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Vehicle Maintenance Guide

This document provides information on maintenance and repair for a vehicle, including: - Scheduled maintenance services such as engine oil changes, air filter replacement, fuel filter replacement, and brake inspections. - Owner inspections including checking fluid levels, tire pressure, lights, and leaks that should be performed while operating the vehicle or monthly. - A table of contents listing additional maintenance topics covered on subsequent pages such as standard bolt specifications and vehicle identification numbers.

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100% found this document useful (1 vote)

503 views1,627 pages

Vehicle Maintenance Guide

Uploaded by

Xuân Hùng Nguyễn

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 1627

SECTION 0B

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

MAINTENANCE AND REPAIR

Replace the air cleaner element every.
MAINTENANCE AND
• Gasoline Engine : 60,000 km (36,000 miles)
LUBRICATION • Diesel Engine : 30,000 km (18,000 miles)
Replace the air cleaner more often under dusty
NORMAL VEHICLE USE conditions.
The maintenance instructions contained in the Fuel Filter Replacement
maintenance schedule are based on the assumption
that the vehicle will be used for the following reasons: Replace the engine fuel filter every.

• To carry passengers and cargo within the limitation • Gasoline Engine : 60,000 km (36,000 miles)
of the tire inflation prassure. Refer to “Tire and • Diesel Engine : 45,000 km (24,000 miles)
Wheel” in section 2E. Spark Plug Replacement
• To be driven on reasonable road surfaces and Replace spark plugs with same type.
within legal operating limits.
• Type : BOSCH : F8DC4
BERU : 14F-8DU4
EXPLANATION OF SCHEDULED Champion : C11YCC
MAINTENANCE SERVICES • Gap : 0.8 ± 0.1 mm
The services listed in the maintenance schedule are Spark Plug Wire Replacement
further explained below. When the following Clean wires and inspect them for burns, cracks or other
maintenance services are performed, make sure all damage. Check the wire boot fit at the Distributor and
the parts are replaced and all the necessary repairs at the spark plugs. Replace the wires as needed.
are done before driving the vehicle. Always use the
proper fluid and lubricants. Brake System Service
Engine Oil and Oil Filter Change Check the disc brake pads or the drum brake linings.
Check the pad and the lining thickness carefully.
Always use above the API SH grade or recommended
engine oil. Tire and Wheel Inspection and Rotation
Engine Oil Viscosity Check the tires for abnormal wear or damage. To
equalize wear and obtain maximum tire life, rotate the
Engine oil viscosity (thickness) has an effect on fuel tires. If irregular or premature wear exists, check the
economy and cold weather operation. Lower viscosity wheel alignment and check for damaged wheels. While
engine oils can provide better fuel economy and cold the tires and wheels are removed, inspect the brakes.
weather performance; however, higher temperature
weather conditions require higher viscosity engine oils
for satisfactory lubrication. Using oils of any viscosity Tire Rotation (Left-hand Drive Type)
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 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
Horn Operation the pan fast enough to give a true oil level reading.
Blow the horn occasionally to make sure it works. Check Engine Coolant Level and Condition
all the button locations.
Check the coolant level in the coolant reservoir tank
Brake System Operation and add coolant if necessary. Inspect the coolant.
Be alert for abnormal sounds, increased brake pedal Replace dirty or rusty coolant.
travel or repeated puling to one side when braking. Windshield Washer Fluid Level
Also, if the brake warning light goes on, or flashes,
Check the washer fluid level in the reservoir. Add fluid
something may be wrong with part of the brake system.
if necessary.
Exhaust System Operation
Be alert to any changes in the sound of the system or AT LEAST TWICE A MONTH
the smell of the fumes. These are signs that the system Tire And Wheel Inspection and Pressure
may be leaking or overheating. Have the system in-
Check
spected and repaired immediately.
Check the tire for abnormal wear or damage. Also check
Tires, Wheels and Alignment Operation for damaged wheels. Check the tire pressure when
Be alert to any vibration of the steering wheel or the the tires are cold (check the spare also, unless it is a
seats at normal highway speeds. This may mean a stow-away).
wheel needs to be balanced. Also, a pull right or left Maintain the recommended pressures. Refer to “Tire
on a straight, level road may show the need for a tire and Wheel” is in section 0B.
pressure adjustment or a wheel alignment.
Steering System Operation AT LEAST MONTHLY
Be alert to changes in the steering action. An inspection Lamp Operation
is needed when the steering wheel is hard to turn or Check the operation of the license plate lamp, the head-
has too much free play, or is unusual sounds are lamps (including the high beams), the parking lamps,
noticed when turning or parking. the fog lamps, the taillamp, the brake lamps, the turn
Headlamp Aim signals, the backup lamps and the hazard warning
flasher.
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
AT EACH FUEL FILL for water, oil, fuel or other fluids, after the vehicle has
A fluid loss in any (except windshield washer) system been parked for a while. Water dripping from the air
may indicate a problem. Have the system inspected conditioning system after use is normal. If you notice
and repaired immediately. fuel leaks or fumes, find the cause and correct it at
once.
Engine Oil Level
Check the oil level and add oil if necessary. The best AT LEAST TWICE A YEAR
time to check the engine oil level is when the oil is
warm. Power Steering System Reservoir Level
1. After stopping the engine, wait a few minutes for Check the power steering fluid level. Keep the power
the oil to drain back to the oil pan. steering fluid at the proper level. Refer to Section 6A,
Power Steering System.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back Brake Master Cylinder Reservoir Level
down all the way. Check the fluid and keep it at the proper level. A low
4. Pull out the oil level indicator and look at the oil fluid level can indicate worn disc brake pads which
level on it. may need to be serviced. Check the breather hole in
the reservoir cover to be free from dirt and check for
5. Add oil, if needed, to keep the oil level above the
an open pas-sage.
lower mark. Avoid overfilling the engine, since this
may cause engine damage. Weather-Strip Lubrication
6. Push the indicator all the way back down into the Apply a thin film silicone grease using a clean cloth.
engine after taking the reading.

SSANGYONG Y200
0B-4 GENERAL INFORMATION

EACH TIME THE OIL IS CHANGED AT LEAST ANNUALLY

Brake System Inspection Lap and Shoulder Belts Condition and
This inspection should be done when the wheels are Operation
removed for rotation. Inspect the lines and the hoses Inspect the belt system including: the webbing, the
for proper hookup, binding, leaks, cracks, chafing, etc. buckles, the latch plates, the retractor, the guide loops
Inspect the disc brake pads for wear. Inspect the and the anchors.
rotors for surface condition. Inspect other brake parts,
the parking brake, etc., at the same time. Inspect the Movable Head Restraint Operation
brakes more often if habit or conditions result in On vehicles with movable head restraints, the restraints
frequent braking. must stay in the desired position.
Steering, Suspension and Front Drive Axle Spare Tire and Jack Storage
Boot And Seal Inspection Be alert to rattles in the rear of the vehicle. The spare
Inspect the front and rear suspension and the steering tire, all the jacking equipment, and the tools must be
system for damaged, loose or missing parts, signs of securely stowed at all times. Oil the jack ratchet or the
wear or lack of lubrication. Inspect the power steering screw mechanism after each use.
line and the hoses for proper hookup, binding, leaks, Key Lock Service
cracks, chafing, etc. Clean and inspect the drive axle
Lubricate the key lock cylinder.
boot and seals for damage, tears or leakage. Replace
the seals if necessary. Body Lubrication Service
Exhaust System Inspection Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the
Inspect the complete system (including the catalytic
latches, the glove box and the console doors, and any
converter if equipped). Inspect the body near the
folding seat hardware.
exhaust system. Look for broken, damaged, missing,
or out-of-position parts as well as open seams, holes, Underbody Flushing
loose connections, or other conditions which could Flushing the underbody will remove any corrosive
cause heat buildup in the floor pan or could let exhaust materials used for ice and snow removal and dust
fumes seep into the trunk or passenger compartment. control. At least every spring clean the underbody.
Throttle Linkage Inspection First, loosen the sediment packed in closed areas of
the vehicle. Then flush the underbody with plain water.
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints Engine Cooling System
and throttle cable joints, the intermediate throttle shaft Inspect the coolant and freeze protection fluid. If the
bearing, the return spring at throttle valve assembly, fluid is dirty or rusty, drain, flush and refill the engine
and the accelerator pedal sliding face with suitable cooling system with new coolant. Keep the coolant at
grease. Check the throttle cable for free movements. the proper mixture in order to ensure proper freeze
Engine Drive Belts protection, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
Inspect all belts for cracks, fraying, wear and proper
swollen, or deteriorated hoses. Tighten the clamps.
tension. Adjust or replace the belts as needed.
Clean the outside of the radiator and the air conditioning
Hood Latch Operation condenser. Wash the filler cap and the neck. Pressure
When opening the hood, note the operation of the test the cooling system and the cap in order to help
secondary latch. It should keep the hood from opening en-sure proper operation.
all the way when the primary latch is released. The
hood must close firmly.

SSANGYONG Y200
GENERAL INFORMATION 0B-5

STANDARD BOLTS SPECIFICATIONS

Torque (N•m / Ib-in)
Bolt* Standard Limit
4T 7T 9T 4T 7T 9T
M3 × 0.5 0.5 N•m 0.9 N•m 1.3 N•m 0.7 N•m 1.2 N•m 17 N•m
(4.5 lb-in) (8 lb-in) (12 lb-in) (6.3 lb-in) (11 lb-in) (15 lb-in)
M4 × 0.7 1.2 N•m 2.0 N•m 3.0 N•m 1.6 N•m 2.6 N•m 4.0 N•m
(11 lb-in) (18 lb-in) (27 lb-in) (14 lb-in) (23 lb-in) (36 lb-in)
M5 × 0.8 2.4 N•m 4.0 N•m 5.6 N•m 3.1 N•m 5.2 N•m 7.6 N•m
(22 lb-in) (36 lb-in) (50 lb-in) (28 lb-in) (47 lb-in) (68 lb-in)
M6 × 1.0 4.0 N•m 6.7 N•m 9.7 N•m 5.4 N•m 9.0 N•m 12.7 N•m
(36 lb-in) (60 lb-in) (87 lb-in) (49 lb-in) (81 lb-in) (114 lb-in)
M8 × 1.25 8.6 N•m 15.7 N•m 22.5 N•m 12.7 N•m 20.6 N•m 30.4 N•m
(77 lb-in) (12 lb-in) (17 lb-in) (9 lb-in) (15.2 lb-in) (22 lb-in)
M10 × 1.25 18.6 N•m 32.3 N•m 46.0 N•m 25.5 N•m 42.1 N•m 60.8 N•m
(14 lb-in) (24 lb-in) (34 lb-in) (19 lb-in) (31 lb-in) (31 lb-in)
M10 × 1.5 18.6 N•m 30.4 N•m 44.1 N•m 24.5 N•m 41.2 N•m 58.8 N•m
(14 lb-in) (22 lb-in) (33 lb-in) (18 lb-in) (30 lb-in) (44 lb-in)
M12 × 1.25 34.3 N•m 56.8 N•m 82.3 N•m 45.0 N•m 75.5 N•m 107.8 N•m
(25lb-in) (42 lb-in) (61 lb-in) (33 lb-in) (56 lb-in) (80 lb-in)
M12 × 1.75 32.3 N•m 53.9 N•m 77.4 N•m 43.1 N•m 71.5 N•m 98.0 N•m
(24 lb-in) (40 lb-in) (57 lb-in) (32 lb-in) (53 lb-in) (73 lb-in)
M14 × 1.5 54.0 N•m 89.2 N•m 127.4 N•m 71.6 N•m 117.6 N•m 166.6 N•m
(40 lb-in) (66 lb-in) (94 lb-in) (53 lb-in) (87 lb-in) (123 lb-in)
M16 × 1.5 81.3 N•m 107.8 N•m 196.0 N•m 107.8 N•m 186.2 N•m 264.6 N•m
(60 lb-in) (80 lb-in) (145 lb-in) (80 lb-in) (138 lb-in) (196 lb-in)
M18 × 1.5 117.6 N•m 196.0 N•m 284.2 N•m 156.8 N•m 264.6 N•m 372.4 N•m
(87 lb-in) (145 lb-in) (210 lb-in) (116 lb-in) (196 lb-in) (276 lb-in)
M20 × 1.5 166.6N•m 274.4 N•m 392.0 N•m 215.6 N•m 362.6 N•m 519.4 N•m
(123 lb-in) (203 lb-in) (290 lb-in) (160 lb-in) (268 lb-in) (384 lb-in)
M22 × 0.5 225.4N•m 372.4 N•m 529.2 N•m 294.0 N•m 490.0 N•m 705.6 N•m
(167 lb-in) (276 lb-in) (392 lb-in) (218 lb-in) (362 lb-in) (522 lb-in)
M24 × 1.5 284.2 N•m 480.2 N•m 686.0 N•m 382.2 N•m 637.0 N•m 921.2 N•m
(210 lb-in) (355 lb-in) (508 lb-in) (283 lb-in) (471 lb-in) (682 lb-in)
M24 × 2.0 274.4 N•m 460.6 N•m 666.4 N•m 372.4 N•m 617.4 N•m 891.8 N•m
(203 lb-in) (341 lb-in) (493 lb-in) (276 lb-in) (457 lb-in) (660 lb-in)

*Diameter X pitch in millimeters

YAA0B020

SSANGYONG Y200
0B-6 GENERAL INFORMATION

BASIC SPECIFICATION
DIMENSION

* ( ): Gasoline engine equipped vehicle YAA0B030

SSANGYONG Y200
GENERAL INFORMATION 0B-7

SPECIFICATIONS

Systems Items Diesel Gasoline G32D (G23D)

General Overall length (mm) 4,270 4,745
Overall width (mm) 1,870 ←
Overall height (mm) 1,760 1,780
Gross vehicle weight (kg) AT : 2405,
2415
MT : 2365
Curb weight (kg) AT : 1950,
-
MT : 1910
Min. turning radius (m) 5.6 ←
Ground clearance (mm) 200 ←
Fuel Diesel Gasoline
Fuel tank capacity 80 L ←
Engine Model OM662LA M162 (M161)
No. of cyl./Compression ratio 5 / 22 : 1 6 / 10 : 1
Total displacement 2,874 cc 3,199 cc
Camshaft arrangement SOHC DOHC
Max. power 120 ps / 4,000 rpm 220 ps / 6,000 rpm
Max. torque 25.5 kg.m / 2,400 rpm 31.9 kg.m / 3,000 rpm
Injection timing BTDC 18° ± 1.0° BTDC 8°
Idle speed 770 ± 50 rpm 770 ± 50 rpm
Cooling system Water-cooled/forced circulation ←
Coolant capacity 10.5 L ~ 11 L 11.3 L ~ 11.5 L
Lubrication Gear pump, forced circulation ←
Max. oil capacity 8.9 L 9.8 L
Turbo charger and cooling type Turbo charger, air-cooled -
Manual Type Remote control,
←
transmission floor change type
Gear ratio 1st 3.969 ←
2nd
2.341 ←
3 rd
1.457 ←
4 th
1.000 ←
5 th
0.851 ←
Rev. 3.705 ←
Automatic Model Electronic ←
transmission Type Floor change type ←
Gear ratio 1 st
2.742 ←
2nd
1.508 ←
3 rd
1.000 ←
4 th
0.708 ←
Rev. 2.429 ←

SSANGYONG Y200
0B-8 GENERAL INFORMATION

SPECIFICATIONS (Cont’d)

Systems Items Diesel Gasoline G32D (G23D)

Transfercase Model Part-time Full-time (Part-Time)
Type Planetary gear type ←
Gear ratio High 1.000 : 1 ←
Low 2.483 : 1 ←
Clutch Type Hydraulic
Torque converter
[A/T: Torque converter]
Disc type Dry single diaphragm type
[A/T: 3 elements 1 stage 2 3 elements 1 stage 2 phases
phases]
Power Type Rack and pinion ←
steering Steering angle Inner 36°17′ ←
Outer 32°40′ ←
Front axle Drive shaft type Ball joint type ←
Axle housing type Build-up type ←
Rear axle Drive shaft type Semi-floating type ←
Axle housing type Build-up type ←
Brake Master cylinder type Tandem type ←
Booster type Vacuum booster ←
Type Front Disc ←
Rear Drum (Disc) Disc (Drum)
Suspension Parking brake Cable type (internal expansion) ←
Front Wishbone + Coil spring ←
Rear 5-link + Coil spring ←
Air Refrigerant R134a ←
conditioner Compressor type Vane type ←
Electrical Battery type/Capacity (V-AH) MF / 12 - 90 MF / 112 - 75
Starter capacity (V-kW) 12 - 2.2 12 - 1.8
Alternator capacity (V-A) 12 - 75 (12 - 90) 12 - 115

SSANGYONG Y200
GENERAL INFORMATION 0B-9

RECOMMENDED FLUIDS AND LUBRICANTS

Usage Specification Service interval Capacity (L)

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

SSANGYONG Y200
0B-10 GENERAL INFORMATION

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.

SSANGYONG Y200
GENERAL INFORMATION 0B-11

MANUFACTURER’S PLATE

1 Type Approval No.

2 Vehicle Identification No.

YAA0B050

Manufacturer’s Plate Location

Gasoline Engine

YAA0B060

Diesel Engine

YAA0B070

SSANGYONG Y200
0B-12 GENERAL INFORMATION

ENGINE NUMBER
Diesel Engine

662 920 1 0 012345

Serial Number

0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M

0 : Common
YAA0B080
1 : Left - Hand Drive
2 : Right - Hand Drive
The engine number is stamped on the cylinder block
in front of injection pump.
5 : REXTON

910 :Non-Intercooler Engine

920 :Intercooler Engine

661 : 2299cc
662 : 2874cc

YAA0B090

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

0 : Common
YAA0B100
1 : Left - Hand Drive
2 : Right - Hand Drive
• The engine number is stamped on the lower rear
side of the alternator.
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.

SSANGYONG Y200
0B-14 GENERAL INFORMATION

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

YAA0B130 YAA0B140

Using Jack

YAA0B150 YAA0B160

Rearward of Front Tire Forward of Rear Tire

SSANGYONG Y200
SECTION 1

ENGINE
SECTION 1A

ENGINE GENERAL INFORMATION

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

DESCRIPTION AND OPERATION

CLEANLINESS AND CARE major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
An automobile engine is a combination of many harness or other electrical parts.
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of ON-ENGINE SERVICE
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating Caution: Disconnect the negative battery cable
of enigne oil should be applied to friction areas during before removing or installing any electrical unit,
assembly, to protect and lubricate the surfaces on or when a tool or equipment could easily come in
initial operation. Proper cleaning and protection of contact with exposed electrical terminals.
machined surfaces and friction areas is part of the Disconnecting this cable will help prevent personal
repair procedure. This is considered standard shop injury and damage to the vehicle. The ignition must
practice even if not specifically stated. also be in LOCK unless otherwise noted.
Whenever valve train components are removed for
Notice: Any time the air cleaner is removed, the intake
service, they should be kept in order. They should be
opening should be covered. This will protect against
installed in the same locations, and with the same
accidental entrance of foreign material, which could
mating surfaces, as when they were removed.
follow the intake passage into the cylinder and cause
Battery cables should be disconnected before any extensive damage when the engine is started.

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-3

COMPONENT LOCATOR
M162 ENGINE
Front View

YAD1A010

1 HFM Sensor 12 Intake Manifold

2 Intake Air Duct 13 Connecting Rod
3 Resonance Flap 14 Exhaust Manifold
4 Cylinder Head Cover 15 Crankshaft
5 Exhaust Camshaft 16 Engine Mounting Bracket
6 Intake Camshaft 17 Starter
7 Cylinder Head 18 Crankcase
8 Spark Plug Connector 19 Oil Pump Sprocket
9 Valve Tappet 20 Oil Strainer
10 Injector 21 Oil Pan
11 Exhaust Valve 22 Drain Plug

SSANGYONG Y200
1A-4 ENGINE GENERAL INFORMATION

Side View

YAD1A020

23 Camshaft Adjuster 27 Oil Pump Drive Chain

24 Cooling Fan and Viscous Clutch 28 Oil Return Pipe
25 Piston 29 Timing Chain
26 Flywheel of Drive Plate 30 Oil Pump

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-5

M161 ENGINE
Front View

YAD1A030

1 HFM Sensor 12 Intake Manifold

2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coil 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan

SSANGYONG Y200
1A-6 ENGINE GENERAL INFORMATION

Side View

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YAD1A040

23 Camshaft Adjuster 29 Oil Pump Drive Chain

24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-7

DIESEL ENGINE
Front View

YAD1A050

SSANGYONG Y200
1A-8 ENGINE GENERAL INFORMATION

Side View

YAD1A060

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-9

DIAGNOSTIC INFORMATION AND PROCEDURE

OIL LEAK DIAGNOSIS Black Light and Dye Method
Most fluid oil leaks are easily located and repaired by A dye and light kit is available for finding leaks, Refer
visually finding the leak and replacing or repairing the to the manufacturer's directions when using the kit.
necessary parts. On some occasions a fluid leak may 1. Pour the specified amount of dye into the engine
be difficult to locate or repair. The following oil fill tube.
procedures may help you in locating and repairing 2. Operate the vehicle normal operating conditions
most leaks. as directed in the kit.
Finding the Leak 3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
1. Identify the fluid. Determine whether it is engine the source.
oil, automatic transmission fluid, power steering
fluid, etc. Repairing the Leak
2. Identify where the fluid is leaking from. Once the origin of the leak has been pinpointed and
2.1 After running the vehicle at normal operating traced back to its source, the cause of the leak must
temperature, park the vehicle over a large be determined in order for it to be repaired properly.
sheet of paper. If a gasket is replaced, but the sealing flange is bent,
2.2 Wait a few minutes. the new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
2.3 You should be able to find the approximate
leak, check for the following conditions and correct
location of the leak by the drippings on the
them as they may cause a leak.
paper.
3. Visually check around the suspected component. Gaskets
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas • The fluid level/pressure is too high.
that are hard to reach. • The crankcase ventilation system is malfunctioning.
4. If the leak still cannot be found, it may be • The fasteners are tightened improperly or the
necessary to clean the suspected area with a threads are dirty or damaged.
degreaser, steam or spray solvent. • The flanges or the sealing surface is warped.
4.1 Clean the area well. • There are scratches, burrs or other damage to the
4.2 Dry the area. sealing surface.
4.3 Operate the vehicle for several miles at • The gasket is damaged or worn.
normal operating temperature and varying • There is cracking or porosity of the component.
speeds. • An improper seal was used (where applicable).
4.4 After operating the vehicle, visually check the
suspected component. Seals
4.5 If you still cannot locate the leak, try using • The fluid level/pressure is too high.
the powder or black light and dye method. • The crankcase ventilation system is malfunctioning.

Powder Method • The seal bore is damaged (scratched, burred or

nicked).
1. Clean the suspected area.
• The seal is damaged or worn.
2. Apply an aerosol-type powder (such as foot
powder) to the suspected area. • Improper installation is evident.

3. Operate the vehicle under normal operating • There are cracks in the components.
conditoins. • The shaft surface is scratched, nicked or damaged.
4. Visually inspect the suspected component. You • A loose or worn bearing is causing excess seal
should be able to trace the leak path over the white wear.
powder surface to the source.

SSANGYONG Y200
1A-10 ENGINE GENERAL INFORMATION

COMPRESSION PRESSURE TEST (GASOLINE ENGINE)

YAD1A070

1 Compression Pressure Tester 3 Adaptor

2 Diagram Sheet 4 Sealing Cone

Standard Service Data

Application M162 Engine M161 Engine
Compression Ratio 10 : 1 10.4 : 1
Normal Engine Temperature 80 °C (176 °F) ←
Normal Compression Pressure Min. 10 bar, Max. 14 bar Min. 11 bar, Max. 15 bar
Permissible Pressure Difference Between Individual
Max. 1.5 bar ←
Cylinders

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-11

Tools Required 5. Crank the engine approx. eight revolutions by

001 589 76 21 00 Compression Pressure Tester using the start motor.
119 589 01 09 00 Spark Plug Wrench 6. Compare the measurements of compression
pressure tester 001 589 76 21 00 with the
Measuring Procedure specifications.
1. Warm the engine up to normal operating 7. Measure the compression pressure of the other
temperature. cylinders in the same way.
2. Remove the spark plugs using the spark plug 8. If measured value is not within the specifications,
wrench 119 589 01 09 00. perform the cylinder pressure leakage test.
3. Place the diagram sheet to compression pressure Notice:
tester 001 589 76 21 00. • Discharge the combustion residues in the
4. Connect the adaptor to compression pressure cylinders before testing the compression
tester 001 589 76 21 00 and install it into the spark pressure.
plug hole. • Apply the parking brake before cranking the
engine.

SSANGYONG Y200
1A-12 ENGINE GENERAL INFORMATION

COMPRESSION PRESSURE TEST (DIESEL ENGINE)

YAD1A080

1 Test Adaptor 3 Compression Pressure Tester

2 Flexible Connector

Standard Service Data

Compression Ratio 22 : 1
Normal Engine Temperature 80 °C (176 °F)
Normal Compression Pressure 28bar
Minimum Compression Pressure Approx.18bar
Permissible Pressure Difference Between Individual
Max. 3bar
Cylinders

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-13

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.
YAD1A090
3. Install the test adapter (1) and connect the flexible
connector (2) to the compression pressure tester
001 589 76 21 00.

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.

SSANGYONG Y200
1A-14 ENGINE GENERAL INFORMATION

CYLINDER PRESSURE LEAKAGE TEST (GASOLINE ENGINE)

YAD1A110

1 Engine Oil Filler Cap 3 Cylinder Pressure Leakage Tester with

2 Vibration Damper Connecting Hose

Permissible Pressure Leakage

At Whole Engine Max. 25 %
At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %

Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark (M162 Engine) OT (TDC) a (120 °) b (240 °)
Cylinder Number 1, 6 2, 5 3, 4
TDC Mark (M161 Engine) OT (TDC) UT (BDC 180 °)
Cylinder Number 1, 4 2, 3

Universal Tool
Cylinder Pressure Leakage Tester Bosch, EFAW 210A
Sun, CLT 228

SSANGYONG Y200
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 • M161 Engine: 1 - 3 - 4 - 2
11. Compare the leakage pressure with the
specifications.

YAD1A130

SSANGYONG Y200
1A-16 ENGINE GENERAL INFORMATION

CYLINDER PRESSURE LEAKAGE TEST (DIESEL ENGINE)

YAD1A140

1 Connector 3 Connection Hose

2 Connection Piece

Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80°C)

At Whole Engine Max. 25 %
At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %

Universal Tools
Cylinder Pressure Leakage Tester Bosch, EFAW 210 A or Sun CLT 228
Connection Piece Bosch order no. 1 687 010 016

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-17

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.
12. Do pressure leakage test for the remaining
cylinders according to the firing order.
• firing order: 1-2-4-5-3
13. Remove the tester.
14. Close the coolant reservoir cap and oil filler cap.
15. Install the air cleaner element and cover.
16. Install the fuel injection nozzle.

SSANGYONG Y200
1A-18 ENGINE GENERAL INFORMATION

GENERAL DIAGNOSIS

Condition Probable Cause Correction

Hard Starting Malfunction of • Faulty fuse. • Replace the fuse.
(With normal Ignition System
cranking) • Faulty spark plug. • Clean, adjust the plug gap or
replace.
• Electric leakage at the high • Replace the cable.
tension cable.
• Poor connection of the high • Replace the cable or wires.
tension cable or lead wires.
• Improper ignition timing. • Adjust the ignition timing.
• Faulty ignition coil. • Replace the ignition coil.
Malfunction of • Lock of fuel in the fuel tank. • Feed the fuel.
Fuel System
• Dirty or clogged fuel filter. • Replace the filter.
• Clogged fuel pipe. • Clean the fuel pipe.
• Malfunction of the fuel pump. • Replace the fuel pump.
• Malfunction of the fuel injector. • Replace the injector.
• The foreign material in the fuel • Clean the fuel tank.
tank.
Decline of • Poor tightening spark plug. • Tighten to the specified torque.
Compression Compression
Pressure
• Cracked cylinder head gasket. • Replace the gasket.
• Inadequate the valve clearance. • Adjust the clearance.
• Leakage of the valve clearance. • Repair the valve.
• Interference of the valve stem. • Replace the valve or the valve
guide.
• Low elasticity or damage of the • Replace the valve spring.
valve spring.
• Abnormal interference of • Replace the piston ring.
pistons and cylinders.
• Excessive wear of pistons, • Replace the ring or the piston
rings, or cylinders. and boring or replace the
cylinder.
Others • Broken timing belt. • Replace the belt.
• Loosening, damage or leakage • Connect the hose correctly or
of the vacuum hose. replace it.
• Leakage of intake system. • Replace intake system.

Engine Noise Valve Noise • Inadequate valve clearance • Adjust the valve clearance.
• Abrasion of valve stem or • Replace the valve stem or the
guide. guide.
• Weak valve spring. • Replace the spring.
Piston, Ring, • Abrasion of the piston, the ring • Boring the cylinder or replace
Cylinder Noise or the cylinder. the piston, the ring or the
cylinder.
Connecting • Abrasion of the connecting rod • Replace the bearing.
Rod Noise bearing.
• Loosened the connecting rod • Tighten to the specified torque
nut.
Crankshaft • Abrasion of the crankshaft • Replace the bearing.
Noise bearing.
• Abrasion of the crankshaft • Grind or replace the crankshaft
journal. journal.
• Loosened bearing cap bolt. • Tighten to the specified torque.

