5 seconds at this time,if all the door of driver seat and passenger seat are closed or switch of tail lamp is OFF , relay of unlock is OFF immediately.
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The waring of opening door 1. At state of warning lamp to the door which is opened, if door is opened up, the state of half closing, if velocity of vehicle is more than V1 (3 km/h 5km/h),after speed of velocity is more than V1, the state of half closing or if door is opened up, the lamp of warning should be ON AND OFF repeatedly. (After switch of IGN 1 is ON .,after the time is passing more than 1.5 second, velocity of vehicle should be sensed.)
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SSANGYONG Y200

The warning of not being pulling key out of key hole 1. If the switch of ignition is turned on and then open up the door, chime bell is operating, if nob of door lock is locking, nob is up from the original position, door should get back to the state of unlock. 2. This function should not be operated under the state of IGN 1 switch of BEING TURNED ON. If the key is pulled or door is closed, the signal of operating should be OFF , should be operated prior to warning lamp of NOT BEING TURNED OFF.
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Central locking function 1. If door lock nob of driver seat or passenger seat is downed, all the door are locked, and if door lock nob of driver seat or passenger seat is lifted, all the door are unlocked. If door of driver seat or passenger seat is locked or unlocked by key at the external area, the same situation will be happen.
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SSANGYONG Y200

Function which is linked with rekes 1. If switch of key reminder is OFF , all the door are locked or unlocked according to the signal of rekes 2. If the rekes is unlocked, lock switch of driver seat door is locked, unlock relay of driver seat is ON for 0.5 seconds(multi-function), and then unlock of rekes is operating, relay of unlock is ON for 0.5 seconds. 3. Under the operation of above 2 number, after 0.5 second of operating the unlock relay to the driver seat, lock switch of driver seat door is locked, release function of the multifunction, before battery is ON/OFF , while unlock of rekes is operating, only relay of unlock is operating. After unlock is operating, within 30seconds, if opening of door is not operated, after 30 seconds, door should be locked automatically.
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The alarming of robbery Function of alarming robbery is made a alarming unrecognized method by intruder, which cause buzzer to make a alarming sound and notice to surrounding people, has operating mode as below . 1. set on the situation of vigilance. Setting on the situation of vigilance is available on condition that door is locked by the transmitter of rekes, but if door is locked by key, state of vigilance should not be set. If switch of ignition is removed, under all the door and hood are closed, signal of lock of operation from the receiver of rekes is transferred low speed into high speed, after that, within 0.5 seconds, lock switch of all the door are transferred ON into OFF, after happening of signal, 0.5 seconds later, should be set to the state of vigilance. As the state of robbery vigilance is set on, siren is operating for 0.05 seconds, tail lamp is operating two times for 0.5 seconds.
SSANGYONG Y200

2. operation of alarm After the situation of robbery vigilance is set on, not released the situation of robbery vigilance, with all the door, tail gate and hood are closing, after this situation are going on more than one second, if door, tail gate and hood is opened, alarm should be operating immediately. If only one thing among alarm conditions is satisfied, immediately the operation should begin to start, siren is operating continuously for 27 seconds, after siren,condition of alarming is again satisfied, once again siren is operating continuously for 27 seconds. Under the state of vigilance, if only tail gate is opened by key, the state of vigilance should be set on the regular state of vigilance into secondary state of vigilance.(At this time, proceed alarming as open up tail gate, hood, assist and rear door ) In other words, while not being releasing condition of vigilance, although switch of tail gate is turned on, alarming is not operating, state of closing tail gate is going on more than one seconds, again back to regular state of vigilance, with siren once, tail lamp is ON/OFF two times for 0.5 seconds. Under the operation of alarming, if battery is removed, and then if the battery is installed, state of memory which is previously removed gets back, this state will be operating. 3. set vigilance of robbery free In case switch of driver key cylinder is unlocked or rekes is unlocked, IGN1 OR IGN2 is turned, under the those condition only, should be set vigilance of robbery free.(while alarming of robbery is turned on, turn IGN1, IGN2 ON, relay of start inhibitor is OFF , alarming of robbery is continuously operating for remaining times ) Setting vigilance of robbery free is released by key of driver seat, key of tail gate, unlock of rekes and lock.
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SSANGYONG Y200

