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Trouble Shooting List

1. EA chamber chamber A Bimetal ly bending A moves to 118 working A chamber zi LSS SSS SS 4244242422422 44441 ree e WoW WO SIL AENEAN 2A WE p y SIS SS t AR PAY AP UM a FA UP P Pg og LVR Rotor Rotation NY LALLA LLAALA ALA Added P Ni a tly o ay r s A wu EN E SLAF BLISS pS SRN GN SA Oil Return Hole Cold Start Condition Not engaged Engaged Viscous is engaged by the friction force of viscosity of silicon oil quee IE NARNAANSM NN Cc SsangYong Motor Company DI Engine Cylinder Head Gasket Leakage amp Vehicle Information Symptoms Oil leak from cylinder head gasket Symptom doesn t be cleared with cylinder head gasket amp Troubleshooting Remove cylinder head cover and vacuum pump and then repair the unmatching pace of intake camshaft cap and cylinder head gt Note If there is oil leak around cylinder head gasket on DI eigine firstly check leak from vacuum pump Check the origin of oil leak at engine idle and driving condition using centain developer white material Check Details gt Check and rework procedure of vacuum pump oil leak volumn of oil leak from vacuum pump will be increased at engine driving condition when engine oil pressur reach to maxmimum level about 5 bar Small amount oil leak at engine idle condition is hard to detect If necessary lower the A T mounting parts using lift jack
2. gt Belt Tensioner Operation Principle DOWN Oil Reservoir Expansion Stage UP Oil flow into the Piston through check valve Compression Stage DOWN Oil flow out though oil gap of piston upper to oil reservoir SsangYong Motor Company Updated 2008 06 17 Check Details gt Caution Take care not to damage the rubber bellow of belt tensioner while removal and installation of fan belt using wrench Note There is no functional problem if belt tensioner has more than 50 oil inside In case of fan belt noise check the sysmptom with released ftec mical information ISI O7ENO12 before fan belt replace Water Pump Pulley Pulley Water Pump P No 6642050110 or Water Pump Pulley ey groove and modified SsangYong Motor Company Lack of Engine Power Injector Corrosion amp Vehicle Information Symptoms Engine lack of power at vehicle start off No engine vibration hesitation and noise No DTC amp Repair History Injector back leak test OK Some corrosion on cylinder head by vehicle flooded amp Possible Causes Partly clogged Injector nozzle amp Troubleshooting Replace all 5 Injectors Injection hole Injection hole could be blocked in case of water intrusion into cylinder Injection hole could be blocked by engine oil in case of vehicle turn over No of Injection hole D27DT 5EA D20DT 6EA D27DPT 7EA Recommendation I
3. Note Do not replace EGR vacuum modulator without inspection should check vacuum pressure and find actual reason of problem correctly Cc SsangYong Motor Company Lack of Engine Power Fuel Pipe Leak amp Vehicle Information Symptoms Lack of engine power and poor acceleration amp Possible Causes Fuel leak from fuel return pipe amp Troubleshooting Replace fuel return pipe with new one SsangYong Motor Company Instruction of Belt Tensioner Replace amp Vehicle Information amp Background On the investigation of replaced belt tensioner SYMC figured out the it was replaced by mis diagnosis Please check belt tension according to this instruction guide and DO NOT REPLACE BELT TENSIONER DUE TO OIL CONTAMINATION amp Instruction Check belt tensioner operation and clean oil contamination of belt tensioner housing according to below precedure 1 Remove the fan belt 2 Spray WD40 around contaminated area 3 Wait around 5 minutes 4 Blow the contamination away using compression air Take care not to direct contact compression air into rubber part of belt tensioner 5 Clean up the rubber part with clean cloth 6 Install the fan belt hole VENTILATION HOLE Belt tensionor has ventilation hole to discharge the hot and pressed evaporative oil gas which is generated during operation This oil gas can misjudge as oil leakage if its mixed with dust around Check Details
4. e e 3 P d PWM signal according to combustion condition engine V j 2 gt E i ER Doo ina ane control actuator temperature and so on This lead to a little bit different sound tone at turbo charger operating 2 Operation Principle Engine Status Modulator Duty 9o Vane Control Actuator Vane Passage 0 75 Pulling Narrow Low load amp low rpm Duty Increases Vacuum Applies ee High load amp high rpm 0 45 Return Wide Duty Decrease Vacuum Release C SsangYong Motor Company Precautions when removing and installing Tire Wheel Nut Vehicle Information Symptoms Impossible to remove Tire wheel Nut amp Possible Causes Mounting Bolt and Nut damaged due to inflow inside of bolt nut when removing and installing tire wheel nut amp Troubleshooting 1 Remove metal chip completely before installing Tire wheel Nut 2 Tighten Nut after pre install wheel nut with hand gt Precautions Remove metal chip completely before installing Tire wheel Nut b Picture peu T ome teeth metal chip occurrence SsangYong Motor Company How to check DC5 speed A T DTC code Vehicle Information Symptoms DC5 speed A T Inspection or action per the situation of affairs Inspection or action per the situation of affairs Vehicle State Shifting D3 lt D4 faulty D4 Shifting at below 50 km after indicating D at D3 D4 or D4 D5 shifting point Not displayi