• Excessive clearance of the • Adjust or replace.

crankshaft thrust bearing.
• Low oil pressure. • Refer to “Page 1A-21” in this
section.

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-23

SPECIFICATIONS
ENGINE SPECIFICATIONS
Application M162 Engine M161 Engine Diesel Engine
Engine Model M162.990 M161.970 Four-Stroke Diesel
Displacement (CC) 3199 2295 2874
Cylinder (Bore x Stroke) (mm) 89.9 x 84.0 90.9 x 88.4 89 x 92.4
PES 5 M55
Fuel Injection / Ignition System MSE 3.63D MSE 3.53D
C320 RS 168
Compression Ratio 10 : 1 10.4 : 1 22 : 1
Number of Cylinders 6 4 5
Camshaft Valve Arrangement DOHC DOHC SOHC
Camshaft Drive Type Chain-Driven ← ←
Max. Output (ps/rpm) 220 / 6000 149 / 5500 120 / 4000
Max. Torque (kg•m/rpm) 31.6 / 3900 22.4 / 4000 25.5 / 4000
Firing Order 1-5-3-6-2-4 1-3-4-2 1-2-4-5-3
Distributorless
Ignition Type ← -
Double Ignition
Ignition Timing BTDC 8° BTDC 6° ± 2° BTDC 18° ± 10°
Valve Timing Intake Open/ ATDC 11° / ATDC 13.15° / ATDC 11.33° /
Close ABDC 34° ABDC 13.57° ABDC 17°
Exhaust Open/ BBDC 31° / BBDC 16.58° / BBDC 28° /
Close BTDC 14° BTDC 17.05° BTDC 15.25°
Valve Clearance Adjustment Automatic Control ← ←
Idle Speed (rpm) 700 ± 50 750 ± 50 720 - 820
Fuel Injection Pressure (kg/cm²) 3-4 3.2 - 4.2 138 - 146
Oil Capacity (liter) 8.2 7.5 8.0 - 9.5
Lubrication Type Forced by Gear Pump ← ←
Full Flow with Combined Full-Flow and
Oil Filter Type
Paper Filter ← Partial Flow Filter
Fuel Unleaded Gasoline ← Diesel

MSE : Engine Control Module

3.63D : 6 Cylinder Version
3.53D : 4 Cylinder Version

SSANGYONG Y200
1A-24 ENGINE GENERAL INFORMATION

PERFORMANCE CURVE
M162 Engine

YAD1A160

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-25

M161 Engine

YAD1A170

SSANGYONG Y200
1A-26 ENGINE GENERAL INFORMATION

Diesel Engine

YAD1A180

SSANGYONG Y200
ENGINE GENERAL INFORMATION 1A-27

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

001 589 76 21 00
001 589 73 21 00
Compression Pressure
Hand Vacuum Pump
Tester

YAD1A190 YAD1A210

120 589 02 09 00
610 589 65 09 00
Spark PlugWrench
Socket

YAD1A220 YAD1A200

SSANGYONG Y200
SECTION 1B1

M162 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
otherwise noted.

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

SSANGYONG Y200
1B1-2 M162 ENGINE MECHANICAL

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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

Removal & Installation Procedure

1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice

Tightening Torque 28 - 47 N•m

(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
9 - 11 N•m
Tightening Torque
(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

SSANGYONG Y200
1B1-4 M162 ENGINE MECHANICAL

9. Loosen the cylinder block drain plug and then drain

the coolant completely.
Installation Notice
Tightening Torque 30 N•m (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
M162 ENGINE MECHANICAL 1B1-5

13. Remove the hydraulic pipe of power steering.

Installation Notice
40 - 50 N•m
Tightening Torque
(30 - 37 lb-ft)

Completely drain the oil.

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

SSANGYONG Y200
1B1-6 M162 ENGINE MECHANICAL

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

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-7

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

SSANGYONG Y200
1B1-8 M162 ENGINE MECHANICAL

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
54 - 68 N•m
Tightening Torque
(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
Upper : 70 N•m (52 lb-ft)
Tightening Torque
Lower : 38 N•m (28 lb-ft)

YAD1B200

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-9

34. Carefully separate the engine assembly from the

vehicle.
35. Installation should follow the removal procedure
in the reverse order.

YAD1B210

SSANGYONG Y200
1B1-10 M162 ENGINE MECHANICAL

POLY V-BELT AND TENSIONING DEVICE

POLY V - BELT
Preceding Work : Removal of cooling fan

YAD1B330

1 Poly V-belt 2 Belt Tensioning Pulley

Removal & Installation Procedure

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)
2. Remove the poly v-belt.
Notice: Check the belt for damage and tensioning
pulley bearing point for wear and replace them if
necessary.
YAD1B250 3. Install the belt by turning the nut of tensioning
pulley clockwise.

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-11

Poly V-Belt Arrangement

YAD1B340

1 Belt Tensioning Pulley 5 Generator Pulley

2 Crankshaft Belt Pulley 6 Idler
3 A/C Compressor Pulley 7 Power Steering Pump Pulley
4 Cooling Fan Pulley 8 Cooling Fan and Water Pump Pulley

SSANGYONG Y200
1B1-12 M162 ENGINE MECHANICAL

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
M162 ENGINE MECHANICAL 1B1-13

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

SSANGYONG Y200
1B1-14 M162 ENGINE MECHANICAL

TENSIONING DEVICE
Preceding Work : Removal of poly v-belt

YAD1B350

1 Belt (L = 2245) 3 Water Pump Pulley

2 Bolt Combi (M8 x 14, 3 pieces) + Washer 4 Nut
........................... 22.5-27.5 N•m (16.6-20.3 lb-ft) 5 Belt Tensioning Pulley

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-15

Removal & Installation Procedure

1. Remove the poly v-belt.
2. Remove the tensioning pulley by turning its
mounting nut counter clockwise as shown in figure.
Installation Notice
40.5 - 49.5 N•m
Tightening Torque
(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 26 - 32 N•m (19 - 24 lb-ft)
YAD1B360

5. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200
1B1-16 M162 ENGINE MECHANICAL

CRANK CASE AND CYLINDER HEAD

CRANKCASE VENTILATION SYSTEM

YAD1B220

1 Crankcase 13 Intake Air Duct (Cross Pipe)

2 Air Admission Port in Crankcase 14 Cylinder Head Cover
3 Oil Drain Port 15 Oil Separator
4 Filter 16 Oil Separator
5 Gasket 17 Air Admission and Vent Connection
6 A/C Bracket 18 Air Admission and Vent Connection
7 Oil Drain Pipe 19 Throttle Valve
8 Oil Pan 20 Vent Line
9 Air Admission Line
10 Vent Line A Fresh Air
11 Restriction Hole (Diameter = 2 mm) B Blowby Gas in Partial Load
12 Intake Manifold 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).

SSANGYONG Y200
1B1-18 M162 ENGINE MECHANICAL

GENERATOR

YAD1B230

1 Nut (M8) .............22.5-27.5 N•m (16.5-20.5 lb-ft) 4 Bolt (M8 x 70, 1 piece)
2 Bolt (M8 x 30, 3 pieces) ........................... 22.5-27.5 N•m (16.5-20.5 lb-ft)
........................... 22.5-27.5 N•m (16.5-20.5 lb-ft) 5 Bolt (M8 x 75, 1 piece)
3 Bolt (M8 x 40, 1 piece) ........................... 22.5-27.5 N•m (16.5-20.5 lb-ft)
........................... 22.5-27.5 N•m (16.5-20.5 lb-ft)

Removal & Installation Procedure

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)

4. Installation should follow the removal procedure

in the reverse order.

YAD1B240

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-19

POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud

YAD1B5A0

1 Vent Hose 8 A/C Bracket

2 Bolt (M8 x 91, 2 pieces) 9 Gasket.................................................... Replace
........................... 22.5-27.5 N•m (16.5-20.5 lb-ft) 10 Bracket
3 Power Steering Pump 11 Bolt (M8 x 22, 2 pieces)
4 Bolt (M8 x 105, 4 pieces) ........................... 22.5-27.5 N•m (16.5-20.5 lb-ft)
........................... 22.5-27.5 N•m (16.5-20.5 lb-ft) 12 Tensioning Pulley
5 Washer 13 Nut ..................... 40.5-49.5 N•m (29.9-36.5 lb-ft)
6 A/C Compressor
7 Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces)
........................... 22.5-27.5 N•m (16.5-20.5 lb-ft)

SSANGYONG Y200
1B1-20 M162 ENGINE MECHANICAL

Removal & Installation Procedure

1. Remove the belt tensioning pulley.
Installation Notice
40.5 - 49.5 N•m
Tightening Torque
(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
22.5 - 27.5 N•m
Tightening Torque
(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
M162 ENGINE MECHANICAL 1B1-21

5. Disconnect the vent hose from the A/C bracket.

Installation Notice
20 - 30 N•m
Tightening Torque
(15 - 22 lb-ft)

YAD1B280

6. Unscrew all the mounting bolts and remove the

A/C bracket and the gasket.
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Installation Notice

;;;;;;;;;
yyyyyyyyy
yyyyyyyyy
;;;;;;;;; Tightening Torque 22.5 - 27.5 N•m
(16.6 - 20.3 lb-ft)
yyyyyyyyy
;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
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;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
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YAD1B290

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.

SSANGYONG Y200
1B1-22 M162 ENGINE MECHANICAL

ENGINE MOUNT

YAD1B300

SSANGYONG Y200
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
1B1-24 M162 ENGINE MECHANICAL

CYLINDER HEAD COVER

YAD1B450

1 Ignition Cable Dust Cover 5 Thrust Piece

2 Bolt (M6 x 65, 8 pieces) 6 Cylinder Head Cover
....................................... 9-11 N•m (80-97 lb-in) 7 Gasket .................................................... Replace
3 Bolt (M6 x 50, 4 pieces) 8 Spart Plug Hole Seal ............................. Replace
....................................... 9-11 N•m (80-97 lb-in) 9 Camshaft Seal ....................................... Replace
4 Spacer Sleeve

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
M162 ENGINE MECHANICAL 1B1-25

Removal & Installation Procedure

1. Remove the intake air duct.
Installation Notice
9 - 11 N•m
Tightening Torque
(80 - 97 lb-in)

YAD1B470

2. Remove the spark plug cover.

Installation Notice
9 - 11 N•m
Tightening Torque
(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
9 - 11 N•m
Tightening Torque
(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
1B1-26 M162 ENGINE MECHANICAL

CYLINDER HEAD FRONT COVER

Preceding Work : Removal of cylinder head cover
Removal of coolant connection fitting

YAD1B510

1 Camshaft Position Sensor 5 Bolt (M8 x 80, 3 pieces)

2 Camshaft Actuator ........................... 22.5-27.5 N•m (16.6-20.3 lb-ft)
3 Upper Guide Rail 6 Front Cover
4 Bolt (M6 x 60, 3 pieces) 7 Rubber Gasket ...................................... Replace
........................... 22.5-27.5 N•m (16.6-20.3 lb-ft) 8 Bolt (M6 x 16, 3 pieces)
.........................................9-11 N•m (80-97 lb-in)

Removal & Installation Procedure

1. Remove the camshaft actuator.
Installation Notice

Tightening Torque 9 - 11 N•m

(80 - 97 lb-in)

YAD1B520

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-27

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

SSANGYONG Y200
1B1-28 M162 ENGINE MECHANICAL

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) 4 Exhaust Camshaft Sprocket

........................ 1st step 55 N•m (141 lb-ft) 5 Cylinder Head
2nd step 90° 6 Gasket .................................................... Replace
3rd step 90° 7 Dowel Sleeve
2 Washers (14 pieces)
3 Flange Bolts (3 pieces)
........................ 1st step 18-22 N•m (13-16 lb-ft)
2nd step 90°±5°

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-29

Tools Required
116 589 01 34 00 Threaded Pin
116 589 20 33 00 Sliding Hammer
617 589 00 10 00 Allen Wrench Socket

Removal & Installation Procedure

1. Rotate the crankshaft so that the piston of number
1 cylinder is at TDC.
Notice: Rotate the crankshaft in the normal engine
direction.

2. Put the alignment marks (arrows) on the timing

YAD1B590
chain and camshaft sprocket.
3. Drain the coolant from the crankcase.

4. Remove the three flange bolts in the exhaust

camshaft sprocket.
Installation Notice
1st step: 18 - 22 N•m
Tightening Torque (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
1B1-30 M162 ENGINE MECHANICAL

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)
Tightening Torque
2nd step : 90°
3rd step : 90°

YAD1B630

8. Check the length of the cylinder head bolt.

Installation Notice
New 160 ± 0.8 mm
Length (L)
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
M162 ENGINE MECHANICAL 1B1-31

OIL PAN

YAD1B5B0

1 Gasket.................................................... Replace 5 Bolt (M6 x 85, 3 pieces)

2 Bolt (M6 x 22, 6 pieces) ....................................... 9-11 N•m (80-97 lb-in)
....................................... 9-11 N•m (80-97 lb-in) 6 Bolt (M8 x 40, 4 pieces)
3 Drain Plug ........ 22.5-27.5 N•m (16.6-20.3 lb-ft) ...........................22.5-27.5 N•m (16.6-20.3 lb-ft)
4 Bolt (M6 x 20, 22 pieces) 7 Bolt (M10) ................................ 40 N•m (30 lb-ft)
....................................... 9-11 N•m (80-97 lb-in) 8 Oil Pan

SSANGYONG Y200
1B1-32 M162 ENGINE MECHANICAL

Removal & Installation Procedure

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
YAD1B5C0
bolt in specified torque.
6. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
M6 X 22, 6 pieces
Others M6 X 20, 28 pieces

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-33

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) 5 Bolt (M8 x 60, 1 piece)

........................... 22.5-27.5 N•m (16.6-20.3 lb-ft) ...........................22.5-27.5 N•m (16.6-20.3 lb-ft)
2 A/C Bracket 6 Seal
3 Bolt (M8 x 65, 3 pieces) 7 Timing Gear Case Cover
........................... 22.5-27.5 N•m (16.6-20.3 lb-ft) 8 Roll Pin
4 Bolt (M8 x 40, 1 piece) 9 Bolt (M6 x 22, 6 pieces)
........................... 22.5-27.5 N•m (16.6-20.3 lb-ft) .........................................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)
Tightening Torque
Bolt (9) :
9 - 11 N•m
(80 - 97 lb-in)

• 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
M162 ENGINE MECHANICAL 1B1-35

CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate

YAD1B710

1 Bolt (M6 x 20, 6 pieces) 4 Sleeve

.........................................9-11 N•m (80-97 lb-in) 5 Bolt (M6 x 85, 2 pieces)
2 Radial Shaft Seal .........................................9-11 N•m (80-97 lb-in)
3 Rear Cover 6 Washer

SSANGYONG Y200
1B1-36 M162 ENGINE MECHANICAL

Tools Required
601 589 03 43 00 Crankshaft Rear Seal Installer

Removal & Installation Procedure

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
M162 ENGINE MECHANICAL 1B1-37

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) 4 Vibration Damper Assembly

.......... 1st step 180- 220 N•m (133-162 lb-ft) 5 Woodruff Key
.......... 2nd step 90°+10° 6 Bolt (M6 x 12, 4 pieces)
2 Vibration Damper Disk ....................................... 9-11 N•m (80-97 lb-in)
3 Bolt (M6 x 20, 6 pieces) 7 Cooling Fan Pulley
............................ 7.7-9.5 N•m (68.1-84.1 lb-in)

SSANGYONG Y200
1B1-38 M162 ENGINE MECHANICAL

Components

YAD1B660

1 Center Bolt (M18 x 50) 7 Crankshaft Sprocket (Camshaft Driven)

2 Vibration Damper Disk 8 Crankshaft Sprocket (Oil Pump Driven)
3 Vibration Damper and Pulley Assembly 9 Crankshaft
4 Woodruff Key 10 Oil Pan
5 Crankshaft Front Seal 11 Oil Pan Gasket
6 Timing Gear Case Cover 12 Oil Pan Mounting Bolt (M6 x 22)

Service Data Standard

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

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-39

Tools Required
602 589 00 40 00 Engine Lock

Removal & Installation Procedure

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
1st step: 180 - 220 N•m
Tightening Torque (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
1B1-40 M162 ENGINE MECHANICAL

CRANKSHAFT FRONT RADIAL SEAL

Preceding Work : Removal of belt pulley and vibration damper

YAD1B780

1 Center Bolt (M18 x 50) 3 Sleeve (Special Tool)

.......... 1st step 180- 220 N•m (133-162 lb-ft) 4 Crankshaft Front Seal
2nd step 90°+10° 5 Key
2 Center Bolt Washer

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-41

Tools Required
601 589 03 14 00 Crankshaft Front Seal Installer

Replacement Procedure
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
YAD1B800
tighten the center bolt until the center bolt and
the damper disk stop in the movement.
Installation Notice
1st step: 180 - 220 N•m
Tightening Torque (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.

SSANGYONG Y200
1B1-42 M162 ENGINE MECHANICAL

CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate

YAD1B840

1 Special Tool 3 Crankshaft Rear Seal

2 Special Tool

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-43

Tools Required
601 589 03 43 00 Crankshaft Rear Seal Installer

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
1B1-44 M162 ENGINE MECHANICAL

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 2 Crankshaft Bearing Cap

(M8 x 55, 14 pieces) 3 Crankshaft Lower Main Bearing
.......... 1st step 50- 60 N•m (37-44 lb-ft) 4 Crankshaft Lower Thrust Bearing
2nd step 90°+5° 5 Crankshaft

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-45

Arrangement of the Thrust Bearing and the Main Bearing

YAD1B870

1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft C Axial Fit Bearing (Number 5 Bearing Point)
4 Lower Main Bearing D Radial Bearing
5 Lower Thrust Bearing

1 - 12 Weight Balance/Color Marking Point

j1 - j7 Journal Main Bearing #1 - #7
l Color Dot Marking

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
1B1-46 M162 ENGINE MECHANICAL

Color Dot Marking Crankshaft Journal Diameter (mm)

Blue 57.960 - 57.965
Yellow 57.955 - 57.960
Red 57.950 - 57.955
White 57.945 - 57.950
Violet 57.940 - 57.945

Selection of Crankshaft Main Bearing

YAD1B880
••• 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 Bearing Color Selected
B Blue
Y Yellow
R Red
W White
V Violet
YAD1B890

Service Data Unit : mm

Crankshaft Crankshaft Connecting Rod Connecting Rod
Crankshaft Standard Thrust Washer
Bearing Jour- Journal Width Bearing Journal Bearing Jourmal
and Repair Size Thickness
nal Diameter at fit bearing Diameter Width
Standard size 57.950 - 57.965 2.15 or 2.20 24.50 - 24.533 47.94 - 47.96 27.958 - 28.042
1st repair size 57.700 - 57.715 47.75
2.25 or
2nd repair size 57.450 - 57.465 - 47.50 -
2.35 or
3rd repair size 57.200 - 57.215 47.25
2.40
4th repair size 56.950 - 56.965 47.00

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-47

Removal & Installation Procedure

1. Unscrew the connecting rod bearing cap bolt and
remove the bearing cap.
Installation Notice
1st step: 40 + 5 N•m
Tightening Torque (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.
YAD1B900 • 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
1st step: 50 - 60 N•m
Tightening Torque (37 - 44 lb-ft)
2nd step: 90°
• 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
YAD1B910 engine oil.
Part No. : 601 030 00 62 2.15 mm • The oil grooves (arrows) in the thrust washers
Part No. : 601 030 01 62 2.20 mm must face outward and insert the thrust bearing
Part No. : 601 030 02 62 2.25 mm into the bearing cap.
Part No. : 601 030 03 62 2.30 mm • There are five kinds of thrust washers by
Part No. : 601 030 04 62 2.40 mm 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
1B1-48 M162 ENGINE MECHANICAL

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 Measuring Position Gap (mm)
Main Bearing Journal Static condition :0.015 - 0.039
( NO. 1, 5, 7) Radial Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.011 - 0.016)
Axial 0.010 - 0.254
Main Bearing Journal Static condition :0.011 - 0.039
( NO. 3, 4, 6) Radial Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.015 - 0.022)
Axial 0.010 - 0.254

(Connecting Rod Bearing Gap)

Item Measuring Position Gap (mm)
Connecting Rod Bearing Radial 0.030 - 0.050

SSANGYONG Y200
1B1-50 M162 ENGINE MECHANICAL

CONNECTING ROD
Preceding Work : Removal of piston

YAD1B970

1 Connecting Rod Bushing 5 Fit Sleeve

2 Oil Gallery 6 Upper Connecting Rod Bearing
3 Balance Weight 7 Lower Connecting Rod Bearing
4 Connecting Rod Bolt (M9 x 52, 12 pieces) 8 BearingShell Lug
.......... 1st step 40+5 N•m (30+3.7 lb-ft) 9 Marking [Indication(//) or Numbers]
2nd step 90°+10°

Service Data Standard

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

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) 51.7 - 52 mm
Max. Length (L) 52.9 mm
Tightening Torque 1st step: 40 + 5 N•m
(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 doesn’t 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
1B1-52 M162 ENGINE MECHANICAL

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 4 Piston

2 Connecting Rod 5 Snap Ring
3 Connecting Rod Bearing Cap Bolt 6 Piston Pin
(M9 x 52, 12 pieces)
.......... 1st step 40+5 N•m (30+3.7 lb-ft)
2nd step 90°+10°

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,
YAD1B2Q0
piston ring, and the snap ring don’t get damaged.

SSANGYONG Y200
1B1-54 M162 ENGINE MECHANICAL

Installation Procedure

YAD1B2R0

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.
YAD1B2S0
6. After aligning the connecting rod and the bearing
cap mark (// or a number), tighten the bolts.
Installation Notice
1st step: 40 + 5 N•m
Tightening Torque (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
M162 ENGINE MECHANICAL 1B1-55

PISTON RING
Preceding Work : Removal of piston

YAD1B2T0

1 Piston Compression Ring 4 Coil Spring and Control Ring

2 Piston Compression Ring 5 Hook Spring
3 Piston Oil Ring

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
Groove 2 0.20 - 0.40 mm
Piston Ring
Groove 3 0.20 - 0.45 mm
Gap Between Groove 1 0.015 - 0.050 mm
The Piston and Groove 2 0.020 - 0.040 mm
The Piston Ring 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
M162 ENGINE MECHANICAL 1B1-57

FLYWHEEL / DRIVEN PLATE

Preceding Work : Removal of manual or automatic transmission

YAD1B810

1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T)

.......... 1st step 45+5 N•m (33+3.7 lb-ft) 4 Dowel Pin
2nd step 90°+10° 5 Flywheel (M/T)
2 Plate

Service Data Standard (Stretch Bolt)

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

SSANGYONG Y200
1B1-58 M162 ENGINE MECHANICAL

Removal & Installation Procedure

1. Unscrew the flywheel mounting bolt.
Installation Notice
1st step: 40 + 5 N•m
Tightening Torque (30 + 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
8.0 mm.
• For the stretch bolt tightening, keep the socket
wrench and Tommy-bar to be 90° and tighten
YAD1B820
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
M162 ENGINE MECHANICAL 1B1-59

Sectional View

YAD1B830

1 Oil Pan 8 Washer

2 Cover 9 Bolt
3 Crankshaft Front Seal 10 Front Drive Plate
4 Flywheel Mounting Bolt 11 Rear Drive Plate
5 Crankshaft 12 Rivet
6 Dowel Pin 13 Segment
7 Washer (thickness = 3.5 mm) 14 Ring Gear

SSANGYONG Y200
1B1-60 M162 ENGINE MECHANICAL

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) 12 Seal Cover

....................................... 9-11 N•m (80-97 lb-in) 13 Camshaft Sprocket and Position Indicator (b)
2 Camshaft Actuator (2 Pin Connector) 14 Adjuster Piston
3 Bolt ........................................... 35 N•m (26 lb-ft) 15 Flange Bolt (M7 x 13, 3 pieces)
4 Armature ........................ 1st step 18-22 N•m (13-16 lb-ft)
5 Roll Pin 2nd step 90° ± 5°
6 Nut (M20 x 1.5) .............. 60-70 N•m (44-52 lb-ft) 16 Flange Shaft
7 Front Cover 17 Compression Spring
8 Seal 18 Control Piston
9 Camshaft Position Sensor 19 Circlip
10 Bolt (M6 x 16, 2 pieces) 20 Oil Gallery
.........................................9-11 N•m (80-97 lb-in) 21 Pin
11 - 22 Intake Camshaft

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-61

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 r pm (‘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
YAD1B0C0
flanged shaft (16) together with the bolted-on
12 Seal Cover camshaft (22) in the ‘retarded position’. The
13 Camshaft Sprocket compressing spring (17) pushes the control
14 Adjust Piston (Stops Towards The Front) piston(18) against the circlip (19). The engine oil
16 Flange Shaft flows through 2 oblique drillings in the camshaft
17 Compression Spring flange and in the flanged shaft (16) in to the working
18 Control Piston (Stops Towards The Rear) chamber (A) and holds the positioning piston (14)
19 Circlip additionally in the ‘retarded’ position with the
22 Intake Camshaft available engine oil pressure.
23 Oil Outlet Drilling Leak oil flows off over control and positioning piston
surface, through the control piston drilling and 2
A Working Chamber (Oil Pressure) drillings (23) in the camshaft flange.
Y49 Electromagnetic Actuator (Not Functioning)

SSANGYONG Y200
1B1-62 M162 ENGINE MECHANICAL

“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
YAD1B0D0
of the effect of the helical teeth on the camshaft
12 Seal Cover sprocket (13), positioning piston (14) and flanged
13 Camshaft Sprocket shaft (16). The engine oil in working chamber ‘A’
14 Adjust Piston (Stops Towards The Front) flows off, assisted by the pushing action of the
16 Flange Shaft adjusting piston (14), over the flanged shaft (16)
17 Compression Spring and through 2 drillings (23) in the camshaft flange.
18 Control Piston (Stops Towards The Rear)
19 Circlip
22 Intake Camshaft
23 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
60 - 70 N•m
Tightening Torque
(44 - 52 lb-ft)
YAD1B0E0

3 Bolt 13 Camshaft Sprocket

4 Amarture 18 Control Piston
6 Nut (M20 x 1.5) 22 Intake Camshaft
12 Seal Cover

SSANGYONG Y200
1B1-64 M162 ENGINE MECHANICAL

6. Unscrew the sprocket bolt from the exhaust

camshaft and remove the sprocket.
Installation Notice

1st step: 18 - 22 N•m

Tightening Torque (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
1st step: 18 - 22 N•m
Tightening Torque (13 - 16 lb-ft)
2nd step: 90° ± 5°
The sprocket bolt is designed to be used only
once, so always replace with new one.
8. Installation should follow the removal procedure
YAD1B0F0 in the reverse order.
9. Adjust the camshaft timing.

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-65

CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
Installation Notice
1st step: 18 - 22 N•m
Tightening Torque (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 M7 x 13 Collar Bolt Torx-T30

e 6.8 mm
16 Flange Shaft
18 Control Piston
22 Intake Camshaft

Exhaust Camshaft Sprocket Bolt

Installation Notice
1st step: 18 - 22 N•m
Tightening Torque (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 M7 x 13 Collar Bolt Torx-T30

e 6.8 mm
13a Camshaft Sprocket
22a Exhaust Camshaft

SSANGYONG Y200
1B1-66 M162 ENGINE MECHANICAL

CAMSHAFT
Preceding Work : Removal of cylinder head cover
Removal of cylinder head front cover
Removal of coolant connection fitting

YAD1B0J0

1 Chain Tensioner Assembly 4 Cylinder Head Front Cover

....................................... 72-88 N•m (53-65 lb-ft) 5 Intake Camshaft Sprocket
2 Exhaust Camshaft Sprocket 6 Chain
3 Upper Guide Rail 7 Wrench

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-67

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
1B1-68 M162 ENGINE MECHANICAL

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 don’t get mixed
up.

10. Remove the intake and exhaust camshafts.

YAD1B0M0

Installation Procedure
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
22.5 - 27.5 N•m
Tightening Torque
(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 o’clock direction at
the intake, 9 o’clock direction at the exhaust).
Notice: Turn the crankshaft and adjust it to OT so
that No. 1 cylinder’s piston would be at TDC.

YAD1B0P0

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-69

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
1st step: 18 - 22 N•m
Tightening Torque (13 - 16 lb-ft)
2nd step: 90° ± 5°
• Make sure that the camshaft sprocket and
timing chain are aligned with marks.
• Replace the sprocket bolt with new one.

YAD1B600

7. Install the chain tensioner screw plug (1) and chain

tensioner assembly (2) and tighten it as specified.
Installation Notice
(1) : 40 N•m (30 lb-ft)
Tightening Torque (2) : 72 - 88 N•m
(53 - 65 lb-ft)

YAD1B0S0

SSANGYONG Y200
1B1-70 M162 ENGINE MECHANICAL

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
M162 ENGINE MECHANICAL 1B1-71

CAMSHAFT TIMING POSITION

Preceding Work : Removal of cylinder head cover
Removal of cylinder head front cover

YAD1B0T0

1 Chain Tensioner Assembly 4 Cylinder Head Front Cover

2 Exhaust Camshaft Sprocket 5 Wrench
3 Upper Guide Rail 6 Holding Pin DW 110-120

SSANGYONG Y200
1B1-72 M162 ENGINE MECHANICAL

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
YAD1B670 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 o’clock direction at the intake
side and to 9 o’clock 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.