Function of auto door lock 1. If switch of IGN is turned ON , and if velocity of vehicle is more than V1(50km/h)all the door is locked automatically,and under this velocity of vehicle, if door is unlocked,but door is automatically locked (after switch of IGN1 is turned, from passing time of 1.5 seconds, velocity should be sensing ) 2. After auto unlock of door is operating, should not operate auto lock of door by velocity of vehicle
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Function of auto unlock of door 1. Under turning ignition switch on, while vehicle is running more than 15km/h, if vehicle has a collision with other vehicle, automatically all the door should be unlocked.(After switch of IGN1 is turned on, and then passing time 1.5 seconds, velocity of vehicle should be sensed.) 2. Auto unlock of door with is operating with average of vehicle velocity which is setting for 8 seconds(While velocity of vehicle is reduced )
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Function of key hole which is illuminated 1. If door is opened under vehicle s stop, as illuminating lamp round key hole, at time of stopping door, is lighting on for 10 seconds, but within 10 seconds, if signal of rekes is operating or if switch is turned ON , should be turned OFF
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SSANGYONG Y200
SELF DIAGNOSIS
Summary
After using the service connector which is installed on the instrument panel of lower driver seat, each failure is diagnosed internal unit of stics, can be checked the state of normal or mode of failure.
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Method to Diagnose
1. While failure is checking, use buzzer 2. While the switch of diagnosis is turned ON , (stics of diagnosis socket box : number 7 and ground 1 is connected), the following operation should not proceed. warning : the first step of light is ON(buzzer is not operating, lock or unlock of door is not operating) warning of seat belt(chime bell is not operating ) warning of key reminder (chime bell is not operating, lock or unlock of door is not operating) central door lock(lock or unlock of door is not operating) 3. While switch of diagnosis is OFF , function of number 2 should get back to original position 4. While switch of diagnosis is ON, data which is diagnosed should output only once 5. If switch is operated by operation of other switch, among them, first input data will be output(buzzer is ON ), and output is OFF for one seconds, and remaining input data is proceeding output.
6. Output of buzzer is as following T1 : 0.3 0.1 seconds T2: 0.3 0.1 seconds T: 0.6 0.2 seconds Notice: If system is diagnosed, switch of diagnosis should be always ON While the diagnosis of system is operated, if system is normal, buzzer is coming out, if system is out of order, buzzer is not coming out.
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SSANGYONG Y200
CHART OF DIAGNOSIS
NO 1 2 3 4 5 6 7 8 9 10 Ignition switch is operating Ignition plus related parts is operated IGN and relay of power window IGN2 : Buzzer,frequency: twice IGN1: Buzzer,frequency: once Power window: buzzer: Three times 11 12 13 Switch parking brake Switch of seat belt Washer switch Buzzer,frequency: once Buzzer,frequency: once Parking of wiper motor: 3 times Switch of washer :once Relay of wiper : twice 14 Wiper auto switch Wiper motor parking: 3times Wiper auto switch; once Relay of wiper : twice 15 16 17 18 IGN, starting plus related parts is operating. Switchof variable volume ALT L Switch of defogger Signal of speed sensor Buzzer, frequency: once Buzzer,frequency: once Buzzer,frequency: once Buzzer,frequency: once Switch of dia gnosis is ON ON Power of battery is supplied Battery plus: related parts is operated Tail gate, rear door lock switch Driver seat door lock switch Passenger seat door lock switch Driver seat door switch Passenger and rear door switch Rekes is operating Switch of key reminder Buzzer,frequency: once Buzzer,frequency: once Buzzer,frequency: once Buzzer,frequency: once Buzzer,frequency: once Buzzer,frequency: once Buzzer,frequency: once Check battery Buzzer,frequency: twice Conditions Switch of diagnosis is Check Confirm 0f beginning to dignose Normal Buzzer,frequency: once Remark
SSANGYONG Y200
REPAIR OF THE SYSTEM

Switch of Outside Mirror
1. Remove upper section of switch (between IP and section of ground ) with driver. Notice: switch is attaching on the upper section
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2. After disconnecting the connector, remove switch assembly. 3. Install the reverse order of removal
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Switch of Center IP
1. After panel of center IP is removed, each switch can be separated. 2. After center panel is removed, disconnect connector 3. Separate each switch from removed panel. 4. Install the reverse order of removal. Notice: While each switch is checked, refer to the following circuit, and then check whether apply an electric current or not, Switch of front fog lamp
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Digital Watch
1. Remove the center panel 2. After releasing fixing screw from the panel, remove the digital watch. 3. After digital watch is fixing on the panel, link the connector, and then install panel on the panel of IP.
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SSANGYONG Y200

Circuit of Digital Watch and Connector
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Switch of Seat Memory

1. Release the fixing screw. 2. Using the (-) driver, like the left picture, separate switch cover of seat memory. 3. After disconnecting the connector, remove the switch. 4. Install the reverse order of removal.
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Diagram of Switch Circuit
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Siren
1. After opening up the hood, disconnect the negative terminal of battery. 2. Disconnect the connector (indicating arrow) of siren. 3. After fixing bolt is released, remove the siren 4. Install the reverse order of removal.
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SSANGYONG Y200
SECTION 9E
BODYS MEASURING DIMENSION