5. Noise come from in right front shock absorber while driving uneven road or depressing brake pedal amp Possible Causes Interference between front coil spring and bracket when vehicle is bounced amp Troubleshooting 1 Check whether coil spring is interfered or not 2 Remove front shock absorber assembly 3 Insert plain washer at upper mounting of shack absorber Interference upper part see the photo 4 Install front shock absorber b Picture zt TUM COIL SPRING 2 INTERFERENCE Dr t Wwe o r A X i fs hd Plain washer install location Plain washer SsangYong Motor Company Coolant temperature rises while driving amp Vehicle Information Symptoms 1 Coolant temperature gauge rises in sudden while driving 2 DTC on ECU H P0644 CAN Cluster error H P0613 TCU CAN data error H P1115 Coolant temperature sensor error 220 J X amp Repair History Engine room wiring replaced Coolant temperature sensor replaced Cluster ground retightened Trouble symtoms remain same amp Troubleshooting Coolant temp sensor check by registance Wring connection between coolant temp sensor and ECU Connector check by eyes C115 ECU connector terminals ECU Pin 101 was defectively connected Intermittent connection failure Check Details P EWD for Actyon D20DT SsangYong Motor Company Cooling Fan Noise at Cold Start amp Vehicle Inform
6. of HP Pump Operation ECU increase curret flow when rail pressure is higher than demand Piston of IMV close orifice and block fuel flow Specifications B Solenoid Control PWM method Normal Open Type B Piston Stroke 1 4 mm B Supply Voltage Battery Voltage B Filter Density 140 m O SsangYong Motor Company Engine Check Lamp Turn ON P0400 Vehicle Information amp Symptoms Engine check lamp turns ON at driving DTC P0400 EGR Control Valve Fault amp Repair History EGR modulator replace Vacuum line check leakage Engine check lamp turns ON again after delect DTC using SCAN 100 at EGR operation condition amp Possible Causes A lot carbon deposit at intake manifold and EGR valve mounting area EGR passage is block almost 90 by carbon amp Troubleshooting Clean the carbon deposit of intake manifold and reinstall EGR Note You could find carbon deposit at intake manifold at the vehicle of over 50 000 km mileage O SsangYong Motor Company Engine Abnormal Noise at Idle Condition amp Vehicle Information Symptoms Engine abnormal noise tapping noise at idling Noise repeart 3 4 second interval at engine idle condtion and noise can be heard minutely at driving Repair History Timing chain and belt tensioner removal amp installation Timing damper removal amp installation Engine acoustic cover removal amp installation Belt water pump pu
7. 5 16 7 8 9 20 2 28 32 33 Ds ermemoeseree entm ohms T s pevoumemwe mmn m sa umo rone wose oy aorarna vanse soooasonoor mm mem OO u pemouneenoeesas ron we ee aeron feronn cwm sr poron case avo w aeoross oror eoeranaoae o reson cwm m pomraeema von eer a remem trennbroseccurns vena ww i enemomesrtnaoxaene Mme mem i psenmpeeser esum ren eere a Ecer mainte osten von eer Intermittent Engine Check Lamp On amp Engine Hesitation Vehicle Information Symptoms 1 Intermittent 1 2 time week engine check lamp turn ON and engine hesitating 2 Engine RPM unstable after starting 3 DTC on ECU P1253 Minimum Rail Pressure Control Malfunction IMV Fault P1259 Too Large High Pressue Fuel in Rain Pressure System amp Repair History Replace HP pump Replace Injectors Replace engine main wiring HP Pump 2nd Injector No 5 again Fuel Sender Check IMV valve at idle Spec 650 mA Actual 710 850 mA Check IMV power line between fuse box and IMV Symptom engine hesitation reproduce while checking the wiring of engine room fuse box amp Troubleshooting Poor contact on C102 Pin no 8 of engine room fuse box Repair the connector pin and symptoms cleared This sysmptom was caused by poor contact of connector pin of IMV power line please check related wiring before fuel system rep
8. O ring part NO 6sb6211089A4 suction pipe suction pipe Gas leakage part i Nol SsangYong Motor Company Noise occurrence when depressing brake pedal fully amp Vehicle Information Symptoms Noise occurrence when depress brake pedal fully amp Possible Causes Being push occurrence between brake pedal return spring and brake pedal bracket when depressing brake pedal fully amp Troubleshooting Attach pad after applying grease between brake pedal return spring and brake pedal bracket gt Picture Hao sieh SsangYong Motor Company Rework case due to diagnosis error regarding brake system amp Vehicle Information Symptoms Same phenomenon occurrence after repairing regarding Intermittently brake problem brake pedal hardness amp Possible Causes Brake badness occurrence by vacuum generation impossible due to boost vacuum hose connecting state bad amp Troubleshooting Check Vacuum pump and Vacuum line Brake boost check 1 stop the engine after idling for 1 2 minutes at this time depress with normally power 1st time distance is big 2nd time pedal distance become shooter better than 1st time 3rd time pedal distance become shorter better than 2nd time at that case is normal 2 At this time depress brake pedal several times in engine stop state after that start engine in brake pedal depressing state at that time if brake pedal down it is no
9. SCAN 100 just disply driving MDP count only you can t see learning count of idle MDP Check Details P Initial MDP learning condition Coolant temp over 60 C Learning time 30 120 seconds considering MDP learning failure After ECU or Injector C3I coding replace Recode C3I code value through SCAN 100 ECU carry out initial MDP learning one time at above condition X if the initial MDP learning is not finished successfully engine makes small vibration at engine is cold SsangYong Motor Company Rework Procedure for DI Engine Oil Pan Leak amp Vehicle Information KYRON ACTYON ACTYON_SUT D20DT ENGINE Symptoms Recently SYMC has been reported field claim of engine oil fan replace on D20DT engine caused by oil leak Especially oil leak from lower area of alternator amp Troubleshooting Spray sealant on engine oil pan and then install the oil fan Notice Do not replace engine oil pan in case of oil leak Do not disassemble the engine by this reason for 4WD model disassemble front axle first Check Details gt REWORK PROCEDURE 1 Disassemble front axle assy for 4WD model don t need to disassembly front model for 2WD model 2 Remove engine oil fan for enough work space 3 Clean up remaining sealant using scraper or brush clean up cylinder block side as well Take care remaining material do not go engine oil pan inside 4 Remove sealant on cylinder block side and then check the g