YAD1B0U0

Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30° .
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. 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
M162 ENGINE MECHANICAL 1B1-73

10. Install the chain to the exhaust camshaft sprocket

and install it to the camshaft.
Installation Notice
1st step: 18 - 22 N•m
Tightening Torque (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
Screw Plug 40 N•m (30 lb-ft)
Tightening
Torque Tensioner 72 - 88 N•m
Assembly (53 - 65 lb-ft)

12. Check the camshaft timing.

SSANGYONG Y200
1B1-74 M162 ENGINE MECHANICAL

VALVE SPRING
Preceding Work : Removal of camshaft
Removal of spark plug

YAD1B0V0

1 Valve Cotter 6 Connecting Hose DW 110-090

2 Upper Retainer 7 Thrust Piece 111 589 25 63 00
3 Valve Spring ......... Check, Replace if necessary 8 Lever Pusher 111 589 18 61 00
4 Valve Stem Seal 9 Supporting Bar 111 589 01 59 00
5 Lower Retainer

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-75

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

Removal & Installation Procedure

1. Place the supporting bar 111 589 01 59 00 (12) at
the camshaft bearing cap and tighten them with
YAD1B1B0 the bearing cap bolt.
Installation Notice
22.5 - 27.5 N•m
Tightening Torque
(16.6 - 20.3 lb-ft)

2. Turn the crankshaft to position the each cylinder

piston at TDC.
Mark on The Vibration
Cylinder
Damper
OT 1, 6
120° 2, 5
240° 3, 4
Notice:
• Remove the valve spring only at TDC.
• Always rotate the crankshaft by holding the
YAD1B1C0 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
1B1-76 M162 ENGINE MECHANICAL

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

(d) 8.5
Size (mm)
(D) 12.3

YAD1B1G0

• Lower Valve Spring Retainer

Thickness (mm) (a) 0.8 - 1.0

YAD1B1H0

• Valve Cotter
(B) 9.0
Size (mm)
(H) 9.2 - 9.8

YAD1B1J0

SSANGYONG Y200
1B1-78 M162 ENGINE MECHANICAL

VALVE STEM SEAL

Preceding Work : Removal of valve spring

YAD1B1K0

1 Drift 119 589 00 43 00 3 Protective Sleeve

2 Valve Stem Seal

Tools Required
119 589 00 43 00 Drift

Replacement Procedure
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
M162 ENGINE MECHANICAL 1B1-79

CHAIN TENSIONER

YAD1B1N0

1 Screw Plug ............................... 40 N•m (30 lb-ft) 6 Thrust Pin

2 Seal 7 Chain Tensioner Housing
3 Filler Pin ....................................... 72-88 N•m (53-65 lb-ft)
4 Compression Spring 8 Seal
5 Snap Ring

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
YAD1B1P0
completely removing the chain tensioner. If the
chain tensioner is tightened again without
completely reducing its tension, then the detent
spring doesn’t return to the original position and
the tension gets exceeded.

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 doesn’t 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 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve) A Oil Supply Hole
11 Compression Spring B Chain Tensioner Oil Storage Hole
12 Thrust Piece

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-83

TIMING CHAIN
Preceding Work : Removal of cylinder head cover
Removal of spark plug

YAD1B1V0

1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge

SSANGYONG Y200
1B1-84 M162 ENGINE MECHANICAL

Tools Required
000 589 58 43 00 Chain Assembly
DW 110-120 Holding Pin

Replacement Procedure
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
M162 ENGINE MECHANICAL 1B1-85

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
YAD1B2A0
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.

YAD1B2B0

YAD1B2C0

SSANGYONG Y200
1B1-86 M162 ENGINE MECHANICAL

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).
Tightening Torque 30 N•m (22 lb-ft)

YAD1B2E0

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-87

17. Rivet the link pin.

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

19. Check the camshaft timing position.

YAD1B2G0

SSANGYONG Y200
1B1-88 M162 ENGINE MECHANICAL

TENSIONING RAIL
Preceding Work : Removal of timing gear case cover

YAD1B2H0

1 Tensioning Rail 3 Tensioning Rail Pin

2 Plastic Guide 4 Guide Rail

Removal & Installation Procedure

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
M162 ENGINE MECHANICAL 1B1-89

CYLINDER HEAD GUIDE RAIL

Preceding Work : Removal of cylinder head cover

YAD1B2J0

1 Chain Tensioner 3 Upper Guide Rail Pin

2 Upper Guide Rail 4 Wrench (Special Tool)

Removal & Installation Procedure

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
Screw Plug 40 N•m (30 lb-ft)
Tightening
Torque Tensioner 72 - 88 N•m
Assembly (53 - 65 lb-ft)

SSANGYONG Y200
1B1-90 M162 ENGINE MECHANICAL

CRANKCASE GUIDE RAIL

Preceding Work : Removal of timing gear case cover

YAD1B2K0

1 Guide Rail 3 Guide Rail Pin

2 Plastic Guide 4 Tensioning Rail

Removal & Installation Procedure

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
M162 ENGINE MECHANICAL 1B1-91

CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of tensioning rail
Removal of crankcase guide rail

YAD1B2L0

1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer

2 Oil Pump Chain Bushing ..................................... 29-35 N•m (21-26 lb-ft)
3 Oil Pump Chain Spring 7 Oil Pump Sprocket
4 Crankshaft Sprocket 8 Oil Pump
5 Key 9 Oil Pump Roller Chain
10 Timing Chain

SSANGYONG Y200
1B1-92 M162 ENGINE MECHANICAL

Tools Required
615 589 01 33 00 Crankshaft Sprocker Puller
Removal & Installation Procedure
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.
YAD1B2N0
Installation Notice

Tightening Torque 29 - 35 N•m

(21 - 26 lb-ft)

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
M162 ENGINE MECHANICAL 1B1-93

LUBRICATION SYSTEM
ENGINE OIL SPECIFICATION

YAD1B2W0

1 Drain Plug ................................ 25 N•m (18 lb-ft) 3 Engine Oil Filler Cap
2 Oil Filter 4 Dipstick Gauge

Specifications

Application Descrition
Capacity Min : 6.7 L, Max : 8.2 L
Quality • API SH or above grade
• ACEA : A2 or A3
• Approved oil by MB Sheet 229.1
Viscosity • Approved oil by MB Sheet 224.1
Replacemant • Initial at 1000-1500 km, Replace every 15000 km

SSANGYONG Y200
1B1-94 M162 ENGINE MECHANICAL

OIL CIRCULATION

YAD1B2X0

1 Oil Pump 20 Oil Supply (To Exhaust Camshaft Bearing)

2 Oil Gallery (to oil filter) 21 Oil Supply (To Intake Camshaft Bearing)
3 Oil Filter 22 Oil Gallery (Oil Supply to Exhaust Valve
4 Oil Pressure Switch Tappet)
5 Main Oil Gallery 23 Oil Gallery (Oil Supply to Intake Valve Tappet)
6 Cylinder Head Closing Cover 24 Camshaft Closing Cover
7 Oil Gallery (At Chain Tensioner) 25 Ball (φ 8 mm)
8 Oil Non-return Valve 26 Screw Plug
9 Chain Tensioner 27 Camshaft Adjuster
10 Vent (Chain Tensioner) 28 Front Closing Cover (Intake Camshaft)
11 Front Closing Cover (φ 17 mm) 29 Front Treaded Bushing (Exhaust Camshaft)
12 Oil Gallery (Perpendicular to The Shaft) 30 Valve tappet
13 Ball (φ 6 mm)
14 Oil Spray Nozzle (Timing Chain) a Oil Gallery (From Oil Pump to Oil Filter)
15 Oil Gallery (At Cylinder Head) b Main Oil Gallery
16 Ball (φ 15mm) c Oil Return Line (Oil Returns to the Oil Pan when
17 Oil Restriction Inner ( φ 4mm) Replacing the Filter Element)
18 Oil Supply (To Exhaust Camshaft)
19 Oil Supply (To Intake Camshaft)

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-95

ENGINE OIL AND OIL FILTER

ELEMENT
Tools Required
103 589 02 09 00 Oil Filter Remover
Replacement Procedure
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

YAD1B3A0
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)

SSANGYONG Y200
1B1-96 M162 ENGINE MECHANICAL

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
M162 ENGINE MECHANICAL 1B1-97

OIL FILTER
Preceding Work : Removal of starter motor
Removal of upper intake manifold

YAD1B3C0

1 Coolant Line 5 Bolt.................... 22.5-27.5 N•m (16.6-20.3 lb-ft)

2 O-ring ..................................................... Replace 6 Oil Filter
3 Clip 7 Gasket ................................................... Replace
4 Hose

SSANGYONG Y200
1B1-98 M162 ENGINE MECHANICAL

Removal & Installation Procedure

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
M162 ENGINE MECHANICAL 1B1-99

OIL PUMP
Preceding Work : Removal of oil pan

YAD1B3E0

1 Bolt (M8 x 20, 1 piece) 3 Bolt (M8 x 35, 3 pieces)

..................................... 29-35 N•m (21-26 lb-ft) .......................... 22.5-27.5 N•m(16.6-20.3 lb-ft)
2 Sprocket (Oil Pump Drive) 4 Spring Pin
5 Oil Pump

Removal & Installation Procedure

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

Tightening Torque 22.5 - 27.5 N•m

YAD1B3F0
(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
1B1-100 M162 ENGINE MECHANICAL

OIL PRESSURE RELIEF VALVE

Preceding Work : Removal of oil pan

YAD1B3G0

1 Screw Plug ............................... 50 N•m (37 lb-ft) 3 Guide Pin

2 Compression Spring 4 Piston

Removal & Installation Procedure

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
M162 ENGINE MECHANICAL 1B1-101

OIL NON-RETURN VALVE

Preceding Work : Removal of timing gear case cover

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 oil-
returning 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.

Replacement Procedure
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

YAD1B3J0

SSANGYONG Y200
1B1-102 M162 ENGINE MECHANICAL

OIL DIPSTICK GUIDE TUBE

YAD1B3K0

1 Oil Dipstick Level Gauge 3 O-ring

2 Oil Dipstick Guide Tube 4 Bolt (M6 x 12, 1 piece) ....9-11 N•m (80-97 lb-in)

Removal & Installation Procedure

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)

3. Install new O-ring to the dipstick guide tube.

4. Installation should follow the removal procedure
in the reverse order.
YAD1B3L0 5. Check for leaks by starting the engine.

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-103

UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work : Removal of crankshaft
Removal of oil spray nozzle

YAD1B3M0

1 Plug 3 Round Bar .................................... φ 11 x 750 mm

2 Steel Ball

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
1B1-104 M162 ENGINE MECHANICAL

YAD1B3N0

1 Plug ........................................................ Replace 4 Main Oil Gallery

2 - 5 Screw Plug
3 -

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
M162 ENGINE MECHANICAL 1B1-105

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) 3 Steel Ball (φ 8mm)

2 Seal

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, φ 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
M162 ENGINE MECHANICAL 1B1-107

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
1B1-108 M162 ENGINE MECHANICAL

CORE PLUGS IN CRANKCASE

Preceding Work : Draining of the coolant

YAD1B3X0

1 Core Plug ............................................... Replace

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-109

Tools Required
102 589 00 15 00 Drift
Replacement Procedure
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
1B1-110 M162 ENGINE MECHANICAL

CYLINDER BORE

YAD1B4D0

Group Code Letter and Cylinder Bore Size

Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm)
A A or X φ 89.900 - φ 90.906
X A, X or B φ 89.906 - φ 89.912
B X or B φ 89.912 - φ 89.918
X+5 X+5 φ 89.950 - φ 89.968
X + 10 X + 10 φ 90.000 - φ 90.018

Repair Size
Type Group Code Letter1) Cylinder Bore Size (mm)
Standard Size φ 89.9 A φ 89.900 - φ 90.906
X φ 89.906 - φ 89.912
B φ 89.912 - φ 89.918
1st Repair Size A φ 90.150 - φ 90.156
(Standard Size + 0.25) X φ 89.156 - φ 90.162
B φ 90.162 - φ 90.168
2nd Repair Size A φ 90.400 - φ 90.406
(Standard Size + 0.5) X φ 90.406 - φ 90.412
B φ 90.412 - φ 90.418
1)
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 0.1 mm
Permissible Deviation of Cylinder Out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm
Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm
Chamfer Angle 60°
Honing Angle 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).

YAD1B4E0

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

Chamfer Angle

YAD1B4F0

SSANGYONG Y200
1B1-112 M162 ENGINE MECHANICAL

CRANKCASE MATING SURFACE

YAD1B4G0

Service Data Standard

Height of The Crankcase “H” (When new) 282.25 - 282.35 mm
Minimum Height After Milling 281.95 mm
Flatness Crankcase Upper Mating Surface 0.03 mm
Crankcase Lower Mating Surface 0.04 mm
Permissible Deviation of Parallelism of The Axial Direction 0.1 mm
Upper to Lower Mating Surface Transverse Direction 0.05 mm
Peak-to-valley Height Crankcase Upper Mating Surface 0.005 - 0.020 mm
Crankcase Lower Mating Surface 0.025 mm

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-113

Chamfering Procedure
1. Chamfer angle : 60°

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
1B1-114 M162 ENGINE MECHANICAL

CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of valves

YAD1B4J0

Service Data Standard

Overall Height of Cylinder Head 135.9 - 136.0 mm
Minimum Height After Machining 135.5 mm
Flatness Axial Direction 0.08 mm
Transverse Direction 0.0 mm
Distance ‘T’ Standard Size Intake 24.21 - 24.75 mm
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm
and Valve Stem)
Repair Size Intake 23.96 - 24.51 mm
Exhaust 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

SSANGYONG Y200
1B1-116 M162 ENGINE MECHANICAL

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Application N•m Lb-Ft Lb-In

A/C Bracket Bolt 22.5 - 27.5 16.6 - 20.3 -
Armature Bolt in Camshaft Actuator 35 26 -
Belt Tensioning Pulley Nut 40.5 - 49.5 29.9 - 36.5 -
Camshaft Actuator Bolt 9 - 11 - 80 - 97
Camshaft Adjuster Mounting Nut 60 - 70 44 - 52 -
Camshaft Bearing Cap Bolt 22.5 - 27.5 16.6 - 20.3 -
Chain Tensioner Assembly 72 - 88 53 - 65 -
Chain Tensioner Screw Plug 40 30 -
Connecting Rod Bearing Cap Bolt 40 + 5 30 + 3.7
-
90° + 10° 90° + 10°
Cooling Fan Bracket Bolt 22.5 - 27.5 16.6 - 20.3 -
Crankshaft Bearing Cap Bolt 50 - 60 37 - 44
-
90° + 5° 90° + 5°
Crankshaft Sealing Rear Cover Mounting Bolt 9 - 11 - 80 - 97
Cylinder Block Drain Plug 30 22 -
Cylinder Head Bolt 55 41
+90° +90° -
+90° +90°
Cylinder Head Cover Bolt 9 - 11 - 80 - 97
Cylinder Head Front Cover Bolt 22.5 - 27.5 16.6 - 20.3 -
Engine Mounting Bracket Nut 70 52 -
Exhaust Camshaft Sprocker Bolt 18 - 22 13 - 16
-
90° ± 5° 90° ± 5°
Exhaust Manifold and Pipe 30 22 -
Flywheel Mounting Bolt 45 + 5 33 + 3.7
-
90° + 10° 90° + 10°
Fuel Feed and Return Hose to Fuel Rail 21 - 25 15 - 18 -
Generator Carrier Bolt 25 18 -
Intake Air Duct Nut 9 - 11 - 80 - 97
Intake Flange Shaft Bolt 18 - 22 13 - 16
-
90° ± 5° 90° ± 5°
Lower Engine Mounting Nut 38 28 -
Oil Dipstick Guide Tube Bolt 9 - 11 - 80 - 97
Oil Drain Plug 22.5 - 27.5 16.6 - 20.3 -
Oil Filter Bolt 22.5 - 27.5 16.6 - 20.3 -
Oil Filter Cover 25 18 -
Oil Gallery Screw Plug in Cylinder Head 15 11 -
Oil Pan Bolt M10 40 30 -
M8 22.5 - 27.5 16.6 - 20.3 -
M6 9 - 11 - 80 -97

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-117

FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N•m Lb-Ft Lb-In

Oil Pressure Relief Valve Screw Plug 50 37 -
Oil Pump Drive Sprocket Bolt 29 - 35 21 - 26 -
Oil Pump Mounting Bolt 22.5 - 27.5 16.6 - 20.3 -
Oil Pump Sprocket Bolt 29 - 35 21 - 26 -
Spark Plug Cover Bolt 9 - 11 - 80 - 97
Steering Pump Bolt 22.5 - 27.5 16.6 - 20.3 -
Tensioning Device Bolt 26 - 32 19 - 24 -
Timing Gear Case Cover Bolt M8 22.5 - 27.5 16.6 - 20.3 -
M6 9 - 11 - 80 - 97
Torque Converter Mounting Bolt 42 31 -
Transmission Mounting Nut 54 - 68 40 - 50 -
Under Cover 28 - 47 21 - 35 -
Upper Engine Mounting Nut 70 52 -
Vibration Damper Center Bolt 180 - 220 133 - 162
-
90° + 10° 90° + 10°
Water Pump Pulley Bolt 22.5 - 27.5 16.6 - 20.3 -

SSANGYONG Y200
1B1-118 M162 ENGINE MECHANICAL

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

000 589 58 43 00 111 589 01 59 00

Chain Assembly Supporting Bar

YAD1B1W0 YAD1B0W0

102 589 00 15 00 111 589 18 61 00

Drift Lever Pusher

YAD1B3Y0 YAD1B0X0

102 589 12 15 00 111 589 20 33 00

Drift Sliding Hammer

YAD1B3P0 YAD1B580

103 589 02 09 00 111 589 25 63 00

Oil Filter Remover Thrust Piece

YAD1B2Y0 YAD1B0Y0

SSANGYONG Y200
M162 ENGINE MECHANICAL 1B1-119

SPECIAL TOOLS TABLE (Cont’d)

601 589 03 43 00
116 589 01 34 00
Crankshaft Rear Seal
Threaded Pin Installer

YAD1B570 YAD1B730

119 589 00 43 00 603 589 00 40 00

Drift Fan Clutch Holder

YAD1B1L0 YAD1B4K0

601 589 03 14 00 615 589 01 33 00

Crankshaft Front Seal Crankshaft Sprocket
Installer Puller

YAD1B790 YAD1B2M0

602 589 00 40 00 617 589 00 10 00

Engine Lock AllenWrench Socket

YAD1B720 YAD1B560

SSANGYONG Y200
1B1-120 M162 ENGINE MECHANICAL

SPECIAL TOOLS TABLE (Cont’d)

DW110-090 DW110-120
Connecting Hose Holding Pin

YAD1B0Z0 YAD1B0K0

DW110-100
Valve Tappet Remover

YAD1B1A0

SSANGYONG Y200
SECTION 1B2

M161 ENGINE MECHANICAL

TABLE OF CONTENTS
Maintenance and Repair ................................... 1B2-2 Valve Stem Seal .............................................. 1B2-63
On-Vehicle Service ............................................. 1B2-2 Chain Tensioner ............................................... 1B2-64
Engine Assembly .............................................. 1B2-2 Timing Chain ................................................... 1B2-68
Crankcase Ventilation System ............................ 1B2-9 Tensioning Rail ................................................ 1B2-73
Generator ........................................................ 1B2-13 Cylinder Head Guide Rail ................................. 1B2-74
Engine Mount .................................................. 1B2-14 Crankcase Guide Rail ...................................... 1B2-76
Poly V-Belt ...................................................... 1B2-16 Crankshaft Sprocket ........................................ 1B2-77
Tensioning Device ........................................... 1B2-18 Piston .............................................................. 1B2-79
Tensioning Device Shock Absorber .................. 1B2-19 Connecting Rod ............................................... 1B2-82
Poly V-Belt Inspection ...................................... 1B2-20 Piston Ring ...................................................... 1B2-84
Cylinder Head Cover ........................................ 1B2-22 Oil Pan ............................................................ 1B2-86
Cylinder Head Front Cover ............................... 1B2-24 Engine Oil and Oil Filter Element ...................... 1B2-88
Cylinder Head ................................................. 1B2-26 Oil Pump ......................................................... 1B2-91
Timing Gear Case Cover .................................. 1B2-30 Oil Pressure Relief Valve .................................. 1B2-93
Crankshaft Sealing Rear Cover ........................ 1B2-33 Oil Non-Return Valve ........................................ 1B2-94
Belt Pulley and Vibration Damper ..................... 1B2-35 Oil Dipstick Guide Tube ................................... 1B2-95
Crankshaft Front Radial Seal ............................ 1B2-38 Unit Repair ........................................................ 1B2-96
Crankshaft Rear Radial Seal ............................. 1B2-40 Core Plugs in Crankcase .................................. 1B2-96
Crankshaft ....................................................... 1B2-41 Cylinder Bore .................................................. 1B2-98
Flywheel / Driven Plate ..................................... 1B2-47 Crankcase Mating Surface ............................. 1B2-100
Camshaft Adjuster ........................................... 1B2-50 Cylinder Head Mating Surface ........................ 1B2-102
Camshaft Sprocket Bolt ................................... 1B2-53 Specifications ................................................. 1B2-104
Camshaft ........................................................ 1B2-54 Fastener Tightening Specifications ................. 1B2-104
Camshaft Timing Position ................................ 1B2-57 Special Tools and Equipment ........................ 1B2-106
Valve Spring .................................................... 1B2-59 Special Tools Table ........................................ 1B2-106
1B2-2 M161 ENGINE MECHANICAL

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
ENGINE ASSEMBLY

YAD1B4S0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-3

Removal & Installation Procedure

1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice
28 - 47 N•m
Tightening Torque
(21 - 35 lb-ft)

YAD1B020

4. Disconnect the coupling of HFM sensor and

remove the air cleaner cross pipe.

YAD1B4T0

5. Remove the air cleaner cover. Remove the

mounting bolts and air cleaner housing and
element assembly.

YAD1B4U0

6. Loosen the radiator drain cock and drain the

coolant.
Notice: Open the coolant reservoir cap.

YAD1B040

SSANGYONG Y200
1B2-4 M161 ENGINE MECHANICAL

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.

YAD1B4V0

8. Remove the cooling fan shroud. Refer to Section

1D2, Engine Cooling.

YAD1B4W0

9. Disconnect the each hose from radiator.

YAD1B4X0

10. Remove the upper mounting bolts of radiator and

then remove the radiator.

YAD1B080

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-5

11. Remove the hydraulic pipe of power steering.

Notice: Completely drain the oil.

YAD1B090

12. Discharge the refrigerant from A/C system, and

disconnect the discharge pipe and suction pipe
from the compressor.

YAD1B4Y0

13. Remove the fuel feed and return line.

Notice: Before removing the fuel lines, release
the pressure in the fuel system.

Installation Notice
21 - 25 N•m
Tightening Torque
(15 - 18 lb-ft)

YAD1B4Z0

14. Disconnect the terminals from the generator.

YAD1B110

SSANGYONG Y200
1B2-6 M161 ENGINE MECHANICAL

15. Disconnect the terminals from starter motor and

remove the starter motor.
16. Disconnect the engine main harness ground.

YAD1B120

17. Disconnect the engine ground wire.

YAD1B130

18. Disconnect following sensors connector.

• HFM sensor.
• Coolant temperature sensor.
• Knock sensor.
• Camshaft and crankshaft sensors.

YAD1B5A0

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.

YAD1B5B0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-7

21. Separate the hose toward engine from canister

purge solenoid valve and canister. Refer to Section
1F2, Engine Control.

YAA1F800

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.

YAD1B5C0

24. Separate the vacuum hose for brake booster.

25. Separate the other vacuum hoses.

YAD1B160

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)

YAD1B5D0

SSANGYONG Y200
1B2-8 M161 ENGINE MECHANICAL

27. Remove the exhaust manifold and exhaust pipe.

Installation Notice
Tightening Torque 30 N•m (22 lb-ft)

YAD1B5E0

28. Remove the transmission. Refer to Section 5A, Au-

tomatic Transmission.

YAD1B5F0

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)

YAD1B5G0

31. Carefully separate the engine assembly from the

vehicle.
32. Installation should follow the removal procedure
in the reverse order.

YAD1B5H0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-9

CRANKCASE VENTILATION SYSTEM

Operation at Idling and Mid- Load

YAD1B5J0

1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling)

2 Cylinder Head Cover 12 Crank Chamber
3 Oil Spearation Chamber (Full-Load or Over Mid- 13 Oil Return Pipe
Load) 14 Oil Pan
4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase
6 Throttle Valve 17 Chain Housing
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling) A Fresh Air
8 Intake Manifold B Blow-By Gas
9 Vent Line (Mid-Load at Idling) D Vent Connection
10 Air Conditioner Bracket

SSANGYONG Y200
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), air-
conditioner 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.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-11

Operation When Full- Load at Partial Load

YAD1B5K0

1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling)

2 Cylinder Head Cover 12 Crank Chamber
3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe
Mid-Load) 14 Oil Pan
4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase
6 Throttle Valve 17 Chain Housing
7 Restrictor, Diameter 1.1mm A Fresh Air
(Mid-Load at Idling) C Blow-By Gas
8 Intake Manifold D Vent Connection
9 Vent Line (Mid-Load at Idling)
10 Air Conditioner Bracket

SSANGYONG Y200
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).

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-13

GENERATOR

YAD1B5L0

1 Bolt (M8 X 40, 3 pieces) 3 Bolt (M8 X 85, 1 piece)

...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) ...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft)
2 Bolt (M8 X 70, 2 pieces) 4 Generator Bracket
...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft)

Removal & Installation Procedure

1. Disconnect the negative battery cable.
2. Remove the drive belt.
3. Remove the generator.
4. 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.

SSANGYONG Y200
1B2-14 M161 ENGINE MECHANICAL

ENGINE MOUNT

YAD1B5M0

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)

YAD1B5G0

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.

YAD1B5N0

SSANGYONG Y200
1B2-16 M161 ENGINE MECHANICAL

POLY V - BELT
Preceding Work: Removal of cooling fan

YAD1B5P0

1 Poly V-Belt (2,155 mm) 3 Belt Tensioner

2 Belt Tensioning Pulley

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.

YAD1A130

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-17

Poly V - Belt Arrangement

YAD1B5Q0

1 Belt Tensioning Pulley 5 Generator Pulley

2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley
3 A/C Compressor Pulley 8 Water Pump Pulley

SSANGYONG Y200
1B2-18 M161 ENGINE MECHANICAL

TENSIONING DEVICE
Preceding Work: Removal of tensioning device shock absorber

YAD1B5R0

1 Bolt (M8 x 75, 2 pieces) + 3 Tensioning Device

Washer ............ 22.5 - 27.5 N•m (16.6 - 0.3 lb-ft) 4 Stud bolt
2 Bolt (M8 x 25, 1 pieces) + 5 Tensioning Arm
Washer ............ 22.5 - 27.5 N•m (16.6 - 0.3 lb-ft)

Removal & Installation Procedure

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
22.5 - 27.5 N•m
Tightening Torque
(16.6 - 20.3 lb-ft)

4. Installation should follow the removal procedure

YAD1B5S0 in the reverse order.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-19

TENSIONING DEVICE SHOCK ABSORBER

YAD1B5T0

1 End Cover 5 Tensioning Device

2 Bolt.................... 40.5 - 9.5 N•m (29.9 - 6.5 lb-ft) 6 Bolt (M8 X 35) + Washer
3 Tensioning Pulley .......................... 22.5 - 7.5 N•m (16.6 - 0.3 lb-ft)
4 Bolt (M8 X 25) + Washer 7 Shock Absorber
.......................... 22.5 - 7.5 N•m (16.6 - 0.3 lb-ft)

Removal & Installation Procedure

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 ab-

sorber (7).
Installation Notice
22.5 - 27.5 N•m
Tightening Torque
(16.6 - 20.3 lb-ft)

SSANGYONG Y200
1B2-20 M161 ENGINE MECHANICAL

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.

YAD1B5U0

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
M161 ENGINE MECHANICAL 1B2-21

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

SSANGYONG Y200
1B2-22 M161 ENGINE MECHANICAL

CYLINDER HEAD COVER

YAD1B5V0

1 Spark Plug Cover 4 Cylinder Head Cover

2 Spark Plug Connector 5 Gasket .................................................... Replace
3 Bolt (M6 X 45 : 4 pieces, M6 X 60 : 6 pieces)
.................................... 9 - 11 N•m (80 - 97 lb-in)

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-23

Removal & Installation Procedure

1. Remove the intake air duct.
Installation Notice

Tightening Torque 9 - 11 N•m

(80 - 97 lb-ft)

YAD1B4T0

YAD1B5A0

2. Remove the spark plug cover.

Installation Notice
9 - 11 N•m
Tightening Torque
(80 - 97 lb-ft)

Notice: Release 3 screws from the spark plug

cover and remove the cover for M161 Engine coil.