TABLE OF CONTENTS
BodyS Measuring Dimension ............................. 9E-2 Under Body(Frame) ............................................. 9E-2 Frame .................................................................. 9E-3 Side Structure Complete ...................................... 9E-4 Engine Room ....................................................... 9E-6 Windshield And Rear Glass ................................. 9E-7 Tail Gate .............................................................. 9E-8 Chart Of Gap ....................................................... 9E-9 Under Coating ................................................... 9E-11 Body Mounting .................................................. 9E-12
9E-2 BODYS MEASURING DIMENSION
BODYS MEASURING DEMENSION

UNDER BODY(FRAME)
YAD9E010
SSANGYONG Y200
BODYS MEASURING DIMENSION 9E-3
FRAME
YAD9E020
SSANGYONG Y200
9E-4 BODY S MEASURING DIMENSION
SIDE STRUCTURE COMPLETE
YAD9E030
SSANGYONG Y200
BODY S MEASURING DIMENSION 9E-5
YAD9E040
SSANGYONG Y200
ENGINE ROOM
YAD9E050
SSANGYONG Y200
WIND SHIELD AND REAR GLASS
YAD9E060
SSANGYONG Y200
TAIL GATE
YAD9E070
SSANGYONG Y200
CHART OF GAP
YAD9E080
Chart of measuring demension

Position A: B: C: D: E: Control of Measuring Demension 2.2 40 3.0 0.5 4
+1 -0.5 +1 -0.5
Position F: G: H: I: J:
Control of Measuring Demension 2.5 5.0 0.5 3.5 4.9 0.5 5.7 -0
+2
4.5 4.2 Variable
SSANGYONG Y200
YAD9E090
Chart of measuring demension

Position A: B: C: D: E: F: G: Control of Measuring Demension 4 4.0 4.5 4.2 Variable 2.2 4.5 4.5
+1 -0.5 +1 -0 +1 -0 +1 -0.5
Position H: I: J: K: L: M: N:
Control of Measuring Demension

1 4.5 + -0

1 2.2 + -0
5 0.5 3.5
6.5 1
SSANGYONG Y200
UNDER COATING
;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;; ; ; ;;;;;;;;; ;;;;;;;;;
SSANGYONG Y200
YAD9E100
BODY MOUNTING
Mounting Point
YAD9E110
SSANGYONG Y200

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SECTION 0B

0B-2 GENERAL INFORMATION

MAINTENANCE AND REPAIR MAINTENANCE AND LUBRICATION

Fuel Filter Replacement

Spark Plug Replacement

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES

Champion : C11YCC Gap : 0.8 0.1 mm

Spark Plug Wire Replacement

Brake System Service

Engine Oil and Oil Filter Change

Tire and Wheel Inspection and Rotation

Engine Oil Viscosity

Cooling System Service

Air Cleaner Element Replacement

GENERAL INFORMATION 0B-3

OWNER INSPECTIONS AND SERVICES

Engine Coolant Level and Condition

Brake System Operation

Windshield Washer Fluid Level

Exhaust System Operation

AT LEAST TWICE A MONTH

Tires, Wheels and Alignment Operation

Steering System Operation

Fluid Leak Check

AT EACH FUEL FILL

Engine Oil Level

AT LEAST TWICE A YEAR

Brake Master Cylinder Reservoir Level

0B-4 GENERAL INFORMATION

EACH TIME THE OIL IS CHANGED

Movable Head Restraint Operation

Spare Tire and Jack Storage

Key Lock Service

Body Lubrication Service

Exhaust System Inspection

Throttle Linkage Inspection

Engine Cooling System

Engine Drive Belts

Hood Latch Operation

GENERAL INFORMATION 0B-5

STANDARD BOLTS SPECIFICATIONS

0B-6 GENERAL INFORMATION

* ( ): Gasoline engine equipped vehicle

GENERAL INFORMATION 0B-7

4 5 Automatic transmission Gear ratio Model Type

2.742 1.508 1.000 0.708 2.429

0B-8 GENERAL INFORMATION

GENERAL INFORMATION 0B-9

RECOMMENDED FLUIDS AND LUBRICANTS

Change every 3 years. And, inspect and replenish as necessary.

0B-10 GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER SYSTEM

GENERAL INFORMATION 0B-11

Manufacturers Plate Location

0B-12 GENERAL INFORMATION

662 920 1 0 012345

Serial Number 0 : Manual T/M 1 : Hydr - Auto Coupling 2 : Automatic T/M

GENERAL INFORMATION 0B-13 Gasolind Engine (3.2L DOHC)

162 990 1 0 012345