10. at engine off and driving condition 292 i injec fon Wes Notice Please carry out initialization amp relearning when you replace related component HP Pump E EGR Throttle Body ECU SsangYong Motor Company Engine Noise Come inside Vehicle Vehicle Information amp Symptoms Customer complain engine noise come inside vehicle at idling and driving actual engine noise at idle condition is normal level amp Possible Causes Engine noise come inside vehicle trough hole for rubber seal of hood release cable Rubber seal of target vehicle was deleted because of deck top modificaion Addition wiring for deck top modifi jon b Ay END E LY 3 DRIVER SIDE DASH Notice If the rubber seal of hood release cable should be removed for certain purpose you should block this hole using sealant or something In case of without rubber seal high tone engine noise come inside vehicle 2 3 dB incresing SsangYong Motor Company Engine Power Lack at Accelerating Vehicle Information ACTYON KYRON D20DT ENGINE Symptoms Engine lack of power at re accelerating after accelerating decelerating refer to photo 1 Engine lack of powe at quick accelerating nomal at smooth accelerating refer to photo 2 No DTC or DTC related Intake Air Sensor amp Possible Causes Wiring damage caused by engine running movement Short circuit at decelerating amp Troubleshooting Same sy
11. Trouble Shooting List Subject Remark 1 Intermittent engine check lamp on engine hesitation 2 Cooling Fan Noise at Cold Start 3 DI Engine Cylinder Head Gasket Leakage Turbo Charger Whistle Noise at Accelerating REXTON Il CDPF EGT Sensor Removal Installation Engine Hesitation after First Delivery Rework Procedure for DI Engine Oil Pan Leak Troubleshooting for DI Engine Alternator Noise Installation Notice for Air Cleaner Assembly Modification of DI Fuel Tank Vent Tube DI Engine Cylinder Head Cover Gasket Leakage E EGR amp Throttle Body Initialization Engine Noise Come inside Vehicle Engine Power Lack at Accelerating Engine Check Lamp ON caused by HID Modification Intermittent Engine Not Start Engine Stop Caused by IMV Malfunction Engine Check Lamp Turn ON P0400 Engine Abnormal Noise at Idle Condition Troubleshooting for Compression Pressure Leak 21 Engine Check Lamp ON Vacuum Hose Damage 22 Engine Check Lamp Turn ON P0400 23 Lack of Engine Power Fuel Pipe Leak 24 Instruction of Belt Tensioner Replace 25 Lack of Engine Power Injector Corrosion 26 Turbo Charger Whistle Noise Case 1 Turbo Charger Noise Case 2 Precautions when removing and installing tire wheel nut 29 How to check DC5 speed A T DTC code 30 DC 5 speed A T Limp Home Mode 31 MB 5 speed A T N2 N3 abnormal speed sensor How to distingush T C motor Impossible to change from 4H to 2H 4 5 7 10 11 12 3 4
12. U gt SsangYong Motor Company Engine Stop Caused by IMV Malfunction amp Vehicle Information Symptoms DTC P1253 Minimum Rail Pressure Control Malfunction IMV Fault Engine impossible to start Engine stop just after restarting Engine stop at decelerating amp Possible Causes IMV Malfunction After disconnecting EF5 15A of engine room fuse box engine can start with loud noise you should turn off the engine immediately Unstable engine idle RPM 704 768 RPM normal 736 RPM at hot engine condition Bad fuel is the major cause of IMV malfunction check fuel quality color smell water contamination Recommendation There was some other reason of engine stop except HP Pump problem please diagnose based on symptom through customer interview vehicle speed engine temp RPM engine check lamp noise etc Note X If you disconnect IMV fuse IMV is fully opened and make maximum fuel pressure over 1 000 BAR In case of engine not start after removal and installation of fuel system cylinder head engine main wiring common rail cylinder head cover HP Pump Injector etc run the fuel system at IMV full open condition and let remaining air goes out You should turn off engine immediately after engine start and insert IMV fuse Check Details gt Function of IMV Inlet Metering Valve Function Control the rail pressure by regulating the amount of fuel which is sent to the pumping element
13. and check the origin of oil leak directly 1 Check oil leak of vacuum pump on the naked eyes 2 Check the matching face of intake camshaft cap and cylinder head rF l A e 7 Ss BERBER Spec of matching face gap within 0 03mm Oil leak should be checked firstly SsangYong Motor Company Check Details 3 Replace intake camshaft cap if the gap is more than 4 Check vacuum pump internal roughness specification Remark Do not reuse vacuum pump o ring replace with new one Clean the oil contamination on cylinder head gasket and cylinder block using cleaner Keep the tightening torque of cylinder head camshaft cap 12 for vacuum pump area Tightening Torque Camshaft cap mounting bolt 25 Nm Do not make gab by over tightening C SsangYong Motor Company Turbo Charger Whistle Noise at Accelerating Vehicle Information Symptoms Whistle noise beep sound from turbo charger area at accelerating over 1 500 RPM Noise is gone while VGT vacuum hose is disconnected by hand because of less turbo pressure generation Distinguishable noise tone like high tone beep sound compare to normal operation sound of D20DT VGT turbo charger amp Possible Cause Tubro charger noise caused by gas leakage from turbo charger mounting area and loosened exhaust manifold Residue of gas leakage amp Troubleshooting Retightened 5 exhause manifold and clean the carbon deposit