YAD1B5X0

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

YAD1B5Y0 in the reverse order.
6. Check for oil leaks by operating the engine.
SSANGYONG Y200
1B2-24 M161 ENGINE MECHANICAL

CYLINDER HEAD FRONT COVER

Preceding Work: Removal of cylinder head cover
Removal of thermostat housing assembly
Removal of engine hanger bracket

YAD1B5Z0

1 Bolt (M6 X 16, 3 pieces) 5 Front Cover (E23 : M161.973)

.................................... 9 - 11 N•m (80 - 97 lb-in) 6 Front Cover (E20 : M161.943)
2 Camshaft Adjuster 7 Sleeve
3 Bolt (M8 X 35, 2 pieces) 8 O-Ring .................................................... Replace
...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 9 Thermostat Housing.
4 Bolt (M6 X 22, 6 pieces)
.................................... 9 - 11 N•m (80 - 97 lb-in)

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-25

Removal & Installation Procedure

1. Disconnect the camshaft adjuster connector and
remove the camshaft adjuster (E23 engine only).
Installation Notice
9 - 11 N•m
Tightening Torque
(80 - 97 lb-ft)

YAD1B6A0

2. Remove the cylinder head front cover.

Installation Notice
Tightening 22.5 - 27.5 N•m
Torque (3) (16.6 - 20.3 lb-ft)
Tightening 9 - 11 N•m
Torque (4) (80 - 97 lb-in)

Apply the sealant at the mating surface of the

cylinder head and the front cover.
3. Remove the O-Ring.

YAD1B6B0 Notice: Replace the O-ring with new one and apply
the sealant.

4. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200
1B2-26 M161 ENGINE MECHANICAL

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)

YAD1B6C0

1 Cylinder Head Bolt (M12 X 100, 10 pieces) 4 Camshaft Bearing cap

.................................... 1ststep 55 N•m (41 lb-ft) 5 Cylinder Head
2nd step 90 ° rotation added 6 Gasket .................................................... Replace
3rd step 90 ° rotation added 7 Dowel Sleeve ............................................... Note
3 Bolt (M8 X 35, 4 pieces)
........................ 22.5 - 27.5 N•m (16.6 - 0.3 lb-ft)

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-27

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

Removal & Installation Procedure

1. Rotate the crankshaft so that the piston of number
1 cylinder is at ATDC 20.

YAD1B6D0

2. Put the holding pin 111 589 03 15 00 into the cam-

shaft bearing cap (number 1, 6).

YAD1B6E0

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)

YAD1B6F0

5. Remove the exhaust camshaft sprocket.

Installation Notice
1st step: 18 - 22 N•m
Tightening Torque (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.

YAD1B6G0

SSANGYONG Y200
1B2-28 M161 ENGINE MECHANICAL

6. Remove the intake camshaft sprocket (E20

engine).
7. Remove the camshaft adjuster (E23, M161.970 en-
gine).
Installation Notice (Flange Bolt)
1st step: 18 - 22 N•m
Tightening Torque (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.
YAD1B6H0
1 Flange Shaft
2 Flange Bolt
3 Compression Spring
4 Adjust Piston
5 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.

YAD1B6J0

9. Unscrew the bolts (A).

Installation Notice
22.5 - 27.5 N•m
Tightening Torque
(16.6 - 20.3 lb-ft)

Bolt (A) : (M8 X 35, 4 pieces)

YAD1B6K0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-29

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 N•m(41 lb-ft)
Tightening Torque 2nd step: +90°
3rd step: +90°
Notice: Operate during engine cooling.
YAD1B6L0

11. Remove the No. 1 bearing cap of the exhaust cam-

shaft.
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.

YAD1B6M0

15. Check the length of the cylinder head bolt.

Installation Notice
When New 100 mm
Length (L)
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.

YAD1B6N0

SSANGYONG Y200
1B2-30 M161 ENGINE MECHANICAL

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

YAD1B6P0

1 Bolt (M8 X 60, 3 pieces) 3 Seal

...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 4 Timing Gear Case Cover
2 Bolt (M8 X 75, 1 piece) 5 O-Ring
...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 6 Sleeve.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-31

Tools Required
116 589 20 33 00 Sliding Hammer
116 589 01 34 00 Threaded Pin

Removal & Installation Procedure

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 °.

YAD1B6D0

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
YAD1B6F0
1st step: 18 - 22 N•m
Tightening Torque (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.

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.

YAD1B6J0

SSANGYONG Y200
1B2-32 M161 ENGINE MECHANICAL

8. Unscrew the bolts (A).

Installation Notice

Tightening Torque 22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

YAD1B6K0

9. Remove the belt pulley and vibration damper.

Installation Notice (Center Bolt)
1st step: 200 + 20 N•m
Tightening Torque (148 +15 lb-ft)
2nd step: 90° ± 10°

YAD1B6Q0

10. Unscrew the bolts (1, 2) on timing gear case cover

and remove the timing gear case cover.
Installation Notice
22.5 - 27.5 N•m
Tightening Torque
(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.
YAD1B6R0

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
M161 ENGINE MECHANICAL 1B2-33

CRANKSHAFT SEALING REAR COVER

Preceding Work: Removal of the automatic transmission drive plate or flywheel

YAD1B6S0

1 Bolt (M6 x 20, 6 pieces) 4 Sleeve

.................................... 9 - 11 N•m (80 - 97 lb-in) 5 Bolt (M6 x 85, 2 pieces)
2 Radial Shaft Seal .................................... 9 - 11 N•m (80 - 97 lb-in)
3 Rear Cover 6 Washer

SSANGYONG Y200
1B2-34 M161 ENGINE MECHANICAL

Tools Required
601 589 03 43 00 Crankshaft Rear Seal Installer

Removal & Installation Procedure

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

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)

8. Installation should follow the removal procedure

in the reverse order.

YAD1B6T0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-35

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 2 Vibration Damper Disk

............... 1st step 200+20 N•m (148 + 15 lb-ft) 5 Vibration Damper Assembly
2nd step 90 ° + 10 ° rotation added 6 Key

SSANGYONG Y200
1B2-36 M161 ENGINE MECHANICAL

Components

YAD1B660

1 Center Bolt (M18 x 50) 7 Crankshaft Sprocket (Camshaft Driven)

2 Center Bolt Washer 8 Crankshaft Sprocket (Oil Pump Driven)
3 Vibration Damper and Pulley Assembly 9 Crankshaft
4 Key 10 Oil Pan
5 Crankshaft Front Seal 11 Oil Pan Gasket
6 Timing Gear Case Cover 12 Oil Pan Mounting Bolt (M6 x 22)

Service Data Standard

Permissble Deviation of The Vibration Damper Radial Runout 0.6 mm

Axial Ruout 0.6 mm

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-37

Tools Required
602 589 00 40 00 Engine Lock

Removal & Installation Procedure

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
1st step: 200 + 20 N•m
Tightening Torque (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
1B2-38 M161 ENGINE MECHANICAL

CRANKSHAFT FRONT RADIAL SEAL

Preceding Work: Removal of belt pulley and vibration damper

YAD1B6X0

1 Center Bolt (M18 x 50) 3 Crankshaft Front Seal Installer

......... 1st step 200 + 20 45 N•m (148 +15 lb-ft) 4 Crankshaft Front Seal
2nd step 90 ° + 10 ° 5 Key
2 Center Bolt Washer

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-39

Tools Required
601 589 03 14 00 Crankshaft Front Seal Installer

Replacement Procedure
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
YAD1B800
tighten the center bolt until the center bolt and
the damper disk stop in the movement.
Installation Notice
1st step: 200 + 20 N•m
Tightening Torque (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.

SSANGYONG Y200
1B2-40 M161 ENGINE MECHANICAL

CRANKSHAFT REAR RADIAL SEAL

Preceding Work: Removal of flywheel or drive plate

YAD1B840

1 Special Tool 3 Crankshaft Rear Seal

2 Special Tool

Tools Required
601 589 03 43 00 Crankshaft Rear Seal Installer

Replacement Procedure
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
M161 ENGINE MECHANICAL 1B2-41

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) 4 Lower Main Bearing

................................... 1ststep 55 N•m (41 lb-ft) 5 Upper Thrust Bearing
2nd step 90 °rotation added 6 Lower Thrust Bearing
2 Bearing Cap 8 Crankshaft.
3 Upper Main Bearing

SSANGYONG Y200
1B2-42 M161 ENGINE MECHANICAL

Arrangement of the Thrust Bearing and the Main Bearing

YAD1B6Z0

1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

(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
M161 ENGINE MECHANICAL 1B2-43

Color Dot Crankshaft Journal Diameter

Marking (mm)
Blue 57.960 - 57.965
Yellow 57.955 - 57.960
Red 57.950 - 57.955
White 57.945 - 57.950
Violet 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
Bearing Color Selected
Mark
B Blue
Y Yellow
YAD1B880
R 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
Bearing Color Selected
Letter
B Blue
Y Yellow
R Red
W White
YAD1B890
V Violet

Service Data

Crankshaft Crankshaft Crankshaft Crankshaft Connecting Rod Connecting Rod

Standard and Bearing Jour- Bearing Journal Width Bearing Journal Bearing Journal
Repair Size nal Diameter Diameter at fit bearing Diameter Width
Standard size 57.940 - 57.965 58 24.50 - 24.533 47.935 - 47.965 27.958 - 28.042
1st repair size 57.705 - 57.715 47.700 - 47.715
2nd repair size 57.450 - 57.465 47.450 - 47.465
3rd repair size 57.205 - 57.215 - - 47.200 - 4.215 -
4th repair size 56.955 - 56.965 46.950 - 46.965

SSANGYONG Y200
1B2-44 M161 ENGINE MECHANICAL

Removal & Installation Procedure

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

• 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 55 N•m (41 lb-ft)+ 90°

• 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.
YAD1B910 • The oil grooves (arrows) in the thrust washers
must face outward and insert the thrust bearing
into the bearing cap.
Part No. : 601 030 00 62 2.15 mm
Part No. : 601 030 01 62 2.20 mm
• There are five kinds of thrust washers by thick-
ness. Select the proper washer when repaired.
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm 3. Remove the crankshaft.
Part No. : 601 030 04 62 2.40 mm 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 Measuring Position Gap (mm)

Static condition : 0.015 - 0.039
Main Bearing Journal Radial Dynamic condition : 0.031 - 0.051
(NO.1,5,7) (Consider the expansion 0.011 - 0.016)
Axial 0.010 - 0254

(Connecting Rod Bearing Gap)

Item Item Gap (mm)

Connection Rod Bearing Radial 0.020 - 0.065

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-47

FLYWHEEL / DRIVEN PLATE

Preceding Work: Removal of manual or automatic transmission

YAD1B810

1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T)

.................. 1st step 45 + 5 N•m (33 + 3.7 lb-ft) 4 Dowel Pin
2nd step 90 ° + 10 ° 5 Flywheel (M/T)
2 Plate

Service Data Standard (Stretch Bolt)

Normal Size D - M x 15
Stretch Side Diameter d When New 8.5 - 0.2 mm
Min. Diameter 8.0 mm
Bolt Length L When New 21.8 - 22.2 mm
Tightening Torque 1st step 45 + 5 N•m (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
1st step: 45 + 5 N•m
Tightening Torque (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 ve-
hicles, 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 OilPan 8 Washer
2 Cover 9 Bolt
3 Radial Seal 10 Front Drive Plate
4 Bolt 11 Rear Drive Plate
5 Crankshaft 12 Rivet
6 Dowel Pin 13 Segment
7 Washer (Thickness : 3.5 mm) 14 Ring Gear

SSANGYONG Y200
1B2-50 M161 ENGINE MECHANICAL

CAMSHAFT ADJUSTER

YAD1B7A0

1 Bolt (M6 X 16, 3 pieces) 11 Flange Bolt (M7 X 13, 3 pieces)

.................................... 9 - 11 N•m (80 - 97 lb-in) .................... 1stStep 18 - 22 N•m (13 - 16 lb-ft)
2 Cylinder Head Front Cover 2nd Step 60 ° ± 5 ° Rotation Added
3 Bolt ........................................... 35 N•m (26 lb-ft) 12 Flange Shaft
4 Armature 13 Compression Spring
5 RollPin 14 Control Piston
6 Nut (M20 X 1.5) ....... 60 - 70 N•m (44 - 52 lb-ft) 15 Circlip
7 Seal Cover 16 Oil Gallery
8 Camshaft Sprocket 17 Straight Pin
9 Adjust Piston 18 Intake Camshaft
10 Conical Spring Y49 Magnetic Actuator (2 - Pin Connector)

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-51

Removal & Installation Procedure

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
1st step: 18 - 22 N•m
Tightening Torque (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.

YAD1B6G0

SSANGYONG Y200
1B2-52 M161 ENGINE MECHANICAL

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
60 - 70 N•m
Tightening Torque
(44 - 52 lb-ft)

YAD1B7B0 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
1st step: 18 - 22 N•m
Tightening Torque (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.

12. Installation should follow the removal procedure

YAD1B7C0 in the reverse order.
13. Check and adjust the camshaft timing.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-53

CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
1st step: 18 - 22 N•m
Tightening Torque (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
YAD1B0G0 16. Flange Shaft
18. Control Piston
22. Intake Camshaft

Exhaust Camshaft Sprocket Bolt

1st step: 18 - 22 N•m
Tightening Torque (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
1B2-54 M161 ENGINE MECHANICAL

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) 4b Camshaft Adjuster and Camshaft

................... 1st Step 18 - 22 NSm (13 - 16 lb-ft) Sprocket (E23)
2nd Step 60 ° ± 5 ° Rotation Added 5 Bearing Cap Bolt (20 pieces)
2 Exhaust Camshaft Sprocket ...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft)
3 Timing Chain 6 Camshaft Bearing Cap
4a Intake Camshaft Spocket (E20) 7 Wrench

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-55

Removal & Installation Procedure

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 40 N•m
Tightening (30 lb-ft)
Torque Tensioner 72 - 88 N•m
Assembly (53 - 65 lb-ft)

YAD1B6F0

4. Remove the exhaust camshaft sprocket.

Installation Notice
1st step: 18 - 22 N•m
Tightening Torque (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
1B2-56 M161 ENGINE MECHANICAL

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 cam-

shaft 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.

10. Check the camshaft timing position.

YAD1B7G0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-57

CAMSHAFT TIMING POSITION

Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover

YAD1B7H0

1 Holding Pin 111 589 03 15 00 6 Bolt (M7 X 13, 3 pieces)

2 Intake Camshaft Sprocket ..................... 1ststep 18 - 22 NSm (13 - 16 lb-ft)
3 Camshaft Bearing Cap 2nd step 60 ° ± 5 ° rotation added
4 Timing Chain 7 StratePin
5 Exhaust Camshaft Sprocket

SSANGYONG Y200
1B2-58 M161 ENGINE MECHANICAL

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
YAD1B6D0 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.

YAD1B6E0

Adjustment Procedure
1. Position the NO.1 cylinder to ATDC 20 °.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. 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
1st step: 18 - 22 N•m
Tightening Torque (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 40 N•m
Tightening (30 lb-ft)
Torque Tensioner 72 - 88 N•m
Assembly (53 - 65 lb-ft)
8. Check the camshaft timing.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-59

VALVE SPRING
Preceding Work: Removal of camshaft
Removal of spark plug

YAD1B0V0

1 Valve Cotter a Lever Pusher 111 589 18 61 00

2 Valve Spring Retainer b Thrust Piece 111 589 25 63 00
3 Valve Spring c Connecting Hose DW 110 - 090
4 Valve Stem Seal d Supporting Bar 111 589 01 59 00
5 Lower Retainer

SSANGYONG Y200
1B2-60 M161 ENGINE MECHANICAL

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

Removal & Installation Procedure

1. Place the supporting bar 111 589 01 59 00 (a) at
the camshaft bearing cap and tighten them with
YAD1B1B0 the bearing cap bolt.
Installation Notice

Tightening Torque 22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

2. Turn the crankshaft to position the each cylinder

piston at TDC.
1st step: 18 - 22 N•m
Tightening Torque (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
M161 ENGINE MECHANICAL 1B2-61

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
(d) 8.5
Size (mm)
(D) 12.3

YAD1B1G0

• Lower Valve Spring Retainer

Size (mm) (a) 0.8 - 1.0

YAD1B1H0

• Valve Cotter
(B) 9.0
Size (mm)
(H) 9.2 - 9.8

YAD1B1J0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-63

VALVE STEM SEAL

Preceding Work: Removal of valve spring

YAD1B1K0

1 Drift 119 589 00 43 00 3 Protective Sleeve

2 Valve Stem Seal

Tools Required
119 589 00 43 00 Drift

Replacement Procedure
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
1B2-64 M161 ENGINE MECHANICAL

CHAIN TENSIONER

YAD1B1N0

1 Screw Plug ............................... 40 N•m (30 lb-ft) 6 Thrust Pin

2 Seal 7 Chain Tensioner Housing
3 Filler Pin .................................. 72 - 88 N•m (53 - 65 lb-ft)
4 Compression Spring 8 Seal
5 Snap Ring

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
YAD1B1P0
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.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-65

4. Carefully unscrew the screw plug (1), and remove

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

2. Install the chain tensioner housing (7), thrust pin

(6), snap ring (5), and the seal (8).
Installation Notice
72 - 88 N•m
Tightening Torque
(53 - 65 lb-ft)

3. Insert the compression spring (4) with the filler

pin (3) into chain tensioner housing.

YAD1B1S0

SSANGYONG Y200
1B2-66 M161 ENGINE MECHANICAL

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 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve)
11 Compression Spring A Oil Supply Hole
12 Thrust Piece B Chain Tensioner Oil Storage Hole

SSANGYONG Y200
1B2-68 M161 ENGINE MECHANICAL

TIMING CHAIN
Preceding Work: Removal of cylinder head cover
Removal of spark plug

YAD1B1V0

1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-69

Tools Required
000 589 58 43 00 Chain Assembly
111 589 03 15 00 Holding Pin

Replacement Procedure
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
1B2-70 M161 ENGINE MECHANICAL

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 revo-
lution 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.
YAD1B2A0 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.

YAD1B2B0

YAD1B2C0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-71

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
1B2-72 M161 ENGINE MECHANICAL

19. Check the camshaft timing position.

YAD1B2G0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-73

TENSIONING RAIL
Preceding Work: Removal of cylinder head

YAD1B7K0

1 Sliding Rail Pin 3 Timing Gear Case Cover

2 Sliding Rail

Removal & Installation Procedure

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
1B2-74 M161 ENGINE MECHANICAL

CYLINDER HEAD GUIDE RAIL

Preceding Work: Removal of cylinder head front cover

YAD1B7L0

1 Bolt (M6 X 45, 2 pieces) 2 Guide Rail

.................................... 9 - 11 N•m (80 - 97 lb-in)

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-75

Tools Required
111 589 03 15 00 Holding Pin

Removal & Installation Procedure

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 40 N•m
YAD1B6E0
Tightening (30 lb-ft)
Torque Tensioner 72 - 88 N•m
Assembly (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)
5. Installation should follow the removal procedure
in the reverse order.

YAD1B7M0

SSANGYONG Y200
1B2-76 M161 ENGINE MECHANICAL

CRANKCASE GUIDE RAIL

Preceding Work: Removal of timing gear case cover

YAD1B7N0

1 Guide Rail Pin 3 Timing Gear Case Cover

2 Guide Rail

Removal & Installation Procedure

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
M161 ENGINE MECHANICAL 1B2-77

CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail

YAD1B2L0

1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer

2 Oil Pump Chain Bushing .................................. 29 - 35 N•m (21 - 26 lb-ft)
3 Oil Pump Chain Spring 7 Oil Pump Sprocket
4 Crankshaft Sprocket 8 Oil Pump
5 Key 9 Oil Pump Roller Chain
10 Timing Chain

SSANGYONG Y200
1B2-78 M161 ENGINE MECHANICAL

Tools Required
615 589 01 33 00 Crankshaft Sprocket Puller

Removal & Installation Procedure

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

YAD1B2N0 sprocket (7) from the oil pump.
Installation Notice
29 - 35 N•m
Tightening Torque
(21 - 26 lb-ft)

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
6. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-79

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 4 Piston

2 Connecting Rod 5 Snap Ring
3 Connecting Rod Bolt (M9 x 52, 8 pieces) 6 Piston Pin
.................................. 1st step 40 N•m (30 lb-ft)
2nd step 90 °

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,
YAD1B2Q0
piston ring, and the snap ring don’t get damaged.

Installation Procedure

YAD1B2R0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-81

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.
YAD1B2S0
6. After aligning the connecting rod and the bearing
cap mark (// or a number), tighten the bolts.
Installation Notice
1st step : 40 N•m (30 lb-ft)
Tightening Torque
2nd step : 90 °

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
1B2-82 M161 ENGINE MECHANICAL

CONNECTING ROD
Preceding Work: Removal of piston

YAD1B970

1 Connecting Rod Bushing 5 Fit Sleeve

2 Oil Gallery 6 Upper Connecting Rod Bearing
3 Balance Weight 7 Lower Connecting Rod Bearing
4 Connecting Rod Bearing Cap Bolt 8 Bearing Shell Lug
(M9 x 52, 8 pieces) 9 Marking [Indication (//) or Numbers]
..................................... 1ststep 40 N•m (30 lb-ft)
2nd step 90 °

Service Data Standard

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

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-83

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) 51.7 - 52 mm

Max. Length (L) 52.9 mm
1st step : 40 N•m
Tightening Torque (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 doesn’t 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
1B2-84 M161 ENGINE MECHANICAL

PISTON RING
Preceding Work: Removal of piston

YAD1B2T0

1 Piston Compression Ring (Top Ring) 4 -

2 Piston Compression Ring (2nd Ring) 5 Spacer
3 Piston Oil Ring 6 SideRail

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-85

Replacement Procedure
1. Measure the piston ring’s gap.
Groove 1 0.20 - 0.40 mm
End Gap of the
Groove 2 0.20 - 0.40 mm
Piston Ring
Groove 3 0.20 - 0.45 mm
Gap Between Groove 1 0.028 - 0.060 mm
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.

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
1B2-86 M161 ENGINE MECHANICAL

OIL PAN

YAD1B7P0

1 Bolt 5 Bolt
2 Bolt 6 OilPan
3 Bolt 7 Gasket
4 Bolt

Removal & Installation Procedure

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
M161 ENGINE MECHANICAL 1B2-87

Oil Circulation

YAD1B7Q0

1 Oil Strainer 16 Oil Supply (To Chain Tensioner)

2 Oil Pump 17 Camshaft
3 Oil Pan 18 Cam Bearing
4 Oil Non-Return Valve 19 Valve
5 Oil Filter 20 Oil Gallery (Supply Oil to Intake Tappet)
6 Oil Filter Bypass Valve 21 Oil Gallery (Supply Oil to Exhaust Tappet)
7 Main Oil Gallery 22 Ball (φ 8 mm)
8 Closing Ball (φ 15 mm) 23 Camshaft Plug
9 Crankshaft 24 Seal
10 Connecting Rod Bearing 25 Screw Plug
11 Crankshaft Bearing 26 Oil Return Gallery
12 Connecting Rod (Cylinder Head and Crankcase)
13 Piston 27 Oil Return Gallery (Crankcase)
14 Oil Spray (Piston Crown Area) 28 End Cover ( φ 20 mm)
15 Non-Return Valve (Crankcase) 29 Oil Return Pipe

SSANGYONG Y200
1B2-88 M161 ENGINE MECHANICAL

ENGINE OIL AND OIL FILTER ELEMENT

YAD1B7R0

1 Oil Filter Cover 25 N•m (18 lb-ft) 4 Oil Drain Plug

2 O-Ring Replace 5 Oil Filter Bypass Valve
3 Oil Filter Element

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-89

Tools Required
103 589 02 09 00 Oil Filter Remover

Replacement Procedure
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
YAD1B7S0 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 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
1B2-90 M161 ENGINE MECHANICAL

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 neces-
sary.

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-91

OIL PUMP
Preceding Work: Removal of oil pan

YAD1B7U0

1 Bolt (M8 X 35, 3 piece) 6 Bolt (M8 X 20, 1 pieces)

...................... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) .................................. 29 - 35 N•m (21 - 26 lb-ft)
2 OilPump 7 Washer
3 Oil Strainer Assembly 8 Sprocket (Oil Pump Drive)
4 Bolt (M6 X 20, 2 pieces) 9 Chain (Oil Pump Drive)
.................................... 9 - 11 N•m (80 - 97 lb-in) 10 Plate-Baffle
(In E23 Engine, These Bolts are Combined with 11 Bolt (M6 X 12, 6 pieces)
Baffle Plate) .................................... 9 - 11 N•m (80 - 97 lb-in)
5 Bolt (M6 X 12, 2 pieces) (E23 Engine Only : Baffle Plate Mounting Bolt)
.................................... 9 - 11 N•m (80 - 97 lb-in)

SSANGYONG Y200
1B2-92 M161 ENGINE MECHANICAL

Removal & Installation Procedure

1. Unscrew the bolt (6) from the oil pump drive
sprocket and separate the oil pump drive chain.
Installation Notice
25 - 39 N•m
Tightening Torque
(21 - 26 lb-ft)

2. Unscrew the bolts (4,5) and remove the oil strainer

assembly (3).
Installation Notice
Bolt (4): 9 - 11 N•m
YAD1B7V0
(80 - 97 lb-ft)
Tightening Torque
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 22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

YAD1B7W0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-93

OIL PRESSURE RELIEF VALVE

Preceding Work: Removal of oil pan

YAD1B7X0

1 Screw Plug ............................... 50 N•m (37 lb-ft) 3 Guide Pin

2 Compression Spring 4 Piston

Removal & Installation Procedure

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
1B2-94 M161 ENGINE MECHANICAL

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 ten-
sioner from drying up. In other words, it stops oil-
returning 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.

Replacement Procedure
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

YAD1B7Z0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-95

OIL DIPSTICK GUIDE TUBE

YAD1B8A0

1 Oil Dipstick Level Gauge 4 Bolt (M6 X 16, 1 piece)

2 Oil Dipstick Guide Tube .................................... 9 - 11 N•m (80 - 97 lb-in)
3 O-Ring 5 Clamp

Removal & Installation Procedure

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
1B2-96 M161 ENGINE MECHANICAL

UNIT REPAIR
CORE PLUGS IN CRANKCASE
Preceding Work: Draining of the coolant

YAD1B8B0

1 Core Plug ............................................... Replace

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-97

Tools Required
102 589 00 15 00 Drift

Replacement Procedure
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
1B2-98 M161 ENGINE MECHANICAL

CYLINDER BORE

YAD1B8C0

Group Code Letter and Cylinder Bore Size

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

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-99

Group Code Letter Cylinder Group Code Letter 1) Cylinder Bore Size (mm)
Standard Size A φ 89.900 - φ 89.906
∅ 90.9 X φ 89.906 - φ 89.912
B φ 89.912 - φ 89.918
1st Repair Size A φ 90.150 - φ 90.156
(Standard Size + 0.25) X φ 89.156 - φ 90.162
B φ 90.162 - φ 90.168
2nd Repair Size A φ 90.400 - φ 90.406
(Standard Size + 0.5) X φ 90.406 - φ 90.412
B φ 90.412 - φ 90.418

1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

Service Data Standard

Wear Limit in Longitudinal and Transverse Direction 0.1 mm

Permissible Deviation of Cylinder Out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm
Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm
Chamfer Angle 75 °
Honing Angle 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
YAD1B4E0 c. Location of the Oil Ring at BDC

Chamfer Angle

YAD1B4F0

SSANGYONG Y200
1B2-100 M161 ENGINE MECHANICAL

CRANKCASE MATING SURFACE

YAD1B4G0

Service Data Standard

Height of The Crankcase ‘H’ (When new) 289.35 - 289.45 mm

Minimum Height After Milling 289.05 mm
Flatness Crankcase Upper Mating Surface 0.03 mm
Crankcase Lower Mating Surface 0.04 mm
Permissible Deviation of Parallelismof The Axial Direction 0.1 mm
Upper to Lower Mating Surface Transverse Direction 0.05 mm
Peak-to-valley Height Crankcase Upper Mating Surface 0.012 - 0.009 mm
Crankcase Lower Mating Surface 0.025 - 0.020 mm

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-101

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
1B2-102 M161 ENGINE MECHANICAL

CYLINDER HEAD MATING SURFACE

Preceding Work: Removal of valves

YAD1B4J0

Service Data Standard

Overall Height of Cylinder Head 135.9 - 136.0 mm

Minimum Height After Machining 135.5 mm
Flatness Axial Direction 0.08 mm
Transverse Direction 0.0 mm
Distance ‘T’ Standard Size Intake 24.21 - 24.75 mm
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm
and Valve Stem) Repair Size Intake 23.96 - 24.51 mm
Exhaust 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
M161 ENGINE MECHANICAL 1B2-103

Measurement of Mating Surfac

Universal Tool

Sceledum, Type RTY

Surface Grinding Machine Roaro
Schio / Italy

SSANGYONG Y200
1B2-104 M161 ENGINE MECHANICAL

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Application N•m Lb-Ft Lb-In

Fuel Feed and Return Line 21 - 25 15 - 18 -
Exhaust Manifold and Pipe 30 22 -
Engine Mounting Nuts 70 52 -
Generator Carrier Bolts 25 18 -
Tensioning Pulley Bolt 40.5 - 49.5 29.9 - 36.5 -
Steering Pump Bolts 22.5 - 27.5 16.6 - 20.3 -
A/C Braket Bolts 22.5 - 27.5 16.6 - 20.3 -
Intake Air Duct Mounting Nuts 9 - 11 - 80 - 97
Spark Plug Cover Bolts 9 - 11 - 80 - 97
Cylinder Head Cover Bolts 9 - 11 - 80 - 97
Magnetic Assembly Bolt 9 - 11 - 80 - 97
Cylinder Head Front Cover Bolts M8 22.5 - 27.5 16.6 - 20.3 -
M6 9 - 11 - 80 - 97
Cylinder Head Bolts 55 41 -
+90° +90° -
+90° +90° 80 - 97
Timing Gear Case Cover Bolts 22.5 - 27.5 16.6 - 20.3 -
Crankshaft Sealing Rear Cover Mounting Bolts 9 - 11 - -
Vibration Damper Center Bolts 200 + 20 148 + 15 -
+90° + 10° +90° + 10° -
Flywheel Mounting Bolt 40 30 -
+90° +90° -
Amarture Bolt in Flywheel 45 + 5 33 + 3.7 -
Camshaft Adjuster Flange Bolts +90° + 10° +90° + 10° -
35 26 -
Intake Flange Shaft Bolts 18 - 22 13 - 16 -
60° ± 5° 60° ± 5° -
Exhaust Camshaft Sprocket Bolts 18 - 22 13 - 16 -
60° ± 5° 60° ± 5° -
Intake Flange Shaft Bolts 18 - 22 13 - 16 -
Exhaust Camshaft Sprocket Bolts 60° ± 5° 60° ± 5° -
Camshaft Bearing Cap Bolts 22.5 - 27.5 16.6 - 20.3 -
Chain Tensioner Screw Plug 40 30 -
Chain Tension Assembly 72 - 88 53 - 65 -
Oil Pump Sprocket Bolt 29 - 35 21 - 26 -
Tensioning Device Bolts 26 - 32 19 - 24 -
Water Pump Pulley 22.5 - 27.5 16.6 - 20.3 -
Upper Intake Manifold Bolt 22.5 - 27.5 16.6 - 20.3 -
Lower Intake Mainfold Bolt 22.5 - 27.5 16.6 - 20.3 -
Flange Bolt to Exhaust Mainfold 30 22 -

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-105

FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N•m Lb-Ft Lb-In

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

SSANGYONG Y200
1B2-106 M161 ENGINE MECHANICAL

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

000 589 58 43 00 103 589 02 09 00

Chain Assembly Oil Filter Remover

YAD1B1W0 YAD1B2Y0

111 589 01 59 00 111 589 25 63 00

Supporting Bar Thrust Piece

YAD1B0W0 YAD1B0Y0

111 589 18 61 00 116 589 20 33 00

Lever Pusher Sliding Hammer

YAD1B0X0 YAD1B580

116 589 01 34 00 119 589 00 43 00

Threaded Pin Drift

YAD1B570 YAD1B1L0

SSANGYONG Y200
M161 ENGINE MECHANICAL 1B2-107

Special Tools Table (Cont’d)

601 589 03 14 00
602 589 00 40 00
Crankshaft Front Seal
Engine Lock
Installer

YAD1B790 YAD1B720

603 589 00 40 00 617 589 00 10 00

Fan Clutch Holder Allen Wrench Socket

YAD1B4K0 YAD1B560

615 589 01 33 00
DW110 - 090
Crankshaft Sprocket
Connecting Hose
Puller

YAD1B2M0 YAD1B0Z0

601 589 03 43 00
DW110 - 100
Crankshaft Rear Seal
Valve Tappet Remover
Installer

YAD1B730 YAD1B1A0

SSANGYONG Y200
1B2-108 M161 ENGINE MECHANICAL

Special Tools Table (Cont’d)

111 589 03 15 00
Holding Pin

YAD1B4R0

SSANGYONG Y200
SECTION 1B3

DIESEL ENGINE MECHANICAL

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

DESCRIPTION AND OPERATION

VALVE DEVICE Function
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.