14. ap between front timing gear case cover and cylinder block if there is gap fix it using sand paper No 600 Check gap SsangYong Motor Company Check Details 5 Spray sealant on engine oil pan like below photo Spray inner hole Don t spray outer hole Note 1 Pay attention to spary sealat circled area as shown above photo Note 2 Sealant Spec DOBO Sealant P No 665 989 50 AO 6 Clean any dirty material like engine oil on matching face of cylinder block and then assemble engine oil pan Keep tightening torque as below i p of zi Y o P j l F I S ey 10Nm f a A _ E z P U Dale DU Lad O G O ird 5 f 7 m 4 SsangYong Motor Company Troubleshooting for DI Engine Alternator Noise amp Vehicle Information Symptoms Turbo charger whistle noise wind noise from engine front side at idle and at engine acceleration condition between 1 200 1 800 RPM like turbo charger sound Noise is gone when vacuum hose of turbo actuator is disconnected amp Possible Causes This is turbo charger normal operation sound VGT air boosting sound and passing sound of exhaust gas VGT type turbo charger used on Actyon Actyon sports Kyron Rexton II models vane inside turbo charger is widen at accelerating and it increase input air volume very quickly In this time turbo charger makes whistle noise whizz Normal opera
15. ation Symptoms Airbag warning lamp on DTC Driver amp Passenger seat pretensioner low high resistance amp Possible Causes Vehicle static electricity by occasion caused seat belt pretentioner resistance error amp Troubleshooting 30 seconds B No Warning lamp Warning lamp on SsangYong Motor Company Electric wiring connection failure DC5 A T Electric Kit Vehicle Information REXTON RODIUS KYRON DC5 A T NENNEN Symptoms Electrical Limp Home Mode Solenoid valve resistance are normal Electrical wiring short open ntermittent driving impossible Shifting shock amp Possible Cause Adaptor plug nut Connection damaged by exterior vibration 7mm nut was stuck by high temperature amp Troubleshooting Check the electric circuit Solenoid Wiring from TCU to plug connector Replace the electric kit P No 20327 00089 SsangYong Motor Company
16. auto ON at Auto mode or turn on head lamp switch ESP warning lamp ON on the vehicle without ESP option 4WD check 4 Low lamp ON on 2WD model Auto curise ON on the vehicle without Auto Cruise option POWER lamp ON regardless of operation of WINTER POWER switch 2 A T LHM gear holding caused by CAN system error 3 Malfunction on electric units SsangYong Motor Company Intermittent Engine Not Start amp Vehicle Information STENGINE O270T DADA Symptoms Engine intermittent not start only engine cranking Engine check lamp turns ON and glow plug warning lamp turns ON Engine could start after 3 4 time cranking repeatly amp Repair History ECU replace Immobilizer antenna replace Main IP wiring replace amp Troubleshooting Engine intermittent not start caused by poor connection of C102 in engine room fuse box Pin 3 amp Pin 4 of C102 was damaged by poor S A Pin 3 ECU power line Jin wd Vit nowe Check Detailsline gt Check details 1 Check all related fuses and relayes 2 Check battery output 12 v at engine main relay Pin 30 and Pin 86 A TAA S If battery power doesn t check l check B is transferred through C102 Pin 3 and C202 Pin 13 3 At IG ON check ECU Pin 9 is grouned At IG ON condition engine main relay operates and battery power is transferred to ECU through Pin 87 and Pin 787a p iena DSL EC
17. eck the related harness for open short and contact 2 Check lock up valve resistance 3 Check Electric KIT 1 Check the related harness for open short and contact 2 Check module pressure valve resistance 3 Check Electric KIT X SsangYong Motor Company How to check when DC 5 speed A T go into Emergency mode amp Vehicle Information E NUN mm NEN NN Renton Kyron Rodius DC AT So Symptoms shifting meter of instrument cluster not display normaly D1 D5 only D display gt Holding for protection A T Emergency mode going into when diagnose with scan 100 P2106 lockup solenoid abnormal P2101 1 2 4 5 Shifting solenoid valve short amp Possible Causes disconnected No7 wiring of C901 connector amp Troubleshooting D Check A T oil quantity Normal 2 Measure resistance of each solenoid valve after disconnecting C901 connector gt normal 3 Measure resisance in TCU connector after connecting C901 connector x when shaking C901 connector No 7 wiring disconnected gt Maintenance quide Iwiring disconnection part Uc Firstly measure resistance in TCU side and then Measure C901 connector Resistance value of A T solenoid valve can be changed highly according to A T inner part temperature Check fully beforehand because You can misjudge A T inside defect above phenomenon x Check TCU sensor data value Scan 100 TCU solenoid supply voltage indicate 3 9 volt when go into A T emerge
18. er of front carrier gear b Picture SsangYong Motor Company How to distingush T C motor Vehicle Information amp Symptoms Comes on 4wd check light Impossible to change 4wd mode amp Possible Causes installed different specification T C motor Troubleshooting omues o 4408 648 006 4423 648 004 Operate 2H 4H 4L 4H 4L 1 distingush marked on the suface of motor How to Distingush distingush marked on connector housing C Part time B TOD gt Picture e Part number ry r English Character O SsangYong Motor Company Impossible to change from 4H to 2H amp Vehicle Information Symptoms Impossible to change 4H 2H while driving amp Possible Causes equipped with another specification tire front equipped Hankook Rear equipped woosung or Kumho Troubleshooting Install Same Tire bland gt Picture HANKOOK FRT KUMHO or Rf WOOSUNG In that case 4WD vehicle power train can be damaged while high speed driving because it is impossible to absorb front rear speed or rotation difference Conversion is delayed due to occurrence Wind up Phenomenon of power train system of transfer case or auto locking hub when changing to 2wd again Tire supplier is 3 front equipped Hankook Rear equipped woosung or Kumho Tire size is same but tire external diameter is different due to manufacture standard tolerance of manufacture compan
19. hen ECU diagnosis TCU signal abnormal history code No TCU trouble code 3 RR RH wheel equipped wheel speed sensor connector verified poor contact gt Occurrence cause If Wheel speed sensor equipped at RR RH wheel occurred vehicle speed error Speed meter of Instrument cluster not operating and Limp Home Mode go into Refer Vehicle not equipped with ABS can not possible to diagnose with scan 100 P vv og Mic m o O SsangYong Motor Company Tightening torque of vehicle lower part amp Vehicle Information Symptoms Noise occurrence while driving amp Possible Causes Loosen Tightening Torque amp Troubleshooting Specified tightening spec REXTON II New KYRON Actyon Actyon Sports 22 kgf m 11 kgf m 10 13 kgf m Refer Service manual gt precautions When tightening chassis part mounting bolt amp nut Tighten with specified torque with torque wrench surely Upper Arm Lower Arm C SsangYong Motor Company REXTON II Air con Gas leakage amp Vehicle Information Rexton II CHASSIS 6862 Symptoms Cold wind not come when using Air conditioner amp Possible Causes Air con Gas leakage at Air con suction hose amp suction pipe amp Troubleshooting 1 Chek if O ring damaged after loosening No 2 Nut 10mm If damaged Replace O ring 2 Loosen No 1 3 Assemble No 1 After assembling No 2 Nut 10mm gt picture Nae ee
20. lace Check Details gt EWD for Rexton II D27DTP IGR G IB1 A22 IGN1 SIG E D27DTP ECU REF SIG 7 1 A48 A33 A82 AS A7 EE E A34 E Br IBB Gr GW BC Bry YW BrW BrR 907 8 ae 9 42 32 M 8 41 27 E DE 22 9 j GY BrB G Br BrB GY BrB EGY BrG GY GV GB Brl BrG 1 5 2 6 4 1 2 2 1 4 2 3 5 tt EE ee oe i L i i it 1 i gs 4 i p 8 L i i P B an E 4 1 1 I Bn d unes DEIN I 1 1 GuuQemuadEUSUEEM EN MG E ERUMES agde DseuEded DGUENGENEEE RE RE RSEN RE US EGR Valve Waste Inlet HFM Sensor Gate Metering Valve Valve SsangYong Motor Company Cooling Fan Noise at Cold Start amp Vehicle Information amp Symptoms Noise like Ue ng U ng from engine room for 2 or 3 minutes after 10 seconds of engine cold start Noise is louder and then disappear when the accel Pedal is pressed a little bit right after engine cold start Engine idle condition noise can be heard easily around engine room then inside vehicle amp Possible Causes Operation Principle This noise is operating sound of viscous clutch at engine cold start condition Noise can be heard temporary because the viscous clutch is engaged duringthe time period for movement of silicon oil from working chamber to storagechamber Especially in case of long time parking silicon oil exists in the working chamberRefer to the operating principle of viscous clutch Storage Working Silicon oil
21. lley and fan removal amp installation amp Possible Causes Lossen timing chain and interference with head cover caused by lower guide rail assembly damage E ecu ee See e o o Q eomoc of Check the sliding rail additionally if engine noise comes again after replacing chain tensioner Check Details gt Check the root cause according to below check procedure step by step 1 Remove chain tensioner and check the tension of timing chain 2 Remove cylinder head cover and check the damage inside head cover especially area which located IN EX camshaft sproket 3 Replace chain tensioner if there is damage mark inside cylinder head cover Tightening Torque of chain tensioner 65 Nm 4 If the noise don t be cleared after new chain tensioner please check damage on guide rails check the engine noise again at idle condition after replacing chain tensioner gt SsangYong Motor Company Troubleshooting for Compression Pressure Leak amp Vehicle Information Symptoms Compression pressure leak with air leaking sound from injection mounting area caused by reuse of injector mounting bolt Symptom happen regardless of engine temperature amp Troubleshooting Remove injectors and clean the injection mounting area using air suction tool and then install the injector with new injector mounting bolt Check Details Injector mounting b
22. move the EGT Sensor Tightening Specification 45 4 5 Nm R x AS ti MEL M ED amp k ate exagonal stopper nut P CDPF E EGT SENSOR Amm hexagon X To Brevet EGT Sensor loosening lock up using stopper bolt gt Caution If the stopper bolt doesn t be removed EGT sensor s bitch can be damaged Take care not to be damaged bending area A of EGT sensor while installation by wrench Keep the tightening torque SsangYong Motor Company Engine Hesitation after First Delivery amp Vehicle Information Symptoms D20DT Engine cylinder balance fault Engine hesitation just after customer delivery at cold engine condition coolant temp less than 60 C D27DT Engine No DTC amp Possible Causes Unfinished initial Idle MDP learning in case of unfinished initial Idle MDP learning there could be engine small hesitation after first delivery x EURO IV model has MDP learning condition at idle condition amp Troubleshooting Keep the engine running at idle condtion more than 1 minute over coolant temp more than 60 9C At idle MDP learning there could be engine noise and vibration Notice Vehicle could be sign off with unfinished Idle MDP learning at winter season because it takes time to increase coolant temp In this case there could be a little engine noise and vibration sfter first delivery Be sure to finish initial idle MDP learning when the ECU or Injector is replaced x
23. mpotm could be happened when HFM sensor disconnected at this time ECU substitute intake air re 1 828 Bar value as internal MAP data and decide engine power IAS GCA 2 00 TB substitution change from 420 to 800 according to E engine RPM n case of wiring damage there is large variation on the value for intake air volume 5 1 000 m stk HFM Sensor value after sensor disconnection ECU substitution at idle condition Request When a customer complaint enigne lack of power check intake air value on SCAN 100 after disconnection sensor connector SsangYong Motor Company Engine Check Lamp ON caused by HID Modification amp Vehicle Information REXTON II EURO IV 52707 OO amp Symptoms Engine check lamp turns ON and lack of power at driving EE Uus UY sp DTC in ECU P1234 VGT Operation Fault BE rrr P213B Abnormal Throttle Control amp Possible Causes Unstable power source caused by HID modification Symptom happens when head lamps turn ON ao o gt Ballast and Bulb Recommendation Check symptom happens whether head lamp turns ON HID High Intensity Discharge consumes a lot current 13 15 A when it turns ON OFF and high frequency waves generated by ballast makes unexptected errors on vehicle CAN system ex Warning lamp of curise control and ABS Check Details gt Symptoms by unauthorized HID modification 1 cluster warning lamps turns ON when head lamp