YAD1BA30

1 Cam 5 Pressure Spring

2 Tappet 6 Ball Valve
3 Guide Sleeve a Supply Chamber
4 Thrust Piece b Working Chamber

The hydraulic valve clearance adjusting elements are

YAD1BA10
installed in the bucket tappets and operate the valves
directly through the thrust pins and guide sleeves.
1 Cam 4 Oil
When the engine is running and a load is applied on
2 Camshaft 5 Valve
the element by cam tip, the element cam go down
3 Tappet
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
The maintenance-free hydraulic valve clearance tappet (2), the load on the guide sleeve (3) is relieved.
adjusting elements automatically compensates the The spring (5) pushes the thrust pin (4) up until the
valve clearance resulting from thermal expansion and tappet is resting against the cam (1). The vacuum
wear. produced in the working chamber (b) as a result of the
This produces a quiet-running valve train. 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.
YAD1BA20
The oil to the supply chamber flows via the groove
provided in the base of the tappet.

SSANGYONG Y200
1B3-6 DIESEL ENGINE MECHANICAL

CYLINDER BLOCK

YAD1BA50

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-7

1 Piston & Piston Ring Assembly 13 Vibration Damper

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

SSANGYONG Y200
1B3-4 DIESEL ENGINE MECHANICAL

COMPONENT LOCATOR
CYLINDER HEAD

YAD1BA40

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-5

1 Blow By Gas Return Hose 11 Cylinder Head

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

SSANGYONG Y200
1B3-8 DIESEL ENGINE MECHANICAL

ENGINE COMPONENT

YAD1BA60

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-9

1 Fuel Filter Assembly 6 A/C Compressor Assembly

2 Oil Filter Assembly 7 Generator Assembly
3 Injection Pump Assembly 8 Turbo Charger Assembly
4 Power Steering Pump Assembly 9 EGR Valve Assembly
5 Starter Assembly

SSANGYONG Y200
1B3-10 DIESEL ENGINE MECHANICAL

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
ENGINE ASSEMBLY

YAD1BA70

1. Engine Assembly

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-11

Removal Procedure
1. Disconnect the negative battery cable.

YAD1BA80

2. Remove the hood.

YAD1BA90

3. Remove the skid plate.

Installation Notice
28 - 47 N•m
Tightening Torque
(21 - 35 lb-ft)

YAD1B020

4. Remove the radiator drain cock and drain the

coolant.
Notice: Open the coolant reservoir tank cap.

YAD1BAA0

SSANGYONG Y200
1B3-12 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-13

10. Remove the hoses (air intake to intercooler,

intercooler to intake duct).

;;
;; YAD1BAF0

11. Loosen the cooling fan shroud bolts and remove

the cooling fan shroud.

;;
Installation Notice

Tightening Torque 3 - 7 N•m

;;
(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

SSANGYONG Y200
1B3-14 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-15

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
1B3-16 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-17

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
54 - 68 N•m
Tightening Torque
(40 - 50 lb-ft)

YAD1BAZ0

30. Remove the engine mounting bracket bolts.

Installation Notice
50 - 75 N•m
Tightening Torque
(37 - 55 lb-ft)

YAD1BB00

SSANGYONG Y200
1B3-18 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-19

POLY V-BELT AND TENSIONING DEVICE

POLY V-BELT

YAD1BB20

1 Nut ........................................... 21 N•m (15 lb-ft) 4 Spring

2 Tensioning Lever 5 Tensioning Lever
3 Bolt 6 Poly V-Belt

SSANGYONG Y200
1B3-20 DIESEL ENGINE MECHANICAL

Removal & Installation Procedure

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 (φ 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 Tensioning Pulley Length of Belt

8 Crankshaft
With Air Conditioner 2,100 mm
9 Generator Length (L)
10 Water Pump Without Air Conditioner 2,040 mm
11 Guide Pulley
12 Power Steering Pump
13 A/C Compressor

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

5. Cord torn out at the side.

6. Outer cords frayed.

YAD1B400

SSANGYONG Y200
1B3-22 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-23

TENSIONING DEVICE
Preceding Work: Removal of cooling fan

YAD1BLJ0

1 Bolt........................................... 21 N•m (15 lb-ft) 10 Tensioning Pulley

2 Damper 11 Socket Bolt .............................. 29 N•m (21 lb-ft)
3 Nut ........................................... 21 N•m (15 lb-ft) 12 Closing Cover
4 Tensioning Lever 13 Washer
5 Guide Rail Pin 14 Tensioning Lever
6 Bolt 15 Fit Bolt.................................... 100 N•m (74 lb-ft)
7 Poly V-Belt 16 Closing Cover
8 Belt Pulley 17 Spring
9 Bolt........................................... 10 N•m (89 lb-in) 18 Bolt........................................... 20 N•m (15 lb-ft)

SSANGYONG Y200
1B3-24 DIESEL ENGINE MECHANICAL

Removal & Installation Procedure

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 (φ 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)
Tightening Torque
bolt (18): 20 N•m
(15 lb-ft)

Pay attention to installation position of the damper.

YAD1BB80

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-25

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

12. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200
1B3-26 DIESEL ENGINE MECHANICAL

CRANKCASE AND CYLINDER HEAD

CYLINDER HEAD

YAD1BBC0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-27

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

SSANGYONG Y200
1B3-28 DIESEL ENGINE MECHANICAL

Cylinder Head Bolt Tightening Torque

Cylinder Head Bolts (12-sided socket head) 1st Step 10 N•m (89 lb-in)
(Engine cold) 2nd Step 35 N•m (26 lb-ft)
3rd Step 180°
M8 Cylinder Head Bolts 25 N•m (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 Max. Length(L)

M10 80 mm 82 mm
M10 102 mm 104 mm
M10 115 mm 117 mm

YAD1BBE0
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
DIESEL ENGINE MECHANICAL 1B3-29

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.
YAD1BBF0 3. Hold the fan with counter holder 603 589 00 40 00
and remove the bolt and then remove the cooling
fan.

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(φ 18, 180 mm). By pushing the rod to the
arrow direction, pull back the bolt.

YAD1BB30

SSANGYONG Y200
1B3-30 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-31

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
1B3-32 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-33

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
1B3-34 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-35

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
1B3-36 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-37

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
1B3-38 DIESEL ENGINE MECHANICAL

Installation Procedure
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 Max. Limit(L)

M10 80 mm 82 mm
M10 102 mm 104 mm
M10 115 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 × 102
3 .............................................. M10 × 115
4 .............................................. M 8 × 50
5 .............................................. M 8 × 80

YAD1BCG0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-39

5. Tighten the cylinder head bolts to specified torque

and torque angle.
1st Step 10 N•m (89 lb-in)
2nd Step 35 N•m (26 lb-ft)
Tightening
Torque Angle 90°
Torque
Wait for 10 minutes
Torque Angle 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 N•m (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
1B3-40 DIESEL ENGINE MECHANICAL

9. Install the fuel filter and connect the pipe.

Installation Notice
Tightening Torque 25 N•m (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 N•m (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
DIESEL ENGINE MECHANICAL 1B3-41

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 N•m (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
1B3-42 DIESEL ENGINE MECHANICAL

YAD1BCR0

19. Check the TDC position of the crankshaft.

YAD1BC10

20. Install the camshaft sprocket bolt.

Installation Notice
1st Step 25 N•m (18 lb-ft)
Tightening Torque
2nd Step 90°

YAD1BC70

Notice: Measure the max. length ‘L’ and replace

the bolt if it exceeds 53.6 mm.

YAD1BCS0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-43

21. Install the exhaust manifold and gasket.

Installation Notice
Tightening Torque 25 N•m (18 lb-ft)

YAD1BCT0

22. Replace the seal and then install the chain

tensioner.
Installation Notice
Tightening Torque 80 N•m (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 N•m (30 lb-ft)

YAD1BCU0

SSANGYONG Y200
1B3-44 DIESEL ENGINE MECHANICAL

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 10 N•m (89 lb-in)
29. Install the blow-by hose.

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 N•m (18 lb-ft)

YAD1BCW0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-45

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 N•m (13 lb-ft)

YAD1BBN0

37. Install the poly V-belt.

Notice: Be careful not to contaminate the belt.

YAD1BCZ0

SSANGYONG Y200
1B3-46 DIESEL ENGINE MECHANICAL

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 N•m (15 lb-ft)

YAD1BB30

39. Install the oil dipstick tube bracket.

Installation Notice
Tightening Torque 10 N•m (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
DIESEL ENGINE MECHANICAL 1B3-47

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
1B3-48 DIESEL ENGINE MECHANICAL

Installation Procedure
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 N•m (96 lb-ft)

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-49

OIL PAN

YAD1BD50

1 Gasket.................................................... Replace 5 Drain Plug ................................ 25 N•m (18 lb-ft)

2 Oil Pan 6 Bolt........................................... 10 N•m (89 lb-in)
3 Bolt........................................... 10 N•m (89 lb-in) 7 Bolt........................................... 25 N•m (18 lb-ft)
4 Washer ................................................... Replace

Notice: Replace the washer seal with new one.

SSANGYONG Y200
1B3-50 DIESEL ENGINE MECHANICAL

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

1 Bolt ...........................................10 N•m (89 lb-in) 13 Bolt ........................................... 32 N•m (24 lb-ft)
2 Cylinder Head Cover 14 Timing Case Cover
3 Gasket.................................................... Replace 15 Bolt ........................................... 23 N•m (17 lb-ft)
4 Socket Bolt .............................. 25 N•m (18 lb-ft) 16 Generator Bracket
5 Fuel Filter 17 Bolt ........................................... 45 N•m (33 lb-ft)
6 Square Nut 18 Bolt ........................................... 25 N•m (18 lb-ft)
7 Oil Pan 19 Bolt ...........................................10 N•m (89 lb-in)
8 Socket Bolt ..............................10 N•m (89 lb-in) 20 Closing Cover
9 Bolt .................................. M6 : 10 N•m (89 lb-in) 21 Socket Bolt .............................. 23 N•m (17 lb-ft)
......................................... M8 : 23 N•m (17 lb-ft) 22 Guide Pulley
10 Power Steering Pump 23 Bolt ............................................. 9 N•m (80 lb-in)
11 Bolt 24 Guide Pulley Bracket
12 Belt Pulley 25 Nut ............................................ 23N•m (17 lb-ft)

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-51

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
1B3-52 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-53

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

Installation Procedure
1. Thoroughly clean the sealing surface and apply
sealant.

YAD1BDG0

2. Install the timing case cover.

Installation Notice
Tightening Torque 10 N•m (89 lb-in)

Bolts arrangement

1. M6 x 60
2. M6 x 70
3. M6 x 40

YAD1BDH0

SSANGYONG Y200
1B3-54 DIESEL ENGINE MECHANICAL

3. Tighten the socket bolts in the chain box.

Installation Notice
Tightening Torque 25 N•m (18 lb-ft)

4. Tighten the oil pan bolts.

Installation Notice
Socket Bolt 10 N•m (89 lb-in)
Tightening
M6 Bolt 10 N•m (89 lb-in)
Torque
M8 Bolt 25 N•m (18 lb-ft)

YAD1BDC0

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 Front 25 N•m (18 lb-ft)

Torque Side 25 N•m (18 lb-ft)

YAD1BDK0

7. Install the generator.

Installation Notice
Tightening Upper 25 N•m (18 lb-ft)
Torque Lower 45 N•m (33 lb-ft)

YAD1BDL0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-55

8. Install the cylinder head cover.

Installation Notice
Tightening Torque 10 N•m (89 lb-in)

9. Tighten the injection pump mounting bolts.

Installation Notice
Tightening Torque 23 N•m (17 lb-ft)

YAD1BDM0

10. Install the fuel filter.

Installation Notice
Tightening Torque 25 N•m (18 lb-ft)

11. Install the vacuum pump.

Installation Notice
Tightening Torque 10 N•m (89 lb-in)

YAD1BDN0

12. Install the power steering pump.

Installation Notice
Tightening Torque 23 N•m (17 lb-ft)

13. Install the power steering pump pulley.

Installation Notice
Tightening Torque 32 N•m (24 lb-ft)

YAD1BDP0

14. Install the guide pulley bracket.

Installation Notice
Tightening Torque 9 N•m (80 lb-in)

YAD1BD80

SSANGYONG Y200
1B3-56 DIESEL ENGINE MECHANICAL

15. Install the guide pulley (22) and fit the closing
cover (20).
Installation Notice
Tightening Torque 23 N•m (17 lb-ft)

YAD1BD70

16. Replace the gasket (3) and install the cylinder

head cover (2).
Installation Notice
Tightening Torque 10 N•m (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
DIESEL ENGINE MECHANICAL 1B3-57

CRANKSHAFT ASSEMBLY
VIBRATION DAMPER AND HUB
Preceding Work: Removal of the cooling fan
Removal of poly V-belt

YAD1BDQ0

SSANGYONG Y200
1B3-58 DIESEL ENGINE MECHANICAL

1 Bolt ...........................................10 N•m (89 lb-in) 13 Radial Seal

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

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-59

Tools Required
103 589 00 33 00 Puller
601 589 03 14 00 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
1B3-60 DIESEL ENGINE MECHANICAL

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 N•m (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 23 N•m (17 lb-ft)

Align the alignment marks.

YAD1BE00

SSANGYONG Y200
1B3-62 DIESEL ENGINE MECHANICAL

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 N•m (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: Don’t 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.
;;;;

;;;;
;;;;
;;;;
A Standard Radial Seal
YAD1BE40 B Repair Radial Seal

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-63

FLYWHEEL AND CRANKSHAFT END COVER

Preceding Work: Removal of the transmission
Removal of the clutch

YAD1BE50

1 Crankshaft Flange 7 Straight Pin

2 End Clver .............................. Clean Loctite 573 8 Flywheel (Manual Transmission)
3 Bolt........................ 10 N•m (89 lb-in) Loctite 573 9 12-Sided Stretch Bolt
4 Radial Seal ............................................ Replace ............................ Check, 45 N•m (33 lb-ft)+ 90°
5 Dowel Sleeve 10 Drive Plate (Automatic Transmission)
6 Bolt........................ 10 N•m (89 lb-in) Loctite 573 11 Flywheel (Automatic Transmission)

SSANGYONG Y200
1B3-64 DIESEL ENGINE MECHANICAL

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.

YAD1BE60

Notice: If the length ‘L’of bolts exceeds 22.5 mm,

replace the bolts.

YAD1BE70

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.

YAD1BE80

4. Remove the radial seal (4) with care not to damage

the sealing surface.

YAD1BE90

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-65

Installation Procedure
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.

YAD1BEA0

4. Install the inner oil seal assembler 601 589 03 43

00 to the crankshaft flange.

YAD1BEB0

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).

YAD1BEC0

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.
;;; ;;;;

;;; ;;;;;
;;;;;
;;; ;;;;;
A Standard Radial Seal
YAD1BED0 B Repair Radial Seal

SSANGYONG Y200
1B3-66 DIESEL ENGINE MECHANICAL

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.

YAD1BEE0

8. Install the flywheel.

Installation Notice
Tightening Torque 45 N•m (33 lb-ft)+ 90°

YAD1BEF0

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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-67

CRANKSHAFT BALL BEARING

YAD1BEH0

1 Spacer 3 Ball Bearing

2 Cover...................................................... Replace 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

Removal & Installation Procedure

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.

YAD1BEJ0

SSANGYONG Y200
1B3-68 DIESEL ENGINE MECHANICAL

CRANKSHAFT
Preceding Work: Removal of the end cover
Removal of the piston
Removal of the crankshaft sprocket

YAD1BEK0

3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower)

4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap
5 Crankshaft 9 Crankshaft Bearing Cap (Fit Bearing)
6 Crankshaft Main Bearing Shells (Lower) 10 12-sided Stretch Bolts .... 55 N•m (41 lb-ft)+ 90°

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-69

Thrust Washer and Bearing Arrangement

YAD1BEL0

3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings

4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)

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 Thrust bearing Thrust bearing

journal diameter journal width journal diameter
Standard size 50.950 - 57.965 24.500 - 24.533
47.950 - 47.965
24.600 - 24.633
Repair size 1 57.500 - 57.715 24.700 - 24.733 47.700 - 47.715
Repair size 2 57.450 - 57.465 24.900 - 24.933 47.450 - 47.650
Repair size 3 57.200 - 57.215 25.000 - 25.033 47.200 - 47.215
Repair size 4 56.950 - 56.965 - 46.950 - 46.965

Bearing Clearances
Crankshaft bearing Thrust bearing
Radial clearances New 0.027 - 0.051 mm 0.026 - 0.068 mm
Limit Max. 0.070 mm Max. 0.080 mm
Axial clearances New 0.100 - 0.254 mm -
Limit Max. 0.300 mm -

Matching Fit Bearing Journal Width to Thrust Bearings

Fit bearing journal width Thrust bearings thickness

24.500 - 24.533 mm 2.15 mm
24.600 - 24.633 mm 2.20 mm
24.700 - 24.733 mm 2.25 mm
24.900 - 24.933 mm 2.35 mm
25.000 - 25.033 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 Color code of relevant crankshaft bearing shell
1 punch mark or blue Blue or white-blue
2 punch marks or yellow Yellow or white-yellow
3 punch marks or red Red or white-red

Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft

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

SSANGYONG Y200
1B3-72 DIESEL ENGINE MECHANICAL

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

Removal & Installation Procedure

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.
YAD1BEM0

3. Remove the crankshaft bearing caps (9) and lower

thrust bearings (7).
4. Remove the lower bearing shell (6) from the bearing
cap (9).

YAD1BEN0

5. Remove the crankshaft (5).

YAD1BEP0

6. Remove the upper thrust bearings (4).

7. Remove the upper bearing shells (3) from
crankcase.

YAD1BEQ0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-73

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
YAD1BER0
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.

YAD1BES0

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 A’s value, A’s value is the mean value.

YAD1BET0

SSANGYONG Y200
1B3-74 DIESEL ENGINE MECHANICAL

14. Measure crankshaft bearing journal diameter (F).

Notice: When measured in A and B, the runout
should not exceed 0.010 mm.

YAD1BEU0

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’ = 0.041 mm

YAD1BEV0

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.

YAD1BEW0

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).

YAD1BEX0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-75

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).

YAD1BEY0

Notice: If the max. length of bolts (L) exceed

63.8 mm, replace them.

YAD1BEZ0

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 55 N•m (41 lb-ft)+ 90°

Install from No. 1 cap.

YAD1BF00

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

YAD1BF10 should be installed on both sides of the thrust
bearing.

SSANGYONG Y200
1B3-76 DIESEL ENGINE MECHANICAL

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.

YAD1BF20

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’ = 0.047 mm

YAD1BF30
Radial Clearance ‘L’ 0.026 - 0.068 mm

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
DIESEL ENGINE MECHANICAL 1B3-77

CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of timing case cover

YAD1BF40

1 12-Sided Stretch Bolt (M11) 10 Washer

............................ Check, 25 N•m (18 lb-ft)+ 90° 11 Bolt........................................... 25 N•m (18 lb-ft)
2 Washer 12 Crankshaft Sprocket
3 Camshaft Sprocket 13 Crankshaft
4 Timing Chain 14 Key
5 Bearing Pin 16 Guide Rail
6 Bearing Pin 17 Spring
7 Oil Pump 18 Bushing
8 Oil Pump Sprocket 19 Tensioning Lever
9 Oil Pump Chain

SSANGYONG Y200
1B3-78 DIESEL ENGINE MECHANICAL

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).

YAD1BF50

2. Pull out tensioning lever (19), spring (17) and

bushing (18) from the bearing pin (6).

YAD1BF60

3. Pull out the guide rail (16).

YAD1BF70

4. Remove the bolt(11) and then remove the washer

(10), oil pump chain (9) and sprocket (8).

YAD1BF80

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-79

5. Place alignment marks (arrow) on the timing chain

(4) and crankshaft sprocket (12).
6. Remove the woodruff key (15).

YAD1BF90

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).

YAD1BC20

10. Remove the crankshaft sprocket (12) by using a

puller 102 589 05 33 00 (20).

YAD1BFA0

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.

YAD1BFB0

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.

YAD1BFC0

3. Fit the timing chain (4) on the crankshaft sprocket

(12).
Notice: Align the alignment marks (arrow) on the
chain and sprocket.

YAD1BF90

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).

YAD1BC20

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-81

Notice: If the max. length ‘L’ of the stretch bolt

exceeds 53.6 mm, replace it.

YAD1BCS0

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).

YAD1BFD0

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).

YAD1BFE0

SSANGYONG Y200
1B3-82 DIESEL ENGINE MECHANICAL

PISTON
Preceding Work: Removal of the cylinder head
Removal of the oil pump

YAD1BFF0

1 Oil Ring 7 Connecting Rod Bushing .......................... Check

2 2nd Ring 8 Connecting Rod
3 Top Ring 9 Connecting Rod Upper Bearing Shell
4 Snap Ring .............................................. Replace 10 Connecting Rod Lower Bearing Shell
5 Piston Pin 11 Connecting Rod Bearing Cap
6 Piston 12 Connecting Rod Bolt ...... 35 N•m (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 Max. 0.12 mm

Piston crown protrusion in TDC position 0.735 - 0.965 mm
Connecting rod bushing diameter 26.012 - 26.018 mm

Connecting Rod Bolt Dimensions

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

SSANGYONG Y200
1B3-84 DIESEL ENGINE MECHANICAL

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).

YAD1BFG0

3. Remove the connecting rod bearing shells (9, 10).

Notice: Be careful not mix the bearing caps and
shells each other.

YAD1BFH0

4. Remove the piston (6) and connecting rod (8).

YAD1BFJ0

5. Remove the snap ring (4) and pull out the piston
pin (5).
6. Separate the piston and connecting rod.

YAD1BFK0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-85

Installation Procedure
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.

YAD1BFL0

2. Coat the piston pin (15) with engine oil and insert
it by hand.
Notice: Do not heat up the piston.

YAD1BFM0

3. Install the new snap ring (4) into the grooves

(arrow).
4. Check the piston rings (1, 2, 3) and replace them
if necessary.

YAD1BFN0

5. Install and arrange the piston rings to be evenly

120° from each ends gap.

YAD1B2V0

SSANGYONG Y200
1B3-86 DIESEL ENGINE MECHANICAL

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.

YAD1BFQ0

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.

YAD1BFR0

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).

YAD1BFS0

11. Measure stretch shaft diameter (C) of the

connecting rod bolts.
Limit ‘C’ 7.1 mm

YAD1BFT0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-87

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.

YAD1BFU0

14. Measure clearance between the piston crown and

cylinder.
Standard Max. 0.12 mm

YAD1BFV0

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.

YAD1BFW0

SSANGYONG Y200
1B3-88 DIESEL ENGINE MECHANICAL

FLYWHEEL RING GEAR

Preceding Work: Removal of flywheel

YAD1BFX0

1 Ring Gear a Centering Collar Diameter

2 Flywheel

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-89

Tools Required
001 589 53 21 00 Dial Gauge
363 589 02 21 00 Dial Gauge Holder

Replacement Procedure
1. Drill a hole into the ring gear (1) (arrow) and snap
with a chisel.
2. Thoroughly clean the collar surfaces of ring gear.

YAD1BFY0

3. Measure diameter (a) of centering collar.

Diameter ‘a’ 275 + 0.5 mm

Notice: If out of standard, replace the flywheel.

YAD1BFZ0

4. Heat up the new ring gear up to 220°C (428°F) by

using a heating device.
Notice: Use temperature measuring chalk.

YAD1BG00

5. Install the new ring gear (1) onto the flywheel (2)
by using a drift.

YAD1BG10

SSANGYONG Y200
1B3-90 DIESEL ENGINE MECHANICAL

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.

YAD1BG20

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-91

TIMING DEVICE AND VALVE

VALVE TAPPETS
Preceding Work: Removal of camshaft

YAD1BG30

1 Valve Tappet 4 Seal ........................................................ Replace

2 Cylinder Head 5 Screw Plug
3 Oil Gallery

SSANGYONG Y200
1B3-92 DIESEL ENGINE MECHANICAL

Tools Required
102 589 03 40 00 Magnetic Bar

Replacement Procedure
1. Pull out the valve tappet (1) using magnetic bar
102 589 03 40 00.

YAD1BG40

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.

YAD1BG50

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-93

VALVE SPRINGS (CYLINDER HEAD REMOVED)

Proceding Work: Remove of cylinder head

YAD1BG60

1 Valve Tappet 5 Cylinder Head

2 Valve Cotters 6 Stud Bolt ................................ 12 N•m (106 lb-in)
3 Spring Retainer 7 Nut ............................. Replace, 25 N•m(18 lb-ft)
4 Valve Spring .......... Check, replace if necessary

SSANGYONG Y200
1B3-94 DIESEL ENGINE MECHANICAL

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

Removal & Installation Procedure

1. Remove the nuts (8) uniformly and then remove
the washer (7), exhaust manifold (9) and gasket.
Installation Notice
YAD1BG70
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).

YAD1BG80

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).

YAD1BG90

4. Install the supporting bridge 601 589 02 59 00

(13) on the cylinder head (5).

YAD1BGA0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-95

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.

YAD1BGB0

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.

YAD1BGC0

SSANGYONG Y200
1B3-96 DIESEL ENGINE MECHANICAL

VALVE SPRINGS (CYLINDER HEAD INSTALLED)

Preceding Work: Removal of camshaft

YAD1BGD0

1 Valve Tappet 4 Valve Spring ......... Check, replace if necessary

2 Valve Cotters 5 Timing Chain
3 Spring Retainer 6 Cylinder Head

Notice: Remove the valve springs only when the piston is at TDC.

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-97

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

Removal & Installation Procedure

1. Remove the valve tappet (1) with magentic bar
102 589 03 40 00.
Notice: Place the valve tappets upside down
YAD1BG40 (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.

YAD1BGE0

4. Install the supporting bar 667 589 02 63 00 (8).

YAD1BGF0

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.

YAD1BGG0

SSANGYONG Y200
1B3-98 DIESEL ENGINE MECHANICAL

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).

YAD1BGH0

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).

YAD1BGG0

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).

YAD1BGE0

13. Coat the valve tappet with oil and install it with
magnetic bar 102 589 03 40 00.

YAD1BG40

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-99

VALVE STEM SEALS

Preceding Work: Removal of camshaft.

YAD1BGJ0

1 Valve Tappet 4 Valve Spring .......... Check, replace if necessary

2 Valve Cotters 5 Valve Stem Seal
3 Spring Retainer 6 Valve

Notice: Remove the valve stem seals when the pistion is positioned at TDC.

SSANGYONG Y200
1B3-100 DIESEL ENGINE MECHANICAL

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 Press Lever
667 589 02 63 00 Supporting Bar

YAD1BGK0 YAD1BGL0

Intake valve stem seal Exhaust valve stem seal

Chamfer Offset All round
Inner diameter ‘d’ 7.3mm 8.2 mm
Color Brown Green
Wire ring Black Yellow

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-101

Replacement Procedure
1. Remove the valve tappet (1) with magnetic bar
102 589 03 40 00.
Notice: Place the valve tappets upside down
(open end upward).

YAD1BG40

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.

YAD1BGM0

4. Install the supporting bar 667 589 02 63 00 (8).

YAD1BGE0

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).

YAD1BGG0

SSANGYONG Y200
1B3-102 DIESEL ENGINE MECHANICAL

6. Remove the spring retainer (3) and valve spring

(4).

YAD1BGH0

7. Remove the valve stem seal with pliers 104 589

00 37 00 (5).

YAD1BGN0

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.

YAD1BGP0

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.

YAD1BGG0

SSANGYONG Y200
1B3-102 DIESEL ENGINE MECHANICAL

6. Remove the spring retainer (3) and valve spring

(4).

YAD1BGH0

7. Remove the valve stem seal with pliers 104 589

00 37 00 (5).

YAD1BGN0

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.

YAD1BGP0

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.

YAD1BGG0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-103

VALVE GUIDES
Preceding Work: Removal of cylinder head
Removal of valve spring
Removal of valve

YAD1BGQ0

1 Cylinder Head 3 Valve Seat Ring

2 Valve Guide a Basic Bore Diameter

Service Data

Outer Diameter Basic Bore Overlap Valve Guide Inner Length

Item Color Code
‘D’ Diameter ‘a’ ‘D’ - ‘a’ Diameter‘ A ’ ‘ L’
Repair size 1 14.251 Red 14.200 - 14.211 0.029
Intake 8.000 - 8.030 39.5
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051
Repair size 1 14.240 - 14.251 Red 14.200 - 14.211 0.029
Exaust 9.000 - 9.050 37.7
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051

SSANGYONG Y200
1B3-104 DIESEL ENGINE MECHANICAL

Notice: Measure center (arrow) of the valve guide and

if the inner diameter ‘A’ exceeds standard value,
replace the guide.

YAD1BGR0

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 GO / NO GO Gauge (for Intake)
103 589 02 15 00 Drift (for Exhaust)
103 589 03 15 00 Drift (for Intake)
115 589 34 63 00 Mounting Device
117 589 03 23 00 GO / NO GO Gauge (for Exhaust)
346 589 00 63 00 Super Cooling Box
601 589 05 15 00 Drift (for Intake)
601 589 06 15 00 Drift (for Exhaust)

Matching Valve Seat - Broaching Tools - Guide Sleeves

Valve Seat Broaching Tool No. Guide Sleeve Tool No. Guide Sleeve Side
Intake 102 589 00 63 00 B
115 589 00 53 00 (14.2 mm)
Exhaust 102 589 08 63 00 B
Intake A
115 589 01 53 00 (14.4 mm) 601 589 15 63 00
Exhaust 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.

YAD1BGS0

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

Replacement Procedure
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
1B3-106 DIESEL ENGINE MECHANICAL

- 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
YAD1BGW0
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.

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
DIESEL ENGINE MECHANICAL 1B3-107

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
1B3-108 DIESEL ENGINE MECHANICAL

VALVE SEAT RINGS

Preceding Work: Removal of valve
Checking of valve guide, replace if necessary
Removal of prechamber

YAD1BH30

1 Cylinder Head D Valve Seat Ring Outer Diameter

2 Valve Seat Ring D1 Valve Seat Ring Inner Diameter
A Height (Cylinder Head Upper / Lower Surface) D2 Basic Bore Diameter
B Height (Cylinder Head Cover Surface / Seat of H Height of Valve Seat Ring
Valve Seat Ring)

Service Data

Item Intake Exhaust

D2 40.000 - 40.016 mm 37.000 - 37.016 mm
D 40.084 - 40.100 mm 37.084 - 37.100 mm
D1 33.400 - 33.600 mm 30.400 - 30.600 mm
H 6.955 - 7.045 mm 6.955 - 7.045 mm
Overlap U=D-D2 0.068 - 0.100 mm 0.068 - 0.100 mm
B 133.4 mm 133.4 mm
A 142.5 mm 142.5 mm

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-109

Commercial Tools
Cylinder Head Clamping Device Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning Tool Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Ring Seat Turning Tool Hunger
D-8000 München 70
Type RDS 1
Order No. 219 00 100
Pneumatic Removal / Installation Device Hunger
(Drift : 8 mm, 9 mm, 14 mm) D-8000 München 70
Type PVM 1
Tensioning Head Hunger
D-8000 München 70
Order No. 250 15 250
Cutting Tool for Recessing Grooves Hunger
D-8000 München 70
Order No. 217 93 601
Test Set for Valves Hunger
D-8000 München 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 Dürr
D-7123 Sachsenherm - Ochsenbach

SSANGYONG Y200
1B3-110 DIESEL ENGINE MECHANICAL

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
DIESEL ENGINE MECHANICAL 1B3-111

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

If overlap value ‘U’ is out of standard,

machine the basic bore for the valve
YAD1BH90
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
Intake 40.516 mm
Max. D2
Exhaust 37.516 mm
Min. B 133.4 mm

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

The basic diameter D2 must be

machined by 0.020 mm in order to get
the required overlap value.
YAD1BHB0

SSANGYONG Y200
1B3-112 DIESEL ENGINE MECHANICAL

15. Hang the cylinder head (1) to the lifting device

and heat in a water tank to approx. 80°C(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
DIESEL ENGINE MECHANICAL 1B3-113

CAMSHAFT
Preceding Work: Removal of cylinder head cover

YAD1BHH0

1 Bolt........................................... 25 N•m (18 lb-ft) 9 Oil Pan

2 Washer 10 Camshaft Sprocket
3 Camshaft Bearing Cap 11 Washer
4 Camshaft 12 12-Sided Bolt (M11)
5 Dowel Pin ................................. Check, 25 N•m (18 lb-ft)+ 90°
6 Locking Washer 13 Gasket ................................................... Replace
7 Timing Chain 14 Chain Tensioner ....................... 80 N•m (59 lb-ft)
8 Cylinder Head

SSANGYONG Y200
1B3-114 DIESEL ENGINE MECHANICAL

Tools Required
602 589 00 40 00 Engine Lock

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
DIESEL ENGINE MECHANICAL 1B3-115

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
1B3-116 DIESEL ENGINE MECHANICAL

9. Pull out the locking washer.

Notice: Check the condition of locking washer and
replace if necessary.

YAD1BCM0

Installation Procedure
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
DIESEL ENGINE MECHANICAL 1B3-117

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
1B3-118 DIESEL ENGINE MECHANICAL

9. Remove the engine lock 602 589 00 40 00.

YAD1BC40

10. Check the TDC marking of OT on the crankshaft.

YAD1BC10

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-119

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 3 Camshaft Sprocket

2 Timing Chain 4 Outer Plate

SSANGYONG Y200
1B3-120 DIESEL ENGINE MECHANICAL

Tools Required
000 589 58 43 00 Chain Assembling Device

Replacement Procedure
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
DIESEL ENGINE MECHANICAL 1B3-121

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
1B3-122 DIESEL ENGINE MECHANICAL

11. Place the fitting tool (8) onto the chain link and
rivet the chain pins one by one.
35 - 40 N•m
Tightening Torque
(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
DIESEL ENGINE MECHANICAL 1B3-123

CHAIN TENSIONER

YAD1BHU0

1 Chain Tensioner ....................... 80 N•m (59 lb-ft) 2 Seal ........................................................ Replace

SSANGYONG Y200
1B3-124 DIESEL ENGINE MECHANICAL

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 Screw Plug 11 Valve Disc

4 Aluminum Gasket 12 O-Ring
5 Ball 13 Snap Ring
6 Ball Guide 14 Compression Spring
7 Compression Spring 15 Filler
8 Compression Spring
9 Housing a Feed Bore from Cylinder Head
10 Thrust Pin b To Oil Pan

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-125

LUBRICATION SYSTEM
OIL FILTER

YAD1BHW0

1 Housing Cap ............................ 25 N•m (18 lb-ft) 5 Bolt........................................... 25 N•m (18 lb-ft)
2 O-Ring .................................................... Replace 6 Oil Pressure Switch
3 Oil Filter ............... Element replace if necessary 7 Gasket
4 Oil Filter Housing

SSANGYONG Y200
1B3-126 DIESEL ENGINE MECHANICAL

Removal & Installation Procedure

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
DIESEL ENGINE MECHANICAL 1B3-127

OIL SPRAY NOZZLE

YAD1BHZ0

1 Fitting Sleeve 3 Combination Bolt ................... 10 N•m (89 lb-in)

2 Oil Spray Nozzle a Oil Duct

Removal & Installation Procedure

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)

3. Installation should follow the removal procedure

in the reverse order.

YAD1BJ00

SSANGYONG Y200
1B3-128 DIESEL ENGINE MECHANICAL

OIL PUMP
Preceding Work: Removal of oil pan

YAD1BJ10

1 Oil Pump 5 Pressure Spring

2 Bolt ........................................... 25 N•m (18 lb-ft) 6 Guide Pin
3 Sprocket 7 Screw Plug ............................... 50 N•m (37 lb-ft)
4 Poston 8 Bolt ........................................... 25 N•m (18 lb-ft)

Removal & Installation Procedure

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
DIESEL ENGINE MECHANICAL 1B3-129

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)

4. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200
1B3-130 DIESEL ENGINE MECHANICAL

UNIT REPAIR
MILLING OF PRECHAMBER SEALING SURFACE

YAD1BJ40

1 Drift 4 Counter Sink (Special Tool - 601 589 00 66 00)

2 Sleeve 5 Cylinder Head
3 Milling Cutter

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
DIESEL ENGINE MECHANICAL 1B3-131

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
YAD1BJ50
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.

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
1B3-132 DIESEL ENGINE MECHANICAL

8. Remeasure size ‘X’ and compare it with the first

measurement and determine the thickness of
spacer ring.
Ex Size before machining 25.7 mm
Size after machining 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
DIESEL ENGINE MECHANICAL 1B3-133

TDC (TDC SENSOR BRACKET) SETTING

Preceding Work: Removal of No.1 cylinder prechamber

YAD1BJB0

1 Measuring Device 3 Cylinder Head

2 Dial Gauge 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.

SSANGYONG Y200
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°.

YAD1BC10

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’.
YAD1BJC0 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.

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 10 N•m (89 lb-in)
The timing mark on the damper must be positioned
YAD1BJD0 at ATDC 20°.

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-135

MACHINING OF FLYWHEEL

YAD1BJE0

1 Flywheel

Machining of Flywheel
;;
yyyy
;;;;
;;
;;;;
yyyy
;;
;;;;
yyyy
;;
;;;;
yyyy
Notice: Flywheels which have scorch marks, scoring
or cracks in the clutch surface should be machined by
;;
;;;;
yyyy
;;
grinding or precision-turning. If the scores or cracks
;;;;
yyyy
;;
;;;;
yyyy
;;
;;;;
yyyy
are severe than permissible specifications, replace the
flywheel.
;;
;;;;
yyyy
;;
;;;;
yyyy
;;
;;;;
yyyy
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;;;;
yyyy
Distance ‘a’ 19.3 - 19.5 mm

;;
;;;;
yyyy
;;
Distance ‘b’ New 16.6 mm
;;;;
yyyy
;;
;;;;
yyyy Repair up to 15.6 mm
;;
;;;;
yyyy
;;
Max. axial runout 0.05 mm
YAD1BJF0

• 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.

SSANGYONG Y200
1B3-136 DIESEL ENGINE MECHANICAL

HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK

YAD1BJG0

1 Cylinder Head Cover 4 Valve Tappet

2 Bolt ...........................................10 N•m (89 lb-in) 5 Cylinder Head
3 Gasket.................................................... Replace

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-137

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
YAD1BJH0 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.

SSANGYONG Y200
1B3-138 DIESEL ENGINE MECHANICAL

VALVE SPRINGS CHECK

Preceding Work : Removal of valve spring

YAD1BJJ0

1 Valve Spring 2 Spring Scale

Service Data

At preloaded
Outer diameter Wire diameter Free length
Length Tension (new) Limit
33.1 mm 4.20 mm 50.0 mm 27 mm 680 - 740 N 612 N

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-139

CHECK AND MACHINING OF VALVES

Preceding Works: Removal of cylinder head
Removal of the vale spring
Removal of the valve

YAD1BJK0

I Valve Length y Half Camshaft Basic Bore Diameter

w Camshaft Cam Basic Diameter z Distance (Cylinder Head Cover Parting Surface
x Distance (Camshaft Basic Bore - Valve Stem) - Valve Stem)

SSANGYONG Y200
1B3-140 DIESEL ENGINE MECHANICAL

Intake Valve Exhaust Valve

YAD1BJL0 YAD1BJM0

Item Intake Valve Exhaust Valve

Valve Disc Diameter ‘d’ 37.90 - 38.10 mm 34.90 - 35.10 mm
Valve Disc Height ‘h’ 1.7 mm 1.7 mm
Setting Angle “α” o r Machining the Valve 45° 45°
Valve Stem Diameter ‘d1’ 7.955 - 7.970 mm 9.945 - 8.960 mm
Valve Length ‘I’ Standard 106.20 - 106.60 mm 106.20 - 106.60 mm
Repair 105.30 - 105.70 105.30 - 105.70 mm
Max. Permissible Runout at Valve Stem and Valve Seat 0.03 mm 0.03 mm

Matching Valves
Camshaft Cam Basic Dia. Camshaft Cam Basic Dia.
Valve to be used
W = 38.0 ± 0.2 mm W = 36.6 ± 0.2 mm
Use machined valve,
19.5 - 20.1 mm if needed
Size (x) 19.5 - 20.3 mm
new repair valve
I = 105.5 ± 0.2 mm
Size (x) 20.4 - 21.4 mm 20.2 - 21.2 mm Reuse valve
Use standard size
Size (x) 21.4 - 21.97 mm 21.2 - 21.97 mm valve
I = 106.4 ± 0.2 mm

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-141

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’.

YAD1BJN0 Intake 1.7 ± 0.15 mm
Service data
Exhaust 1.7 ± 0.15 mm

3. Machine the valve.

Notice: Pay attention to setting angle ‘α’ .

YAD1BJP0

4. Measure radial runout between valve stem and

valve seat with a dial gauge 001 589 32 21 00.
Limit Max. 0.03 mm

YAD1BJQ0

SSANGYONG Y200
1B3-142 DIESEL ENGINE MECHANICAL

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).

38 ± 0.2 mm
Diameter ‘w’
or 37.6 ± 0.2 mm

YAD1BJT0

10. Measure distance ‘z’ (cylinder head cover parting

surface - valve stem).

YAD1BJU0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-143

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
1B3-144 DIESEL ENGINE MECHANICAL

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 Valve a Valve Arreare

2 Valve Seat Ring b Valve Seat Width
3 Cylinder Head α Valve Seat Angle
4 Valve Guide β Valve Seat Free Angle

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-145

Service Data
Item Intake Exhaust
Valve Arrears ‘a’ 0.1 - 0.7 mm 0.1 - 0.7 mm
Valve Seat Width ‘b’ 1.2 - 1.7 mm 1.5 - 2.0 mm
Valve Seat Angle ‘α’ 45° 45°
Valve Seat Free Angle ‘β’ 65° 65°
Permissible Radial Runout 0.03 mm 0.03 mm
Valve Length ‘I’ Standard 106.20 - 106.60 mm 106.20 - 106.60 mm
Repair 105.30 - 105.70 mm 105.30 - 105.70 mm

Matching Valves
Camshaft Cam Basic Dia. Camshaft Cam Basic Dia.
Valve to be Used
w = 38.0 ± 0.2 mm w = 37.6 ± 0.2 mm
Use machined valve,
19.5 - 20.3 mm 19.5 - 20.1 mm if needed
Size (x)
use pair valve
1 = 105.5 ± 0.2 mm
Size (x) 20.4 - 21.4 mm 20.2 - 21.2 mm Reuse valve
Use standard size
Size (x) 21.4 - 21.97 mm 21.2 - 21.97 mm valve
I = 106.4 ± 0.2 mm

Commercial Tools
Cylinder Head Clamping Devie Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning Tool Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Test Sat for Valves Hunger
D-8000 München 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 (α =45°).

YAD1BJW0

2. Measure valve seat width ‘b’.

Valve seat Intake 1.2 - 1.7 mm
width ‘b’ Exhaust 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 ‘β’ =65°.

YAD1BJY0

4. Measure radial runout.

Runout Max. 0.03 mm

YAD1BJZ0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-147

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).

38 ± 0.2 mm
Diameter ‘w’
or 37.6 ± 0.2 mm

YAD1BJT0

7. Measure distance ‘z’ (cylinder head cover parting

surface - valve stem).

YAD1BJU0

SSANGYONG Y200
1B3-148 DIESEL ENGINE MECHANICAL

YAD1BJK0

I Length of Valve y Half Camshaft Basic Bore Diameter

w Camshaft Cam Basic Circle Diameter z Distance (CylinderHead Cover Parting Surface -
x Distance (Camshaft Basic Bore - Valve Stem) 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
DIESEL ENGINE MECHANICAL 1B3-149

CAMSHAFT TIMING TEST

Preceding Work: Removal of glow plug

YAD1BK00

1 Cylinder Head Cover 4 Valve Tappet

2 Bolt........................................... 10 N•m (89 lb-in) 5 Cylinder Head
3 Gasket.................................................... Replace

Timing

Intake valve Exhaust valve

Condition of camshaft
Open Close Open Close
New ATDC 11.33° ABDC 17° BBDC 28° BTDC 15.25°
After approx. 20,000km ATDC 12° ABDC 18° BBDC 27° BTDC 14°
*
At 2mm of valve lifting stroke.

SSANGYONG Y200
1B3-150 DIESEL ENGINE MECHANICAL

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).
Notice: Do not rotate the engine at the bolt of the
YAD1BK10 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 ATDC 11.33°
After approx. ATDC 12°

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,
YAD1BC10 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
DIESEL ENGINE MECHANICAL 1B3-151

CYLINDER HEAD PRESSURE LEAKAGE TEST

Preceding Work: Removal of the cylinder head
Removal of the exhaust manifold
Removal of the valve

YAD1BK30

1 Feed Pipe
2 Bolt
3 Return Connection
4 Gasket.................................................................. Replace
5 Coolant Gallery .................................................... Sealing
6 Pressure Measuring Plate ................................... Completely tight to the cylinder head
7 Cylinder Head ......................................................
Immerse with pressure measuring plate into warm water of approx. 60°C (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
1B3-152 DIESEL ENGINE MECHANICAL

FACING CYLINDER HEAD MATING SURFACE

Preceding Work: Removal of prechamber
Cylinder head pressure leakage test

YAD1BK40

1 Valve B Longitudinal Direction

2 Cylinder Head C Transverse Direction
3 Prechamber a Valve Arrears
A Height of Cylinder Head b Prechamber Protrusion

Service Data

Height ‘A’ 142.9 - 143.1 mm

(Cylinder Head Surface - Cylinder Head Cover Surface)
Minimum Height After Machining 142.5 mm
Permissible Unevenness of Parting Surface In Longitudinal Direction 0.08 mm
In Transverse Direction 0.0 mm
Permissible Variation of Parallelism (Longitud. direction) Max. 0.1 mm
Peak-to-Valley Height 0.0017 mm
Valve Arrears ‘a’ Intake Valve 0.1 - 0.7 mm
Exhaust Valve 0.1 - 0.7 mm
Prechamber Protrusion ‘c’ 7.6 - 8.1 mm

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-153

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
1B3-154 DIESEL ENGINE MECHANICAL

REPLACEMENT OF CRANKCASE CORE PLUG

Core Plug

YAD1BK70

Service Data

φ 34 mm
Left
3 EA
φ 34 mm
Right
3 EA
φ 17 mm
Front
1 EA
φ 34 mm
Rear
1 EA

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-155

Tools Required
102 589 00 15 00 Drift
102 589 12 15 00 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
1B3-156 DIESEL ENGINE MECHANICAL

FACING CRANKCASE CONTACTING SURFACE

YAD1BK90

1 Crankcase B Longitudinal Direction

2 Crankcase Contacting Surface C Transverse Direction

Y Height (crankcase upper surface - crankcase

lower surface)

Service Data

Height ‘Y’ Min. 299.62 mm

Permissible unevenness of contacting surface In longitudinal direction (B) 0.06 mm
In transverse direction (C) 0.06 mm
Permissible roughness upper contacting surface 0.0006 - 0.0016 mm
Permissible variation of parallelism of crankcase upper 0.05 mm
surface to lower surface in longitudinal direction
Piston protrusion at TDC to crankcase upper surface Max. 0.965 mm
Min. 0.735 mm

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-157

CYLINDER BORE MEASUREMENT

YAD1BKA0

1 Crankcase Contacting Surface a Longitudinal Direction

2 TDC of 1 st Piston Ring b Transverse Direction
3 BDC of Ring c,d,e Measuring Point

Service Data

Standard size Code letter ‘A’ 89.000 - 89.006 mm

Code letter ‘X’ 89.006 - 89.012 mm
Code letter ‘B’ 89.012 - 89.018 mm
Wear limit in direction of travel and in transverse direction Max. 0.20 mm
Permissible deviation of cylinder shape When new 0.01 mm
Wear limit 0.05 mm
Honing angle 50° ± 10°

SSANGYONG Y200
1B3-158 DIESEL ENGINE MECHANICAL

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application N•m Lb-Ft Lb-In
12-Sided Stretch Bolt (Flywheel) 45 + 90° 33 + 90° -
Camshaft Bearing Cap Bolt 25 18 -
Camshaft Sprocket Bolt 25 + 90° 18 + 90° -
Chain Tensioner 80 59 -
Connecting Rod Bearing Cap Bolt 35 + 90° 26+ 90° -
Cooling Fan Belt Pulley Bolt 10 - 89
Cooling Fan Shroud Bolt 3-7 - 27 - 62
Crankshaft Bearing Cap Bolt 55 + 90° 41 + 90° -
Crankshaft Belt Pulley Bolt 23 17 -
Cylinder Head Bolt 1st Step 10 - 89
2nd Step 35 26 -
Torque Angel 90° 90° -
Wait For 10 min 10 min -
Torque Angel 90° 90° -
Cylinder Head Cover Bolt 10 - 89
Damper Bolt 21 15 -
Drain Plug (Cylinder Head) 30 22 -
End Cover Bolt 10 - 89
Engine Mounting Bolt 50 - 75 37 - 55 -
Exhaust Manifold Nut 25 18 -
Fuel Filter Pipe Bolt 25 18 -
Fuel Line (to Injection Pump) 13 10 -
Fuel Pipe (to Injection Nozzle) 18 13 -
Fuel Pipe (to Injection Pump) 18 13 -
Generator Bracket Bolt 25 18 -
Generator Mounting Bolt Upper 25 18 -
Lower 45 33 -
Guide Pulley Bolt 23 17 -
Guide Pulley Bracket Bolt 9 - 80
Hub Bolt 200 + 90° 148 + 90° -
Idle Pulley Bolt 23 17 -
Injection Nozzle 40 30 -
Injection Pump Mounting Bolt 23 17 -
Intake Manifold Nut 25 18 -
Oil Dipstick Tube Bracket Bolt 10 - 89
Oil Filter Housing Bolt 25 18 -
Oil Filter Housing Cap 25 18 -

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-159

FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N•m Lb-Ft Lb-In

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

SSANGYONG Y200
1B3-160 DIESEL ENGINE MECHANICAL

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

000 589 04 14 00 000 589 25 33 00

Tensioning Strap Internal Extractor

YAD1BKW0 YAD1BKS0

000 589 10 53 00 000 589 33 33 00

Reamer (for Exhaust) Counter Support

YAD1BLC0 YAD1BKR0

000 589 10 68 00 000 589 58 43 00

Cylinder Brush Chain Assembling
Device

YAD1BL60 YAD1B1W0

000 589 21 53 00 001 589 32 21 00

Reamer (for Intake) Dial Gauge

YAD1BLD0 YAD1BLG0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-161

SPECIAL TOOLS TABLE (Cont’d)

001 589 53 21 00
102 589 05 33 00
Dial Gauge
Puller

YAD1BKJ0 YAD1BKU0

102 589 00 15 00
102 589 12 15 00
φ 34) Drift
(φ
φ 17) Drift
(φ

YAD1B3Y0 YAD1B1A0

102 589 00 23 00
103 589 00 33 00
Go/No Go Gauge
Puller
(for Intake)

YAD1BLF0 YAD1BKM0

102 589 03 40 00 103 589 02 15 00

Magnetic Bar Drift (for Exhaust)

YAD1BKX0 YAD1BL80

SSANGYONG Y200
1B3-162 DIESEL ENGINE MECHANICAL

SPECIAL TOOLS TABLE (Cont’d)

104 589 00 37 00 116 589 03 07 00

Pliers T Type Socket Wrench

YAD1BL40 YAD1BKF0

105 589 03 15 00 116 589 06 63 00

Drift (for Intake) Magnetic Finger

YAD1BL70 YAD1BL10

115 589 34 63 00
Mounting Device 116 589 07 15 00
Drift

YAD1BKG0 YAD1BKV0

116 589 02 34 00 116 589 20 33 00

Thread Bolt Sliding Hammer

YAD1BLH0 YAD1B580

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-163

SPECIAL TOOLS TABLE (Cont’d)

117 589 03 23 00 601 589 00 25 00

Go/No Go Gauge Pressure Testing Device
(for Exhaust)

YAD1BLE0 YAD1BKH0

346 589 00 63 00 601 589 00 66 00

Super Cooling Box Counter Sink

YAD1BL90 YAD1BKD0

363 589 02 21 00
601 589 01 59 00
Dial Gauge Holder
Assembling Board

YAD1BKQ0 YAD1BKY0

601 589 02 43 00
366 589 00 21 05 Drift
Extension

YAD1BKP0 YAD1BL50

SSANGYONG Y200
1B3-164 DIESEL ENGINE MECHANICAL

SPECIAL TOOLS TABLE (Cont’d)

601 589 02 59 00
601 589 06 15 00
Supporting Bridge
Drift (for Exhaust)

YAD1BKZ0 YAD1BLB0

601 589 03 14 00 601 589 07 21 00

Sleeve Measuring Device

YAD1B790 YAD1BKK0

601 589 03 43 00
602 589 00 40 00
Oil Seal Assembler
Engine Lock

YAD1BKN0 YAD1B720

601 589 05 15 00 603 589 00 09 00

Drift (for Intake) Serration Wrench

YAD1BLA0 YAD1BKB0

SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-165

SPECIAL TOOLS TABLE (Cont’d)

667 589 00 31 00
603 589 00 40 00
Press Lever
Counter Holder

YAD1B4K0 YAD1BL00

603 589 01 40 00 667 589 01 21 00

Holding Wheel Fixing Device

YAD1BL20 YAD1BKL0

657 589 03 63 00 667 589 02 63 00

Sliding Hammer Supporting Bar

YAD1BKC0 YAD1BL30

667 589 00 23 00
Height Gauge

YAD1BKE0

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 Resonance Flap ................................................1F1-66
Diagnostic Information and Procedure ............. 1F1-4 Stop Lamp Switch ............................................. 1F1-67
Failure Code Diagnosis ...................................... 1F1-4 Engine RPM ..................................................... 1F1-68
Clearing Failure Codes ....................................... 1F1-4 Exhaust System ................................................ 1F1-69
Failure Codes Table ........................................... 1F1-4 Catalytic Converter ...........................................1F1-69
Ignition System ................................................... 1F1-8 Oxygen Sensor ................................................. 1F1-70
Ignition Coil ......................................................1F1-10 Engine Control Module .................................... 1F1-76
Crankshaft Position (CKP) Sensor .....................1F1-12 Serial Data Communication ............................... 1F1-77
Camshaft Position (CMP) Sensor ....................... 1F1-16 Internal Failure .................................................. 1F1-79
Camshaft Actuator ............................................1F1-20 Electronic Throttle Controller Safety Malfunction . 1F1-80
Knock Sensor (KS) ...........................................1F1-22 Immobilizer ......................................................1F1-82
Spark Plug ....................................................... 1F1-24 Maintenance and Repair ................................. 1F1-83
System Voltage ................................................1F1-28 On-Vehicle Service ........................................... 1F1-83
Ignition Switch .................................................. 1F1-29 Discharging the Pressure in Fuel System .......... 1F1-83
Fuel System ...................................................... 1F1-30 Fuel Pump ........................................................ 1F1-83
Fuel Pump ........................................................ 1F1-32 Fuel Filter .......................................................... 1F1-84
Fuel Injector ......................................................1F1-36 Fuel Tank .......................................................... 1F1-85
Purge Control Valve .......................................... 1F1-40 Fuel Pressure Regulator .................................... 1F1-86
Fuel Rail ...........................................................1F1-42 Fuel Rail and Injector ........................................1F1-87
Fuel Pressure Regulator .................................... 1F1-44 Engine Coolant Temperature Sensor .................. 1F1-88
Induction System .............................................. 1F1-46 Throttle Body (Integrated with the Actuator) .......1F1-89
Throttle Valve Actuator ...................................... 1F1-46 Hot Film Air Mass (HFM) Sensor ........................ 1F1-90
Hot Film Air Mass (HFM) Sensor ........................ 1F1-50 Knock Sensor ................................................... 1F1-90
Engine Coolant Temperature (ECT) Sensor ........ 1F1-54 Pedal Position Sensor ....................................... 1F1-91
Accelerator Pedal Module .................................1F1-58 Oxygen Sensor ................................................. 1F1-91
Clutch Switch ................................................... 1F1-61 Purge Control Valve .......................................... 1F1-92
Cooling Fan ......................................................1F1-62 Canister............................................................ 1F1-92
A/C Compressor Relay .....................................1F1-63 Camshaft Position Sensor .................................1F1-92
Cruise Control Switch ........................................1F1-64 Crankshaft Position Sensor ............................... 1F1-93
Traction Control System (TCS) ...........................1F1-65 Engine Control Module ...................................... 1F1-93
1F1-2 M162 ENGINE CONTROLS