24. n case of blocked injection hole its very difficult to troubleshooting Can t be detected by Injector back leak test In case of flooded vehicle or vehicle turn over replace all Injector with new one In case of flooded vehicle replace vacuum modulator at the same time O SsangYong Motor Company Turbo Charger Whistle Noise Case 1 amp Vehicle Information Symptoms Wind noise from engine front side intake manifold at accelerating at the vehicle speed of 40 80 km h over 1 500 RPM continuously Distinguishable noise tone compare to normal operation sound of D20DT VGT turbo inlet This noise seems to come from EGR valve side if you seated at driver seat amp Possible Causes gab N Interference noise between turbo charger vacuum actuator and mounting bracket amp Troubleshooting Fixed the interference of mounting bracket with screw driver Remark This noise seems to come from EGR valve side if you seated at driver se In case of poor installation of air clear housing gab caused by poor mou there could be similar whistle noise Check Details gt Field Case Whistle noise from air cleaner housing Symptom Wind noise from engine front side intake manifold at accelerating over 1 500 RPM caused by air cleaning housing leak due to poor workmanship while air cleaner replacement Repair History No result after replacing Tharger EGR valve and Vacuum Modulator several times Possible Cause
25. ncy mode 3 5 volt indicated when NO 7 wiring of C901 connector disconnected gt SsangYong Motor Company MB 5 speed A T N2 N3 abnormal speed sensor amp Vehicle Information Symptoms 1 Speed indicator of Instrument cluster does not display Emergency Mode 2 Intermittently occurrence 1 or 2 time per month Occurrence interval shorten gradually Recovered normally when Key OFF ON 3 TCU Trouble code P0700 TCU signal abnormal 4 Mainly occurrence in car of long driving distance amp Possible Causes x Dust powder Generation due to inside coating peeling off of mission oil cooler pipe Not inner part particular of mission amp Troubleshooting 1 Check A T Oil quantity 2 Check wiring contract condition between TCU and N2 N3 sensor Check C901 connector Adaptor Check Plug Electric Kit wiring 3 Check dust powder on N2 N3 sensor after removing valve body 4 Remove and Clean Foreign particular foreign particular on N2 N3 sensor of Electric KIT and then install valve body and then check normal operation In that case foreign material attached on N2 N3 sensor is magnetism It may cause Sensor malfunction If necessary replace mission filter gt Refer N3 N2 Speed sensor Speed sensor is located in upper part of electric KIT Sensor signal part is installed while keeping equality distance with front carrier gear N3 speed sensor senses sun gear speed of front carrier gear N2 Speed sensor senses the speed of carri
26. ng shifting grade at instrument cluster and impossible driving Emergency mode go into while driving Holding D Impossible vehicle forwading reversing Emergency mode while driving holding D DTC P2503 Faulty recognition of currently selected gear P2500 Invalid transmission gear ratio P2502 Poor gear mesh transmission slip P220A Abnormal speed sensor output P2105 3 4 shift solenoid valve short P2500 Invalid transmission gear ratio P2502 Poor gear mesh transmission slip P2200 T M Oil temperature sensor short P2203 Faulty speed sensor N3 signal P220A Abnormal speed sensor output signal N2 N3 P2100 Defective 1 2 4 5 shift solenoid valve P2106 Defective lockup clutch solenoid valve P2106 Defective lockup clutch solenoid valve Defective modulator pressure solenoid valve P2221 Abnormal T M oil temperature sensor signal Inspection Action 1 Check the related harness for open short and contact 2 Check shift pressure solenoid valve 3 Replace Valve body 1 same After reset in same condition 2 Check Oil quantity 3 Replace valve body 4 Replace A T 1 Check the related harness for open short and contact 2 Adapter Plug Locking not contract 1 T C internal part burned 1 Check the related harness for open short and contact 2 Electric Kit damage 1 Check the related harness for open short and contact 2 Check solenoid resistance 3 Replace Electric KIT Solenoid valve 1 Ch
27. ngine idle and at driving condition 3 Clean developer using cleaner Pee eer ee errr 9p 4 NND OMM j i708 qu X M a THEE E it nm 1 PERPER d w TITTET BEEN AQ 3O 3JUluWpmyxpn a MOO ALL AN SM MUNDI A od X IUD M LSJ i E M CHE Iv J sj o Y P 1 i f SERE M o NM ua Ay M r Spray developer to check oil leak Developer gt SsangYong Motor Company E EGR amp Throttle Body Initialization Vehicle Information RV ALL aLeuRoencnes SS amp Background This is a SCAN 100 update function for EURO IV engine amp Update details New function of INITIALIZATION amp RELEARNING on EURO IV DI engine 1 Rail Pressure Reset To reset ECU relarn value according to HP Pump aging ECU memorize offset valuve to HP Pump performance correction HP Pump max offset value H 50 Nm rm G lon UE DER C A 4 Injector H H Resisi AN Dri 2 Short 85 DIAGNOSTIC TROUBLE CODES 2 EGR Position Relearning To relearn max open position and max close position for E EGR Display DTC in case of incorrect EGR position P1407 8 Fault EGR close open position 5 DIAGNOSTIC TROUBLE EDU 3 Throttle Body Relearning To relearn max open position and max close position for throttle body 482 FAN Drive 1 Short to 7 1 iB Th ernal Short in H In case of incorrect T Body position abnormal tapping eB Inte O SUMA a noise happens