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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-3

ENGINE AND ECM PROBLEM CHECK REPORT

VEHICLE AND CUSTOMER INFORMATION
Date Problem Occurred
Customer Name Vehicle Model
Driver Name VIN
Purchase date Engine Model
Km
License No. Mileage
miles

MIL INFORMATION
Condition of MIL o Remains on o Sometimes illuminates o Does not illuminate
DTC inspection o Normal o Malfunction code(s) (code )
(if available) o Freeze Frame data ( )

PROBLEM DESCRIPTION
o Engine Does Not Start o No cranking o No initial combustion o No complete combustion
o Hard to Start o Slow cranking
o Others
o Poor Idling o Incorrect first Idle o Abnormal idle rpm o High (rpm) o Low (rpm)
o Idling Unstable o Others
o Poor Driveability o Hesitation o Back fire o Muffler explosion (after-burning)
o Surging o Knocking o Poor performance o Other
o Engine Stall o Soon after starting o After accelerator pedal depressed
o After accelerator pedal released o During A/C operation
o Shifting from N to D or D to N
o At full steering o Others
o Others

CONDITION WHEN PROBLEM OCCURS

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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-5

FAILURE CODES TABLE (Cont’d)

Failure See Page Description

code
44 1F1-62 Cooling fan (HI) relay short circuit to power
45 1F1-62 Cooling fan (HI) relay short circuit to ground or open
54 1F1-41 Purge control circuit malfunction
56 1F1-23 No.1 knock sensor signal failure
57 1F1-23 No.2 knock sensor signal failure
58 1F1-17 Camshaft position sensor signal : No.1 cylinder synchronization failure
59 1F1-78 CAN communication failure : MSR data transmission not plausible
60 1F1-78 CAN communication failure : ASR data transmission not plausible
62 1F1-61 Clutch switch defective
64 1F1-11 No ignition voltage output (No.1 ignition coil)
65 1F1-11 No ignition voltage output (No.2 ignition coil)
66 1F1-11 No ignition voltage output (No.3 ignition coil)
67 1F1-13 Crankshaft position sensor adaptation failure
68 1F1-25 Random/Multiple Misfire
71 1F1-29 Starter signal recognition failure
72 1F1-37 No.1 injector short circuit to battery
73 1F1-37 No.1 injector short circuit to ground or open
74 1F1-37 No.2 injector short circuit to battery
75 1F1-37 No.2 injector short circuit to ground or open
76 1F1-37 No.3 injector short circuit to battery
77 1F1-38 No.3 injector short circuit to ground or open
78 1F1-38 No.4 injector short circuit to battery
79 1F1-38 No.4 injector short circuit to ground or open
80 1F1-72 Oxygen sensor high voltage
81 1F1-73 Bank 1 system short term fuel trim adaptation below lean threshold
82 1F1-72 Oxygen sensor no activity detected
83 1F1-72 Oxygen sensor not lean after overrun fuel shut -off
84 1F1-72 Oxygen sensor slow response
85 1F1-72 Oxygen sensor heater failure
86 1F1-72 Oxygen sensor heater short circuit to battery
87 1F1-72 Oxygen sensor heater short circuit to ground or open
89 1F1-72 Oxygen sensor low voltage
93 1F1-73 Bank 1 system short term fuel trim adaptation above rich threshold
96 1F1-73 Bank 1 system short term fuel trim at rich stop
97 1F1-73 Bank 1 system short term fuel trim at lean stop
98 1F1-73 Bank 1 system idle adaptation failure (above rich threshold)
99 1F1-73 Bank 1 system idle adaptation failure (below lean threshold)
100 1F1-73 Bank 1 system learning control failure (rich, low load)
101 1F1-73 Bank 1 system learning control failure (lean, low load)
102 1F1-73 Bank 1 system learning control failure (rich, high load)

SSANGYONG Y200
1F1-6 M162 ENGINE CONTROLS

FAILURE CODES TABLE (Cont’d)

Failure See Page Description

code
103 1F1-73 Bank 1 system learning control failure (lean, high load)
104 1F1-47 Throttle position sensor 1 low voltage
105 1F1-47 Throttle position sensor 1 high voltage
108 1F1-47 Throttle position sensor 2 low voltage
109 1F1-47 Throttle position sensor 2 high voltage
110 1F1-80 Throttle actuator learning data fault
116 1F1-47 Throttle actuator learning control failure
117 1F1-80 Exceed fuel -cut safety time
119 1F1-47 Throttle valve return spring failure
120 1F1-80 Cruise control interruption memory failure
121 1F1-47 Throttle actuator failure
122 1F1-59 Accelerator pedal position sensor signal failure
123 1F1-47 Different Mass air flow sensor signal with throttle position sensor
125 1F1-47 Both throttle position sensors failure
126 1F1-48 Throttle position sensor 1 not plausible with throttle position sensor 2
127 1F1-48 High permanent throttle signal
129 1F1-64 Cruise control “OFF” due to message counter failure
130 1F1-64 Vehicle speed signal failure
131 1F1-64 Vehicle speed signal failure
132 1F1-64 Cruise control lever failure
133 1F1-64 Cruise control acceleration failure
134 1F1-64 Cruise control deceleration failure
135 1F1-67 Stop lamp switch failure
136 1F1-79 ECU failure (RAM)
137 1F1-79 ECU failure (EPROM)
138 1F1-80 Call monitoring
139 1F1-80 Servo motor control output interruption memory failure
140 1F1-80 Servo motor open/short
141 1F1-82 Unprogramed ECU with immobilizer
142 1F1-79 Uncoded/unprogramed ECU
143 1F1-79 ECU failure (EEPROM/Flash-EPROM checksum failure)
144 1F1-79 ECU failure (coding ID checksum failure)
145 1F1-79 ECU failure (coding checksum failure)
146 1F1-79 ECU failure (programing checksum failure)
150 1F1-65 TCS input signal short circuit to battery
151 1F1-65 TCS input signal short circuit to ground or open
160 1F1-59 Accelerator pedal position sensor 1 low voltage
161 1F1-59 Accelerator pedal position sensor 1 high voltage
162 1F1-59 Accelerator pedal position sensor 2 low voltage
163 1F1-59 Accelerator pedal position sensor 2 high voltage
164 1F1-59 Accelerator pedal position sensor 1 not plausible with pedal position sensor 2

SSANGYONG Y200
1F1-4 M162 ENGINE CONTROLS

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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-7

FAILURE CODES TABLE (Cont’d)

Failure See Page Description

code
167 1F1-59 Both setpoint accelerator pedal position sensor defective
185 1F1-48 Mass air flow sensor and throttle position sensor failure
186 1F1-80 ECU failure (incompatible CPU)
187 1F1-80 ECU failure (CPUs communication failure)
188 1F1-80 ECU failure (CPU 2 configuration failure)
189 1F1-80 ECU failure (CPU 2 fault)
190 1F1-80 ECU failure (CPU run time failure between CPUs)
192 1F1-38 No.5 injector short circuit to battery
193 1F1-38 No.5 injector short circuit to ground or open
194 1F1-38 No.6 injector short circuit to battery
195 1F1-38 No.6 injector short circuit to ground or open
198 1F1-66 Resonance flap short circuit to battery
199 1F1-66 Resonance flap short circuit to ground or open
226 1F1-21 Camshaft actuator short circuit to battery
227 1F1-21 Camshaft actuator short circuit to ground or open
228 1F1-63 A/C compressor relay short circuit to battery
229 1F1-63 A/C compressor relay short circuit to ground or open
231 1F1-80 ECU failure (CPU 2 cruise control message counter failure)
232 1F1-80 Over decceleration limit (CPU 2)
233 1F1-80 Over acceleration limit (CPU 2)
234 1F1-80 Cruise control lever dual operation (CPU 2)
235 1F1-80 Cruise control lever safety terminal failure (CPU 2)
236 1F1-80 Unusual pedal position variation (CPU 2)
237 1F1-80 Unusual throttle position variation (CPU 2)
238 1F1-80 Unusual throttle controller monitor data comparison fault (CPU 2)
239 1F1-81 Unusual accelerator pedal position sensor comparison fault (CPU 2)
240 1F1-81 Throttle potentiometer comparision fault (CPU 2)
241 1F1-81 Unusual CPU communication (CPU 2)
242 1F1-81 Unusual CPU configuration (CPU 2)
243 1F1-81 A/D converter failure (CPU 2)
244 1F1-81 Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2
245 1F1-81 Position controller setpoint fault between CPU 1 and CPU 2
246 1F1-81 MSR setpoint fault between CPU 1 and CPU 2
247 1F1-81 Idle control setpoint fault between CPU 1 and CPU 2
248 1F1-81 A/D converteroverflow (CPU 2)
249 1F1-81 ROM f aul t (CPU 2)
250 1F1-81 RAM f aul t (CPU 2)
251 1F1-85 Cycle monitor fault (CPU 2)

SSANGYONG Y200
1F1-8 M162 ENGINE CONTROLS

IGNITION SYSTEM
This ignition system does not use a conventional These systems use the EST signal from the ECM to
distributor and coil. It uses a crankshaft position control the EST. The ECM uses the following
sensor input to the Engine Control Module (ECM). The information:
ECM then determines Electronic Spark Timing (EST) • Engine load (mass air flow sensor).
and triggers the electronic ignition system ignition coil.
• Engine temperature.
This type of distributorless ignition system uses a
‘‘waste spark” method of spark distribution. Each • Intake air temperature.
cylinder is paired with the cylinder that is opposite it • Crankshaft position.
(1-6 or 2-5 or 3-4). The spark occurs simultaneously in • Engine speed (rpm).
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.

YAD1F080

SSANGYONG Y200
1F1-10 M162 ENGINE CONTROLS

IGNITION COIL

YAD1F090

1 Control Cable Connection 5a, 5b Secondary Voltage Connection

2 Ignition Cable E Iron Core
3 Spark Plug Connector L1 Secondary Ignition Coil
4 Coupling Plug L2 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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-11

YAD1F100

Failure
Description Trouble Area Maintenance Hint
Code
No ignition voltage Malfunction of ignition circuit • Inspection the ECM pin 70 (71 and72)
output Primary current values or about short circuit or open with bad
64 (No. 1 ignition coil) secondary short circuit contact
• Inspection the power source to ignition

No ignition voltage • Inspection the power source to ignition

output coil
65
(No. 2 ignition coil) • Inspection the ignition coil, high tension
cords etc.

No ignition voltage • Inspection the spark plug (wet, cracks,

output wear, improper gap, burned electrodes,
66 heavy deposit)
(No. 3 ignition coil)
• 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 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.

SSANGYONG Y200
1F1-12 M162 ENGINE CONTROLS

CRANKSHAFT POSITION (CKP) SENSOR

YAD1F110

1 Crankshaft Position Sensor 3 Segment

2 Bolt 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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-13

YAD1F120

Failure
Description Trouble Area Maintenance Hint
Code
Crankshaft position Even through cam position • Monitoring the actual rpm through or
17 sensor signal failure recognition is normal, no scan tool
(no engine revolution crankshaft position signal
signal) recognition • Inspection the ECM pin 100, 99 about
short circuit with bad contact
Crankshaft position When more than applicable
sensor signal failure revolution values or implau- • Inspection the CKP sensor
18
(rpm > max. value) sible to 60-2 teeth scan tool • Inspection the air gap between sensor
and drive plate
Crankshaft position When implausible recognition • Inspection the drive plate (teeth condi-
sensor signal failure of cam and crank angle signal tion)
20 (gap recognition failure) or intermittent sensing the
signal or error count of • Inspection the ECM
undetected gap.
Crankshaft position When faulty crank angle
67 sensor adaptation sensor adaption
failure

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 Ω

Notice: Measure the insulator resistance of the CKP sensor if out of the specified value.

SSANGYONG Y200
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 kΩ

Notice: Measure the check and ground terminal of

the CKP sensor if out of the specified value.

SSANGYONG Y200
1F1-16 M162 ENGINE CONTROLS

CAMSHAFT POSITION (CMP) SENSOR

YAD1F140

1 Camshaft Position Sensor Connector 3 Camshaft Position Sensor

2 Bolt 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
M162 ENGINE CONTROLS 1F1-17

YAD1F150

Failure
Description Trouble Area Maintenance Hint
Code
Camshaft position When no cam recognition • Inspection the source voltage of CMP
sensor signal : No. 1 signal during TN 24 counts sensor
19 cylinder recognition more.
failure (maintain the constant low or • Inspection the ECM pin 106, 104 about
short circuit or open with bad contact
high level)
Camshaft position When synchronization fault of • Inspection the CMP sensor
sensor signal : No. 1 cylinder 1 • Inspection the damage of sensor or
58 cylinder synchronization (TDC recognition) sprocket
failure
• Inspection the ECM

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
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.

SSANGYONG Y200
1F1-20 M162 ENGINE CONTROLS

CAMSHAFT ACTUATOR

YAD1F170

1 Bolt 4 Armature
2 Camshaft Actuator 5 Roll Pin
3 Bolt 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 Camshaft Position Effect
Engine stop Retard -
Idle speed is improved
0 ~ 1,500 rpm Retard Blow-by gas is decreased
Valve overlap is decreased
Torque is increased
1,500 ~ 4,300 rpm Advanced Fuel loss is decreased
NOx is decreased
Above 4,300 rpm Retard Engine overrun is prohibited

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-21

YAD1F150

Failure
Description Trouble Area Maintenance Hint
Code
Camshaft actuator short When malfunction of cam • Monitoring the actual operational status
circuit to battery phasing control through scan tool
226
• Inspection the ECM pin 73 about short
circuit or open
Camshaft actuator short • Inspection the power source short circuit
circuit to ground or or open to cam actuator
227 open
• Inspection the magnet and hardware
• Inspection the ECM

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
Notice: If the measured value is not within the specified value, check the cable.

SSANGYONG Y200
1F1-22 M162 ENGINE CONTROLS

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
M162 ENGINE CONTROLS 1F1-23

YAD1F190

Failure
Description Trouble Area Maintenance Hint
Code
No. 1 knock sensor When recognition in more than • Inspection the ECM pin 118, 117about
signal failure control gain threshold at short circuit or open with bad contact
normal operational condition of
56 other system during over 75 • Inspection the KS 1 malfunction
and 3,000 rpm running area • Inspection the ECM
(cylinder 1, 2, 3)
• Inspection the ECM pin 115, 114 about
short circuit or open with bad contact
No. 2 knock sensor When recognition in more than
signal failure control gain threshold at • Inspection the KS 2 malfunction
normal operational condition of • Inspection the ECM
57 other system during over 75
and 3,000 rpm running area
(cylinder 4, 5, 6)

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 signal’s 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 MΩ

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.

SSANGYONG Y200
1F1-24 M162 ENGINE CONTROLS

SPARK PLUG

YAD1F200

1 Ignition Coil Cable Cover T 1/1 Ignition Coil Cylinder 2 and 5

2 Bolt T 1/2 Ignition Coil Cylinder 3 and 4
3 Spark Plug T 1/3 Ignition Coil Cylinder 1 and 6

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-25

YAD1F210

Failure
Description Trouble Area Maintenance Hint
Code
Random / Multiple When detection misfire of • Inspection the ignition system
Misfire multiple cylinder for source of
over the emission • Inspection the injection system
threshold or catalyst damage • Inspection the fuel pressure
• Inspection the compression pressure
• Inspection the valve timing or clearance
68
• 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.

SSANGYONG Y200
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 kΩ
Notice: Replace the spark plug cable if the measured values is out of the specified values.

SSANGYONG Y200
1F1-28 M162 ENGINE CONTROLS

SYSTEM VOLTAGE

YAD1F220

Failure
Description Trouble Area Maintenance Hint
Code
System voltage too low Malfunction in recognition of • Monitoring the actual battery voltages
system source voltage. Less through the scan tool
than minimum 8 volts in
2,000 rpm below, or less than • Inspection the Engine Control Module
(ECM) pin 12, 11, 10, 5 about short
10 volts in 2,000 rpm above.
08 circuit or open with bad contact
• Inspection the over voltage protection
relay
• Inspection the battery
• Inspection ECM

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-29

IGNITION SWITCH

YAD1F230

Failure
Description Trouble Area Maintenance Hint
Code
Starter signal When not detection of starter • Inspection the Engine Control Module
recognition failure signal (ECM) pin 2 circuit short or open with
71 bad contact
• Inspection ECM

SSANGYONG Y200
1F1-30 M162 ENGINE CONTROLS

FUEL SYSTEM
The function of the fuel metering system is to deliver the amount of fuel delivered in the starting mode by
the correct amount of fuel to the engine under all changing how long the fuel injector is turned on and
operating conditions. off. This is done by ‘‘pulsing” the fuel injectors for
The fuel is delivered to the engine by the individual very short times.
fuel injectors mounted into the intake manifold near Run Mode
each cylinder.
The run mode has two conditions called ‘‘open loop”
The main fuel control sensors are the Mass Air Flow and ‘‘closed loop”.
(MAF) sensor and the oxygen (O2) sensors.
The MAF sensor monitors the mass flow of the air being
Open Loop
drawn into the engine. An electrically heated element When the engine is first started and it is above 690 rpm,
is mounted in the intake air stream, where it is cooled the system goes into “open loop” operation. In “open
by the flow of incoming air. Engine Control Module loop”, the ECM ignores the signal from the O2S and
(ECM) modulates the flow of heating current to maintain calculates the air/fuel ratio based on inputs from the
the temperature differential between the heated film ECT sensor and the MAF sensor. The ECM stays in
and the intake air at a constant level. The amount of “open loop” until the following conditions are met:
heating current required to maintain the temperature • The O2 has a varying voltage output, showing that
thus provides an index for the mass air flow. This it is hot enough to operate properly.
concept automatically compensates for variations in
air density, as this is one of the factors that determines
• The ECT sensor is above a specified temperature
(22.5 °C).
the amount of warmth that the surrounding air absorbs
from the heated element. MAF sensor is located • A specific amount of time has elapsed after starting
between the air filter and the throttle valve. the engine.
Under high fuel demands, the MAF sensor reads a Closed Loop
high mass flow condition, such as wide open throttle. The specific values for the above conditions vary with
The ECM uses this information to enrich the mixture, different engines and are stored in the Electronically
thus increasing the fuel injector on—time, to provide Erasable programmable Read-Only Memory (EEPROM).
the correct amount of fuel. When decelerating, the mass When these conditions are met, the system goes into
flow decreases. This mass flow change is sensed by “closed loop” operation. In “closed loop”, the ECM
the MAF sensor and read by the ECM, which then calculates the air/fuel ratio (fuel injector on-time) based
decreases the fuel injector on—time due to the low fuel on the signals from the O2 sensors. This allows the
demand conditions. air/fuel ratio to stay very close to 14.7 to 1.
The O2 sensors are located in the exhaust pipe before
Acceleration Mode
catalytic converter. The O2 sensors indicate to the ECM
the amount of oxygen in the exhaust gas, and the ECM The ECM responds to rapid changes in throttle position
changes the air/fuel ratio to the engine by controlling and airflow and provides extra fuel.
the fuel injectors. The best air/fuel ratio to minimize Deceleration Mode
exhaust emissions is 14.7 to 1, which allows the
The ECM responds to changes in throttle position and
catalytic converter to operate most efficiently. Because
airflow and reduces the amount of fuel. When
of the constant measuring and adjusting of the air/fuel
deceleration is very fast, the ECM can cut off fuel
ratio, the fuel injection system is called a “closed loop”
completely for short periods of time.
system.
The ECM uses voltage inputs from several sensors to Battery Voltage Correction Mode
determine how much fuel to provide to the engine. The When battery voltage is low, the ECM can compensate
fuel is delivered under one of several conditions, called for a weak spark delivered by the ignition module by
‘‘modes”. using the following methods:
Starting Mode • Increasing the fuel injector pulse width.
When the ignition is turned ON, the ECM turns the fuel • Increasing the idle speed rpm.
pump relay on for 1 second. The fuel pump then builds • Increasing the ignition dwell time.
fuel pressure. The ECM also checks the Engine Coolant
Fuel Cut-Off Mode
Temperature (ECT) sensor and the Throttle Position (TP)
sensor and determines the proper air/fuel ratio for No fuel is delivered by the fuel injectors when the
starting the engine. This ranges from1.5 to 1 at ignition is off. This prevents dieseling or engine run-
-36 ° C (-33 °F) coolant temperature to 14.7 to 1 at on. Also, the fuel is not delivered if there are no reference
94 °C (201 °F) coolant temperature. The ECM controls pulses received from the CKP sensor. This prevents
flooding.

SSANGYONG Y200
1F1-32 M162 ENGINE CONTROLS

FUEL PUMP

YAD1F240

1 Flange and Harness Assembly 5 Thermistor

2 Spring 6 Float Arm
3 Fuel Pump 7 Thermistor Housing
4 Float 8 Resistor Card and Wiper

Requirements for Fuel Pump

Item Specified Value Item Specified Value
System Pressure 3.8 bar Minimum Delivery at 8V 30 Litre/Hr
Maximum Pressure 8.5 bar (12 V) Operating Voltage 8V
Maximum Allowable
Minimum Pressure 5.0 bar (12 V) 7.5 A
Current
Nominal Voltage 12 V Ambient Temperature -30 ~ +70 °C
Minimum Amount of Fuel 114 Liter/Hr (12 V, 3.8 bar, Maximum Amount of Fuel 165 Liter/Hr (12V, 3.8 bar,
Supply -30 ~ +70 °C) Supply -30 ~ +70 °C)

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-33

YAD1F250

Failure
Description Trouble Area Maintenance Hint
Code

34
Fuel pump relay short When short circuit to power • Inspection the Engine Control Module
circuit to battery source (ECM) pin 33 about short circuit or open
with bad contact
Fuel pump relay short When short circuit to ground
35 circuit to ground or or open open with bad contact • Inspection the fuel pump relay
open
• Inspection the ECM

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 0 V (for1 ~ 2 sec.)
Cranking 0V

SSANGYONG Y200
1F1-34 M162 ENGINE CONTROLS

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 ~9 A

Notice: Replace the fuel pump relay if the measured value is over 9 A.

SSANGYONG Y200
1F1-36 M162 ENGINE CONTROLS

FUEL INJECTOR

YAD1F260

1 Fuel Rail 4 Injector

2 O-Ring 5 O-Ring
3 Injector Bracket

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 injector’s 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
M162 ENGINE CONTROLS 1F1-37

YAD1F270

Failure
Description Trouble Area Maintenance Hint
Code
No. 1 injector short When malfunction of injector • Inspection the power to injector #1 or
circuit to battery circuit bad contact
72
Injector #1 short circuit to • Inspection the injector
power • Inspection the ECM
No. 1 injector short When malfunction of injector • Inspection the ECM pin 63 about short
circuit to ground or circuit circuit or open with bad contact
73
open • Inspection the injector
Injector #1 short circuit to
ground or open • Inspection the ECM
No. 2 injector short When malfunction of injector • Inspection the power to injector #2 or
circuit to battery circuit bad contact
74
Injector #2 short circuit to • Inspection the injector
power • Inspection the ECM
No. 2 injector short When malfunction of injector • Inspection the ECM pin 61 about short
circuit to ground or circuit circuit or open with bad contact
75
open • Inspection the injector
Injector #2 short circuit to
ground or open • Inspection the ECM
No. 3 injector short When malfunction of injector • Inspection the power to injector #3 or
circuit to battery circuit bad contact
76
Injector #3 short circuit to • Inspection the injector
power • Inspection the ECM

SSANGYONG Y200
1F1-38 M162 ENGINE CONTROLS

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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-39

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
YAD1F280
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
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 Ω

Notice: Replace the fuel injector if the measured

value is out of the specified values. Check the
YAD1F290
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 8.0 ms
Engine Idle 3 ~5 ms
Wide Open Throttle (WOT) 14 ms

SSANGYONG Y200
1F1-40 M162 ENGINE CONTROLS

PURGE CONTROL VALVE

YAD1F300

1 Purge Control Valve 3 Line to Conister

2 Line to Engine

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
M162 ENGINE CONTROLS 1F1-41

YAD1F310

Failure
Description Trouble Area Maintenance Hint
Code

40
Purge control valve When short circuit to power • Inspection the ECM pin 34 about short
short circuit to battery source circuit or open with bad contact.
Purge control valve When short circuit to ground • Inspection the source power of valve
41 short circuit to ground or open circuit or open with
or open bad contact • Inspection the purge control solenoid
vale
Purge control circuit When malfunction of purge
54 malfunction control : not work vale • Inspection the ECM

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
YAD1F0J0 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.)
Specified Value
purge control valve
operates at this time

Notice: Test while at normal temperature and at

idling state by operating the engine.

SSANGYONG Y200
1F1-42 M162 ENGINE CONTROLS

FUEL RAIL

YAD1F320

1 Injector Connector 5 Fuel Return Line

2 Injector 6 Bolt
3 Fuel Rail 7 Vacuum Hose
4 Fuel Supply Line 8 O-Ring

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-43

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.
YAD1F330 Vacuum Hose Connected (bar) 3.2 ~ 3.6
Vacuum Hose Disconnected (bar) 3.7 ~ 4.2

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 • Fuel leakage at the
drops slowly injector
• Faulty fuel pressure
regulator’s
diaphragm and O-ring
YAD1F340 Fuel pressure • Faulty check valve in
drops rapidly 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

SSANGYONG Y200
1F1-44 M162 ENGINE CONTROLS

FUEL PRESSURE REGULATOR

YAD1F350

1 Vacuum Hose 4 O-Ring

2 Circlip 5 O-Ring
3 Fuel Pressure Regulator

Function of the Fuel Pressure Regulator

<Operating at full load>

There is no negative pressure applied to the spring
YAD1F360 chamber (9) during the full load, and it is separated
from the fuel chamber (8) by the diaphragm (5).
2 Fuel return line A Valves Closed When the fuel pressure goes up, the diaphragm forces
3 Valve B Valves Opened the compression spring (6) in the direction of
5 Diaphragm compression. At this moment, the valve (3) sticks to
6 Compression Spring the diaphragm by the fuel pressure, and the fuel return
8 Fuel Chamber line (2) opens. The fuel over supplied returns to the
9 Spring Chamber fuel tank through the return line.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-45

The pressure difference between the fuel pressure and

the intake manifold is about 3.8 bars during the full
load.

YAD1F390

1 Fuel Pressure Regulator

2 Intake Manifold
YAD1F370 3 Fuel Return (to fuel tank)
4 Fuel Supply (from fuel pump)
1 Fuel Pressure Regulator 7 Fuel Pressure (approx. 3.2 bars)
2 Intake Manifold 8 Intake Manifold Negative Pressure (0.6 bars)
3 Fuel Return (to fuel tank)
4 Fuel Supply (from fuel pump)
5 Fuel Pressure (approx. 3.8 bars) <Fuel Pressure Diagram>
6 Intake Manifold Negative Pressure (0 bar)

<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 Fuel pressure
B Intake Manifold Negative Pressure
LL Idling
TL Partial load
VL Full load

YAD1F380

Consequently, the fuel pressure in the fuel distributor

changes by the intake manifold’s 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.