28. of turbo charger Tightening Torque Ex Manifold mounting nut 40 Nm Turbo Charger mounting nut 25 Nm Notice In case of turbo charger noise check the gas leaking from exhaust mounting area frist Do not replace turbo charger without checking gas leakage SsangYong Motor Company Check Details gt In case of turbo charger noise Xx Turbo charger truns about 200 000 RPM while accelerating if there is abnormal operating sound whistle find the root cases with reference to below sample cases 1 Check the intake hose clamp connection of front and rear side of turbo charger Especially air leaking from rubber crack makes abnormal noise 2 Check air cleaner housing bolt connection Intake air leak caused by air cleaner housing positiong problem 3 Exhause gas leak caused by EGR pipe bellow lower area crack Check the carbon deposit of bellow lower area 4 Alternator noise whistle noise while accelerating Check the noise after disconnecting fan belt 5 Exhaust manifold mounting nut and turbo charger mounting nut beep sound while accelerating Retightent mounting nut Replace gasket in case of damage SsangYong Motor Company REXTON II CDPF EGT Sensor Removal Installation Vehicle Information REXTON II D27DTP CDPF amp Background This is a insturction manual for Rexton II CDPF EGT Sensor Check Details gt How to replace CDPF EGT Sensor 1 Loosen the hexagonal stopper bolt 4mm 2 Re
29. olt gt SsangYong Motor Company Engine Check Lamp ON Vacuum Hose Damage amp Vehicle Information amp Symptoms Intermittent engine check lamp turn ON DTC P0400 EGR Control Valve Fault Before vacuum hose interfere amp Possible Causes Vacuum Hose for 4WD locking hub damage by interference with engine acoustic cover EGR out of control by vacuum leakage In case of vacuum leak it effect EGR valve operation firstly amp Troubleshooting Cut out the damaged vacuum hose and reconnect If necessary replace vacuum hose Check Details gt In case of P0400 on Rexton D27DT model check vacuum hose interference and modify hose route if necessary Pull down vaccum hose a little bit and tie up with neighborhood pipe keep some space from engine acoustic cover secure the space more than 10 mm s NU Pull down and tie up f gt SsangYong Motor Company Engine Check Lamp Turn ON P0400 amp Vehicle Information amp Symptoms Engine check lamp turns ON at driving DTC P0400 EGR Control Valve Fault amp Repair History EGR modulator replace EGR valve and EGR vacuum hose replace ECU replace amp Troubleshooting Check EGR vacuum pressure using vacuum gauge Unit 0 9bar 90kPa 675mm Vacuum leak less than 0 5 bar Found 4WD solenoide valve vacuum hose crack Replace damaged vacuum hose vacuum leak mle by hose 4WD SOLENOID VALVE
30. over by hand While installation air cleaner house use only screw driver or electric tool Tightening Torque Air cleaner mousing bolt 5 Nm CAUTION Do not over tighten air clear housing using such as air tool SsangYong Motor Company Modification of DI Fuel Tank Vent Tube amp Vehicle Information KYRON ACTYON ACTYON SUT D20DT ENGINE MEN amp Background This is a modification notice for fuel tank ventilation tube on D20DT engine amp Modification Details ITEM BEFORE AFTER Rotate ventilation hose 90 and make connection to mounting bracket for Changes side of frame fuel tank refer to below photo Change hose size 370 165 mm amp delete mounting clip Vantilation hose is connected to right Photos nsert the ventilation hose into upper hole of fuel tank mounting bracket Fuel Tank Assy 2211009405 Parts Fuel Tank Assy 2211009404 Ventilation Tube 2218009402 Info Ventilation Tube 2218009401 SsangYong Motor Company Check Details gt Effective date by model Effective Date VIN No ACTYON 049664 dint T A ACTYONSPORTS SPORTS Oct 20th 2008 We will inform effective date amp VIN no for eu e SPORTS eee 084772 gt Interchangeability Interchangeability uH between old amp new Should replace ventilation tube os new type together Ventilation Tube Should use correct ventilation tube Check
31. rmal 3 Depress brake pedal While idling at this state stop the engine if pedal height does not variable for 30 seconds it is normal gt Picture SsangYong Motor Company DC A T electric fault amp Vehicle Information Symptoms Indicated D on instrument cluster while driving or start engine again after engine off amp Possible Causes Interference occurrence between wiring and center console lower part amp Troubleshooting 1 When diagnose TCU P2220 T M oil temperature sensor short appeared 2 Check A T OIL gt Normal 3 Check adaptor plug installing state and connector pin gt Normal 4 Check voltage B7 wiring of TCU side oil temperature sensor gt 0 04mV wiring short x B7 wiring basic voltage when KEY ON P N 5V R 1 364V D 1 363V gt picture SsangYong Motor Company Trouble shooting for front hub noise occurrence amp Vehicle Information REXTON KYRON Symptoms When full turning while low speed driving Noise occurrence at Front Huber amp Possible Causes amp Troubleshooting When checking Off A Con Don t confuse Air con compressor operation noise Retighten Front upper arm Lower arm etc Check Noise after removing and installing Tire If same phenomenon occurred Replace retainer ring gt picture SsangYong Motor Company Troubleshooting for front shock absorber amp Vehicle Information Symptoms
32. s Unexpected air input casused by air cleaner housing leak Troubleshooting Reinstall air cleaner housing housing bolt tightening torque 4 2 6 2 Nm Cc SsangYong Motor Company Turbo Charger Noise Case 2 amp Vehicle Information Symptoms Whistle noise beep sound from engine front side at accelerating at the vehicle speed of 40 50 km h between 1 000 2 000 RPM like turbo charager noise Noise can be heard at engine stall test around 1 800 RPM Noise is severe at cold engine than hot engine Normal no noise at engine idle condition Noise is gone when fan belt is removed amp Possible Causes Noise comes from idle pulley bearing amp Troubleshooting Check whether noise is disapperared after removing engine fan belt EEGR valve one by one Also should check clamps and bolts of IN EX hose Noise is gone when RESM fan belt is removed Ki Check Details gt Characteristic of Rexton II D27DPT Turbo Charger 1 Noise Characteristic At accelerating over 1 000 RPM there is whistle sound It means that turbo charger works normally Also at releasing accel Pedal tip out suddenly there would be exhaust harsh sound such as shriring and sould level will be different according to vehicle vw RM variation road condition and engine temp N Before engine warm up sould level could be bigger than hot engine condition e Point Turbo Charger on D27DTP engine is controlled by ECU
33. the part no for fuel tank assy first CAUTIONS If you use new type fuel tank assy in steady of old type fuel tank you should replace ventilation tube with new type part no 22180009402 at the same time SYMC do not allow any modification for fuel system please don t make any changed to rework Don t cut off ventilation tube for voluntary modificaction Other voluntary modification SsangYong Motor Company DI Engine Cylinder Head Cover Gasket Leakage amp Vehicle Information REXTON RODIUS ACTYON KYRON ENGINE NEN Origin of oil leak Symptoms Oil leakage from cylinder head cover pr fag n at 7 ae ot ee gt 7 4 JJ mu At rf 1 Mw A SAKI bt a m lt A After sealant spray on crescretic edge of cylinder head install cylinder head cover Troubleshooting Remove the cylinder head cover and then spray sealant loctite on crescretic seal E Spray sealant loctitie on cylinder N iir Pme ie head cover gasket not to be damaged gt MU MU by the edge of cylinder cover v y ge of cy i Check Details gt Note Spray a small sealant loctite and take care not to flow inside engine Do not replace cylinder head cover by this reason RECHECK OIL LEAKAGE USING CERTAIN DEVELOPER gt How to check oil leak 1 Clean leak oil using certain cleaner WD40 and then spray developer white material around leak area 2 Check oil leak at e
34. ting sound in case of D20DT engine check the sound after disconnecting vacuum hose for turbo charger If there is no sound DO NO REPLACE ALTERNATOR VGT turbo charger operating sound amp Troubleshooting Refer to below check details SsangYong Motor Company Check Details p CHECK PROCEDURE FOR ALTERNATOR NOISE Refer to turbo charger check procedure on service manual No Noise Noise increase Check EGR pipes at electric load condtion No Noise if you remove engine fan belt pulleys including alternator don t rotate REMARK n cas of damaged diaod inside alternator there could be abnormal alternator noise whizz This noise usually get increases at the electric load condtion head lamp warmer etc and also charging voltage is abnormally high SsangYong Motor Company Installation Notice for Air Cleaner Assembly Vehicle Information KYRON ACTYON ACTYON SUT D20DT ENGINE amp Symptoms This is installtion notice for air cleaner assembly Please refer to below work procedure when you replace air cleaner assembly Work Procedure Push air clearner element up down left right side by hand and make tight position inside housing while replacing air cleaner element Do not air cleaner element come off the housing Il TU T Hy V i Tighten the air cleaner housing bolt by numeric order as shown left photo by pushing upper housing c
35. ushing part supply amp Vehicle Information Symptoms Noise occurrence while driving due to TGS lever bearing wear Especially occurrence at that time Mileage 50 000 60 000 km amp Possible Causes TGS lever bearing wear amp Troubleshooting Part number 2029920010 Part Name Bushing No relation DURA lever and BTRA TGS LEVER gt Picture lt TGS LEVER ASS Y gt lt TGS LEVER Bearing Bushing gt SsangYong Motor Company REXTON II Poor shifting amp Vehicle Information REXTON II CHASSIS 3 2101 Symptoms D Poor shifting from 2 speed to 3 speed while driving 2 When shifting from 2 speed to 3 speed Impossible to shift after rasing 3000RPM 4000RPM amp Possible Causes Chassis variant coding error Shift lever coding BTRA amp Troubleshooting D No DTC code 2 A T Oil quantity check Normal 3 Change ECU chassis variant coding BTRA gt DURA gt Picture oz AOF Mos o y 1A A A HT TE aE A HEX SsangYong Motor Company Limp Home Mode by abnormal vehicle speed sensor amp Vehicle Information ACTYON CHASSIS 364001 Symptoms Car derived only Di Limp Home Mode Speed gauge of Instrument cluster not operating 0 km standstill amp Possible Causes Wheel speed sensor connector poor contact amp Troubleshooting D When test driving above phenomenon not reoccur customer complain that occurred intermittently 2 W
36. y Precaution to protect same defect reoccurrence must use same company and same specification tire after checking brand and Tire external diameter SsangYong Motor Company New REXTON under part Noise amp Vehicle Information New REXTON CHASSIS 199007 Symptoms Noise occurrence at the lower part of body when engine start off and D while idling Parking 2 when engine start off 3 when driving uneven road amp Possible Causes Interference noise between steel tube and washer Troubleshooting Insert plane washer to separate steel tube mounting nut 14mm After removing insulator Washer specification 014 5 Plain washer D14 5 Plain washer oro Noise Occurrence part 22 Inset plain washer after disassembling insulator C SsangYong Motor Company 4WD Abnormal amp Vehicle Information Symptoms Impossible to change 2H gt 4H amp Possible Causes Vacuum leakage amp Troubleshooting Refer to the below instruction gt Picture 1 stop the engine While 2wd mode and then remove front left and right tire Remove hose connected in locking hub actuator 2 Check if vacuum is made with vacuum gauge Normal if vacuum keep up approx 30 second 3 Check also if vacuum is maintained in locking hub actuator with vacuum gauge x If minute leakage occurred it may cause clink noise due to poor 4WD engage SsangYong Motor Company TGS LEVER bearing b

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