SSANGYONG Y200
1F1-46 M162 ENGINE CONTROLS

INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR

YAD1F410

The throttle actuator is actuated by the Engine Control Consequently, the throttle valve opening is a constant
Module(ECM) according to the position of the 10-12 °approximately.
accelerator pedal position. At no load, this produces an engine speed of about
It has two potentiometers which signal the position of 1,800 rpm
the throttle valve to the ECM to enable it to recognize
Driving
the various engine load states.
When driving (part/full throttle), the servo motor controls
Ignition “Off” the throttle valve in line with the various load states
In the de-energized states the throttle valve position and according to the input signals from the pedal value
is determined to be spring capsule. sensor according to the input signals from the pedal
value sensor according to the position of the
Ignition “On” accelerator pedal.
When the ignition S/W on the servo motor in the throttle The function of the EA (electronic accelerator) in the
actuator is operated by the ECM. The throttle valve ECM determines the opening angle of the throttle valve
adopts a position in line with the coolant temperature. through the throttle actuator. Further functions are;
Closed position • Idle speed control
In the closed throttle position, the servo motor controls • Cruise control
engine speed by operating the throttle valve further
• Reducing engine torque for ASR/ABS operation
(greater mixture) or closing it further (reduced mixture),
depending on coolant temperature and engine load. • Electronic accelerator emergency running
When this is done, the throttle valve can be closed • Storing faults
further by the servo motor overcoming the force of the • Data transfer through CAN
spring capsule (mechanical end stop). If the actuator
is deenergized, the throttle valve is resting against
the spring capsule.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-47

YAD1F420

Failure
Description Trouble Area Maintenance Hint
Code

104
Throttle position sensor TPS 1 short circuit to ground • Monitoring the actual values through
1 low voltage or open
• Inspection the ECM pin 84, 85, 87, 112,
Throttle position sensor TPS 1 short circuit to power 67, 68 about short circuit or open with
105
1 high voltage bad contact

108
Throttle position sensor TPS 2 short circuit to ground • Inspection the throttle valve actuator
2 low voltage or open
• Inspection the ECM
Throttle position sensor TPS 2 short circuit to power
109
2 high voltage
Throttle actuator When actuator adaption
116 learning control failure fluctuation or not meet the
condition scan tool
Throttle valve return When return spring defective
119 spring failure of actuator with bad contact

Throttle actuator failure When supply voltage of the

121 actuator short circuit to power
Inspection the ECM
Different mass air flow When shut down of output
123 sensor signal with driver
throttle position sensor
Both throttle position When defective of both
125 sensor failure potentiometers

SSANGYONG Y200
1F1-48 M162 ENGINE CONTROLS

Failure
Description Trouble Area Maintenance Hint
Code
Throttle position sensor When difference between TPS • Monitoring the actual values through
1 not plausible with 1 and TPS 2 scan tool
126
Throttle position sensor • Inspection the ECM pin 84, 85, 87, 112,
2 67, 68 about short circuit or open with
bad contact
127 High permanent throttle When failure of wiring harness
signal or actuator • Inspection the throttle valve actuator
Mass air flow sensor When difference between MAF • Inspection the ECM
185 and throttle position and TPS signal
sensor failure

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 Specified Value

Closed 0.3 ~ 0.9 v
TPS 1
Opened 1 4.0 ~ 4.6 v
Closed 4.0 ~ 4.6 v
TPS 2 Opened 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 Specified Value

Ignition “ON” 0.8 ~ 2.3 v
Engine 1.0 ~ 2.5 v
Status Idling (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 Ω

SSANGYONG Y200
1F1-50 M162 ENGINE CONTROLS

HOT FILM AIR MASS (HFM) SENSOR

YAD1F430

1 Housing 4 Connector
2 Protector Net 5 Hot Film Air Mass Sensor
3 Electronic Housing 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 over-
temperature 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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-51

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) Voltage (V) Mass Air Flow (kg/h) Voltage (V)
0 0.95 ~ 1.05 250 3.51
10 1.28 370 3.93
15 1.41 480 4.23
30 1.71 640 4.56
60 2.16 800 4.82
120 2.76

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) Ω)
R min.(Ω Ω)
R nom. (Ω Ω)
R max. (Ω
-40 35140 39260 43760
-20 12660 13850 15120
0 5119 5499 5829
20 2290 2420 2551
40 1096 1166 1238
60 565 609 654
80 312 340 370
100 184 202 222
120 114 127 141
130 91 102 114

SSANGYONG Y200
1F1-52 M162 ENGINE CONTROLS

YAD1F440

Failure
Description Trouble Area Maintenance Hint
Code

03
Intake air temperature IAT sensor short circuit to • Monitoring the actual air temperature
sensor low voltage ground or open through scan tool

04
Intake air temperature IAT sensor short circuit to • Inspection the ECM pin 80, 79 about
sensor high voltage power short circuit or open with bad contact
Intake air temperature Malfunction in recognition of • Inspection the IAT sensor (integrated in
05 sensor plausibility IAT HFM sensor)
When functional problem • Inspection the ECM
Mass air flow sensor Malfunction in recognition of • Monitoring the actual air mass flow
09 plausibility MAF through scan tool
When air mass not plausible • Inspection the ECM pin 81, 105 about
short circuit or open with bad contact
10 Mass air flow sensor MAF sensor short circuit to
low voltage ground or open • Inspection the MAF sensor (integrated 11
in HFM sensor)
Mass air flow sensor MAF sensor short circuit to
11 high voltage power • Inspection the ECM

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 element’s 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.

SSANGYONG Y200
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 Specified Value
Ignition “ON” 0.9 ~ 1.1 V
Engine 1.3 ~ 1.7 V
Status Idling (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. 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).

SSANGYONG Y200
1F1-54 M162 ENGINE CONTROLS

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

YAD1F450

1 Artificial Resin Housing 4 Connector

2 Metal Housing 5 Engine Coolant Temperature Sensor
3 NTC (Negative Temperature Coefficient)
Resistor

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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-55

Ω)
Temperature (°C) Resistance (Ω Voltage (V)
-40 48,550 4.90
-30 27,000 4.82
-20 15,570 4.70
-10 9,450 4.52
0 5,890 4.43
10 3,790 3.96
20 2,500 3.57
30 1,692 3.14
40 1,170 2.70
YAD1F460
50 826 2.26
60 594 1.86
70 434 1.51
80 322 1.22
90 243 0.98
100 185 0.78
110 143 0.63
120 111.6 0.50
130 88 0.40
140 71.2 0.33

SSANGYONG Y200
1F1-56 M162 ENGINE CONTROLS

YAD1F470

Failure
Description Trouble Area Maintenance Hint
Code
Engine coolant ECT sensor short circuit to • Monitoring the actual coolant temperature
00 temperature sensor low ground or open through scan tool
voltage
• Inspection the ECM pin 78, 79 about
Engine coolant ECT sensor short circuit to short circuit or open with bad contact
01 temperature sensor high power
voltage • Inspection the ECT sensor

Engine coolant Malfunction in recognition of • Inspection the ECM

temperature sensor ECT
02 plausibility
When drop to about 50 °C
below after warm up
Engine coolant Malfunction in recognition of
temperature insufficient ECT
06 for closed loop fuel
When minimum temperature
control
for lambda control after
warm up

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) Specified Value (V)
20 3.57
80 1.22
100 0.78

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-57

3. Turn the ignition switch to “OFF” position.

4. Disconnect the ECT sensor connector.
5. Turn the ignition switch to “ON” position.
6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4.

Temperature (°C) Ω)
Specified Value (Ω
20 2,500
80 322
100 185
Notice: Replace wiring and coolant temperature sensor if out of specified value.

SSANGYONG Y200
1F1-58 M162 ENGINE CONTROLS

ACCELERATOR PEDAL MODULE

YAD1F480

1 Accelerator Pedal 4 6-Pin Connector

2 Accelerator Pedal Sensor 5 Kick-down Switch
3 Bolts 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
M162 ENGINE CONTROLS 1F1-59

YAD1F490

Acceleration pedal APP 1 sensor short circuit to • Inspection the ECM

161 position sensor 1 high power

voltage
Acceleration pedal APP 2 sensor short circuit to
162 position sensor 2 low ground or open
voltage
Acceleration pedal APP 2 sensor short circuit to
163 position sensor 2 high power bad contact
voltage
Accelerator pedal When difference between APP
position sensor 1 not 1 sensor and APP 2 sensor
plausible with
164 accelerator pedal
position sensor 2

Both setpoint When defective of both APP

accelerator pedal sensor
167 position sensor
defective

SSANGYONG Y200
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 Specified Value (V)
Closed Throttle Valve 0.3 ~ 0.7
Fully Depressed Throttle Valve 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 Specified Value (V)
Closed Throttle Valve 0.1 ~ 0.4
Fully Depressed Throttle Valve 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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-61

CLUTCH SWITCH

YAD1F500

Failure
Description Trouble Area Maintenance Hint
Code
Clutch switch defective When malfunction of clutch • Inspection the Engine Control Module
switch (ECM) pin 43 about shout circuit or open
62
• Inspection the clutch switch
• Inspection the ECM

SSANGYONG Y200
1F1-62 M162 ENGINE CONTROLS

COOLING FAN

YAD1F510

Failure
Description Trouble Area Maintenance Hint
Code
Cooling fan (HI) relay Cooling fan short circuit to • Inspection the Engine Control Module
44 short circuit to power power (ECM) pin 35 about short circuit or open
with bad contact
Cooling fan (HI) relay Cooling fan short circuit to • Inspection the power source
short circuit to ground ground or open with bad
45 or open contact • Inspection the cooling fan
• Inspection the ECM

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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-63

A/C COMPRESSOR RELAY

YAD1F520

Failure
Description Trouble Area Maintenance Hint
Code
A/C compressor relay When malfunction of A/C • Monitoring the actual operation through
228 short circuit to battery compressor control scan tool
• Inspection the Engine Control Module
A/c compressor relay (ECM) pin 44 about short circuit or open
short circuit to ground with bad contact
229 or open
• Inspection the relay short circuit or open
• Inspection the ECM

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.

SSANGYONG Y200
1F1-64 M162 ENGINE CONTROLS

CRUISE CONTROL SWITCH

YAD1F530

Failure
Description Trouble Area Maintenance Hint
Code
Cruise control “OFF” Cruise control system • Monitoring the actual recognition status
129 due to message counter message counter fault and vehicle speed signal through scan
failure tool
Vehicle speed signal When malfunction of • Inspection the Engine Control Module
130 failure auto-cruise system (ECM) pin 52 53 54 55 57 about short
Implausible condition of circuit or open with bad contact
Vehicle speed signal
131 vehicle speed signal.
failure • Inspection the CAN and ABS

132
Cruise control lever Cruise control lever • Inspection the cruise control lever switch
failure defective
• Inspection the ECM
Cruise control Cruise control system
133 acceleration failure Implausible condition of
acceleration signal

Cruise control Cruise control system

134 deceleration failure Implausible condition of
deceleration signal

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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-65

TRACTION CONTROL SYSTEM (TCS)

YAD1F540

Failure
Description Trouble Area Maintenance Hint
Code

150
TCS input signal short TCS short circuit to power • Inspection the Engine Control Module
circuit to battery (ECM) pin 45 about short circuit or open
with bad contact
TCS input signal short TCS short circuit to ground or
151 circuit to ground or open • Inspection the TCS lamp of I/P cluster.
open
• Inspection the ECM

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.

SSANGYONG Y200
1F1-66 M162 ENGINE CONTROLS

RESONANCE FLAP

YAD1F150

Failure
Description Trouble Area Maintenance Hint
Code
Resonance flap short Resonance flap short circuit to • Monitoring the actual operational status
circuit to battery power and vehicle speed signal through scan
198 tool
• Inspection the Engine Control Module
(ECM) pin 97 about short circuit or open
with bad contact
Resonance flap short Resonance flap short circuit to
circuit to ground or ground or open • Inspection the power source short circuit
or open to resonance flap
open
199
• Inspection the resonance flap solenoid
and hardware
• Inspection the ECM

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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-67

STOP LAMP SWITCH

YAD1F550

Failure
Description Trouble Area Maintenance Hint
Code
Stop lamp switch failure When malfunction of stop • Monitoring the actual operational status
lamp switch - implausible and vehicle speed signal through scan
condition of stop lamp signal tool
input
• Inspection the Engine Control Module
135 (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.

SSANGYONG Y200
1F1-68 M162 ENGINE CONTROLS

ENGINE RPM

YAD1F560

Failure
Description Trouble Area Maintenance Hint
Code
Engine rpm output When short circuit to battery • Inspection the cluster panel board circuit
32 circuit short circuit to
battery • Inspection the ECM

Engine rpm output When short circuit to ground • Monitoring the actual rpm in cluster
33 circuit short circuit to or open • Inspection the Engine Control Module
ground or open (ECM) pin 60 about short circuit or open

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-69

EXHAUST SYSTEM
CATALYTIC CONVERTER These catalysts in the 3-way catalytic converter are
the rare metals platinum (Pt) and rhodium (Rh).
The purpose of the catalytic converter is to convert
The catalytic converter consists essentially of three
the three pollutants of carbon monoxide(CO),
main elements. The exhaust gases flow through the
hydrocarbons (HC) and oxides of nitrogen (NOx)
catalytic converter and, in so doing, coming into
contained in the exhaust of gasoline engines, into the
contact with rare metals (Pt and Rh).
harmless compounds of water (H2O), carbon dioxide
(CO2) and nitrogen (N2). The following chemical reaction are produced.
The catalytic converter contains a catalyst, a word CO + O 2 → CO 2
coming from the Greek and which designates the HC + O 2 → CO 2 + H 2O
element essential for catalyst which triggers chemical NO x → N 2 + O 2
reactions without itself being consumed.

SSANGYONG Y200
1F1-70 M162 ENGINE CONTROLS

OXYGEN SENSOR

YAD1F570

The oxygen sensor is unique among the engine control When the exhaust gas is rich (below 14.7:1), the voltage
sensors because is acts like a battery and is able to output is high, above450mv. When the exhaust gas is
generate its own low voltage signal. It is located the lean (above 14.7:1 air/fuel ratio), the sensor’s voltage
exhaust system and monitors the amount of oxygen in output is low, below 450 mv.
the exhaust stream and provides feedback to the The ECM uses oxygen sensor information for:
Engine Control Module (ECM).
• Open loop / closed loop criteria
The electrically heated oxygen sensor warms up quickly
and remains hot, even at idle when the exhaust manifold • Ideal air / fuel ratio
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.

YAD1F580

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-71

YAD1F590

SSANGYONG Y200
1F1-72 M162 ENGINE CONTROLS

YAD1F600

Failure
Description Trouble Area Maintenance Hint
Code
Oxygen sensor high When recognition the output • Monitoring the actual output signal
voltage that more than nominal through scan tool
80 threshold, malfunction of
sensing voltage. • Inspection the ECM pin 16, 17 about
short circuit or open with bad contact
Oxygen sensor low When recognition the output
voltage that more than nominal • Inspection the oxygen sensor
89 threshold, malfunction of • Inspection the ECM
sensing voltage.
Oxygen sensor no When recognition the output
82 activity detected that not active the sensor etc.

Oxygen sensor not lean When recognition the output

83 after overrun fuel that no lean signal after
shut-off overrun fuel shut-off
Oxygen sensor slow When slow response of sensor
84 response signal
Oxygen sensor heater When recognition the heating • Monitoring the heating status through
85 failure circuit scan tool
Oxygen sensor heater When recognition the heating • Inspection the ECM pin 9 about short
86 short circuit to battery currents that more or less than circuit or open with bad contact
set values (less than 0.2 A or
more than 2 A) • Inspection the heating power source

Oxygen sensor heater When recognition the heating • Inspection the heating circuit of oxygen
sensor
87 short circuit to ground voltages than less than set
or open values (less than 2v) • Inspection the ECM

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-73

Bank 1 system short When recognition the value

term fuel trim more than nominal control
adaptation above rich threshold, it means that when
93 threshold big deviation in control range
of adaptation values through
fuel and air mixture formation

Bank 1 system short When recognition the short

96 term fuel trim at rich term fuel trim that more than
stop nominal threshold
Bank 1 system short When recognition the short
97 term fuel trim at lean term fuel trim that less than
stop nominal threshold
Bank 1 system idle When recognition the long
98 adaptation failure term fuel trim exceeds rich
(above rich threshold) threshold
Bank 1 system idle When recognition the long
99 adaptation failure term fuel trim exceeds lean
(below rich threshold) threshold
Bank 1 system learning When recognition the long
100 control failure (rich, low term fuel trim exceeds rich
load) threshold
Bank 1 system learning When recognition the long
101 control failure (lean, low term fuel trim exceeds lean
load) threshold
Bank 1 system learning When recognition the long
102 control failure (rich, high term fuel trim exceeds rich
load) threshold
Bank 1 system learning When recognition the long
103 control failure (rich, low term fuel trim exceeds lean
load) threshold

SSANGYONG Y200
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
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 A

Notice: If the measured value is not within the specified value, the possible cause may be in cable, oxygen
sensor or ECM

SSANGYONG Y200
1F1-76 M162 ENGINE CONTROLS

ENGINE CONTROL MODULE

YAD1F610

1 Cover 5 Pin
2 Plate Vehicle Side : No. 13-60
3 Connector Engine Side : No. 73-120
4 Flat Pin A Vehicle Side Connector : Black
Vehicle Side : No. 1-12 B Engine Side Connector : Gray
Engine Side : No. 61-72

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 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 intake manifold resonance
flap, the camshaft actuator, the canister purge valve, etc., by controlling the ground circuit.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-77

SERIAL DATA COMMUNICATION

YAD1F620

Failure
Description Trouble Area Maintenance Hint
Code
CAN communication When CAN signal message • Inspection the ASR unit with CAN
failure: ASR/MSR missing or implausibility for connection
ASR/MSR unit or not
23 initialized condition • Inspection the Engine Control Module
(ECM) pin 38, 37 about short circuit or
open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ABS unit with CAN
failure: ABS missing or implausibility for connection
ABS unit or not initialized
24
condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the TCM unit with CAN
failure: TCU (A/T only) missing or implausibility for connection
26 TCU unit or not initialized
condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM

SSANGYONG Y200
1F1-78 M162 ENGINE CONTROLS

Failure
Description Trouble Area Maintenance Hint
Code
CAN communication When CAN signal message • Inspection the TOD unit with CAN
failure: TOD (E32 only) missing or implausibility for connection
TOD unit or not initialized
27 condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ABS/ABD unit with CAN
failure: ID 200h not missing or implausibility for connection
plausible ABS/ABD unit or not initialized
29
condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ABS/ABD unit with CAN
failure: ID 208h not missing or implausibility for connection
30 plausible ABS/ABD unit or not
initialized condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the each control unit with CAN
failure: communication missing or implausibility for connection
initialization failure each unit
31
(ABS, ASR, TCM, TOD etc.) • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
or not initialized condition
• Inspection the ECM
CAN communication When CAN signal message • Inspection the MSR unit with CAN
failure: MSR data missing or implausibility for connection
transmission not MSR unit or not initialized
59 plausible condition • Inspection the Engine Control Module
(ECM) pin 38, 37 about short circuit or
open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ASR unit with CAN
failure: ASR data missing or implausibility for connection
transmission not ASR unit or not initialized
60 plausible condition • Inspection the Engine Control Module
(ECM) pin 38, 37 about short circuit or
open with bad contact
• Inspection the ECM

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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-79

INTERNAL FAILURE
Failure
Description Trouble Area Maintenance Hint
Code
Transmission coding When faulty of variant coding • Inspection the coding condition through
failure of transmission scan tool
• Inspection the Engine Control Module
21 (ECM)
• Inspection the CAN line
• Inspection the TCM
ECM failure (RAM) When malfunction of random • Inspection the ECM
136 access memory - ECM internal
error
Uncoded/ unprogramed When malfunction of ECM • Fulfill the ECM variant coding
142 ECM coding-required ECM
encoding
137 ECM failure (EPROM) When malfunction of ECM • Inspection the ECM
internal
ECM failure (EEPROM/
143 Flash - EPPOM
checksum failure)
ECM failure (coding ID
144 checksum failure)
ECM failure (coding
145 checksum failure)
ECM failure
146 (programming
checksum failure)

SSANGYONG Y200
1F1-80 M162 ENGINE CONTROLS

ELECTRONIC THROTTLE CONTROLLER SAFETY MALFUNCTION

Failure
Description Trouble Area Maintenance Hint
Code

110
Throttle actuator System internal failure • Inspection the Engine Control Module
learning data fault (ECM)
Exceed fuel-cut safety
117 time
Cruise control
120 interruption memory
failure
138 Call Monitoring
Servo motor control
139 output interruption
memory failure
140 Servo motor open/short
ECM failure
186 (incompatible CPU)
ECM failure (CPUs
187 communication failure)
ECM failure (CPU 2
188
configuration failure)
ECM failure (CPU 2
189 fault)
ECM failure (CPU run
190 time failure between
CPUs)
ECM failure (CPU 2
231 cruise control message
counter failure)
Over deceleration limit
232 (CPU 2)
Over acceleration limit
233
(CPU 2)
Cruise control lever dual
234 operation (CPU 2)
Cruise control lever
235 safety terminal failure
(CPU 2)
Unusual pedal position
236 variation (CPU 2)
Unusual throttle position
237
variation (CPU 2)
Unusual throttle
controller monitoring
238 data comparison fault
(CPU 2)

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-81

Failure
Description Trouble Area Maintenance Hint
Code
Unusual accelerator System internal failure • Inspection the Engine Control Module
pedal position sensor
239 comparison fault
(CPU 2)
Throttle potentiometer
240 comparison fault
(CPU 2)
Unusual CPU
241
communication (CPU 2)

242 Unusual CPU

configuration (CPU 2)
A/D converter failure
243 (CPU 2)
Accelerator pedal
244 position sensor set-
point fault between CPU
1 and CPU 2 (ECM)
Position controller set-
245 point fault between CPU
1 and CPU 2

MSR setpoint fault

246 between CPU 1 and
CPU 2
Idle control setpoint
247 fault between CPU 1
and CPU 2
A/D converter overflow
248
(CPU 2)
249 ROM fault (CPU 2)
250 RAM fault (CPU 2)
Cycle monitor fault
251
(CPU 2)

SSANGYONG Y200
1F1-82 M162 ENGINE CONTROLS

IMMOBILIZER

YAD1F630

Failure
Description Trouble Area Maintenance Hint
Code
Communication with When missing the • D Inspection the Engine Control Module
transponder missing transponder signal (ECM) pin 13, 14 about short circuit or
open with bad contact
• Inspection the power source or ground
25 short circuit or open of immobilizer unit
• Inspection the transponder condition
(broken etc.)
• Inspection the ECM
Unprogramed ECM with When malfunction of • Fulfill the immobilizer pairing
immobilizer immobilizer

141 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.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-83

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 doesn’t 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
Removal and Installation Procedure
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
YAA1F170 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.

SSANGYONG Y200
1F1-84 M162 ENGINE CONTROLS

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
Removal and Installation Procedure
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.
YAA1F190 3. Disconnect the fuel lines from the fuel filter.
Installation Notice
Tightening Torque 28 N•m (21 lb-ft)

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. Remove the fuel filter.

6. Install the fuel filter.
7. Perform a leak test of the fuel filter.
8. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-85

FUEL TANK
Removal and Installation Procedure
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

SSANGYONG Y200
1F1-86 M162 ENGINE CONTROLS

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

FUEL PRESSURE REGULATOR

Removal and Installation Procedure
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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-87

FUEL RAIL AND INJECTORS

Removal and Installation Procedure
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
KAA1F440 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)

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

SSANGYONG Y200
1F1-88 M162 ENGINE CONTROLS

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.

ENGINE COOLANT
TEMPERATURE SENSOR
Removal and Installation Procedure
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
YAA1F150 system.

4. Remove the engine coolant temperature sensor

from the pump hosing.
Installation Notice
Tightening Torque 30 N•m (22 lb-ft)

5. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-89

THROTTLE BODY (INTEGRATED

WITH THE ACTUATOR)
Removal and Installation Procedure
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 9 N•m (80 lb-ft)
KAA1F010

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 12 N•m (106 lb-ft)

9. Remove the vacuum hose.

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

SSANGYONG Y200
1F1-90 M162 ENGINE CONTROLS

HOT FILM AIR MASS (HFM)

SENSOR
Removal and Installation Procedure
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 25 N•m (18 lb-ft)

KAA1F180
4. Remove the knock sensor.
5. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-91

PEDAL POSITION SENSOR

Removal and installation Procedure
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)

4. Remove the pedal and sensor assembly.

5. Installation should follow the removal procedure
KAA1F410
in the reverse order.

OXYGEN SENSOR
Removal and Installation Procedure
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.

YAD1F640 3. Carefully remove the oxygen sensor from the
exhaust pipe.
Installation Notice
Tightening Torque 55 N•m (41 lb-ft)

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 anti-

seize compound, if needed.
5. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
1F1-92 M162 ENGINE CONTROLS

PURGE CONTROL VALVE

Removal and Installation Procedure
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
YAD1F650
in the reverse order.

CANISTER
Removal and Installation Procedure
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

Removal and Installation Procedure
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 10 N•m (89 lb-ft)

KAA1F170

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-93

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

Removal and installation Procedure
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 25 N•m (18 lb-ft)

KAA1F160 4. Installation should follow the removal procedure

in the reverse order.

ENGINE CONTROL MODULE

Removal and installation Procedure
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 25 N•m (18 lb-ft)

KAA1F200
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
1F1-94 M162 ENGINE CONTROLS

ECM WIRING DIAGRAM (3.2L DOHC - 1 OF 7) (MSE 3.63D) SCHEMATIC AND ROUTING DIAGRAMS

YAD1F010

SSANGYONG Y200
SSANGYONG Y200

ECM WIRING DIAGRAM (3.2L DOHC - 2 OF 7) (MSE 3.63D)

M162 ENGINE CONTROLS 1F1-95

YAD1F020
1F1-96 M162 ENGINE CONTROLS
ECM WIRING DIAGRAM (3.2L DOHC - 3 OF 7) (MSE 3.63D)
SSANGYONG Y200

YAD1F030
SSANGYONG Y200

ECM WIRING DIAGRAM (3.2L DOHC - 4 OF 7) (MSE 3.63D)

M162 ENGINE CONTROLS 1F1-97

YAD1F040
1F1-98 M162 ENGINE CONTROLS
ECM WIRING DIAGRAM (3.2L DOHC - 5 OF 7) (MSE 3.63D)
SSANGYONG Y200

YAD1F050
SSANGYONG Y200

ECM WIRING DIAGRAM (3.2L DOHC - 6 OF 7) (MSE 3.63D)

M162 ENGINE CONTROLS 1F1-99

YAD1F060
1F1-100 M162 ENGINE CONTROLS
ECM WIRING DIAGRAM (3.2L DOHC - 7 OF 7) (MSE 3.63D)
SSANGYONG Y200

YAD1F070
M162 ENGINE CONTROLS 1F1-101

SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter Unit Value
Engine Coolant Temp. °C greater than 95 °C after warm up
-40 ~ 130 °C (varies with ambient
Intake Air Temp. °C
temp. or engine mode)
Engine RPM rpm 700 ± 50 (P/N), 600 ± 50 (D)
Regular RPM rpm 700 ± 50 (P/N), 600 ± 50 (D)
Engine Load % 18 ~ 25 %
Mass Air Flow Meter Kg/h 16 ~ 25 Kg/h
0 °TA (up to 100 °TA at t he wi de
Throttle Position Angle °TA open throttle)
Spark Advance °CA °CA (6 ~ 9 °CA)
Indicated Engine Torque Nm Varies with engine condition
Injection Time ms 3 ~5 ms
Battery Voltage V 13.5 ~ 14.1 v (engine running)
Front Axle Speed Km/h 0 ~ 265 Km/h
Rear Axle Speed Km/h 0 ~ 265 Km/h
Accel. Pedal Position 1 V 0.4 ~ 4.8 V
Accel. Pedal Position 2 V 0.2 ~ 2.4 V
Throttle Position 1 V 0.3 ~ 4.6 V
Throttle Position 2 V 0.3 ~ 4.6 V
Fuel Integrator 0.8 ~ 1.2
Oxygen Sensor mv 100 ~ 900 mv
A/C S/W Condition 1=ON/0=OFF -
Full Load State 1=ON/0=OFF -
Shift Gear State (A/T) 1=ON/0=OFF -
A/C Control State 1=ON/0=OFF -
Clutch Switch (M/T) 1=ON/0=OFF -
Cam Actuator State 1=ON/0=OFF -
Knocking Control 1=ON/0=OFF -
Protect Mission 1=ON/0=OFF -
Purge Control Valve 1=ON/0=OFF -
Lambda Function 1=ON/0=OFF -
Catalyst Heating 1=ON/0=OFF -
Overrun Fuel Cut 1=ON/0=OFF -
Ful l Fuel Cut 1=ON/0=OFF -
Brake Switch 1=ON/0=OFF -
Cruise Control Status 1=ON/0=OFF -
*Condition : Warmed up, idle, P/N or neutral

SSANGYONG Y200
1F1-102 M162 ENGINE CONTROLS

FASTENER TIGHTENING SPECIFICATIONS

Application N•m Lb-Ft Lb-In

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

SSANGYONG Y200
M162 ENGINE CONTROLS 1F1-103

FUEL SYSTEM SPECIFICATION This type of fuel can reduce vehicle performance and
damage components of the fuel system.
Use Only Unleaded Fuel Rated at 89 Octane
Caution: Use of methanol may damage the fuel sys-
or Higher tem.
Fuel quality and additives contained in fuel have a
significant effect on power output, drivability, and life Vehicle Fueling from Drums or Storage
of theengine. Containers
Fuel with too low an octane number can cause engine For safety reasons (particularly when using noncom-
knock. mercial fueling systems) fuel containers, pumps and
Caution: Use of fuel with an octane number lower hoses must be properly earthed.
than 89 may damage engine and exhaust system. Static electricity build up can occur under certain atmo-
spheric and fuel flow conditions if unearthed hoses,
Notice: To prevent accidental use of leaded fuel, the par-ticularly plastic, are fitted to the fuel-dispensing
nozzles for leaded fuel are larger, and will not fit the pump.
fuel filler neck of your vehicle.
It is therefore recommended that earthed pumps with
Do Not Use Methanol integrally earthed hoses be used, and that storage
containers be properly earthed during all
Fuels containing methanol (wood alcohol) should not noncommercial fueling operations.
be used in vehicle.

TEMPERATURE VS RESISTANCE
ECT sensor IAT sensor
°C °F
ohms (Ω)
Temperature vs Resistance Values (Approximate)
130 266 88 102
120 248 111.6 127
110 230 143 159
100 212 202 202
90 194 261 261
80 176 340 340
70 158 452 452
60 140 609 609
50 122 835 835
40 113 1166 1166
30 86 1662 1662
20 68 2420 2420
10 50 3604 3604
0 32 5499 5499
-10 14 8609 8609
-20 -4 13850 13850
-30 -22 22960 22960
-40 -40 39260 39260

SSANGYONG Y200
1F1-104 M162 ENGINE CONTROLS

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

661 589 00 46 00 103 589 00 21 00

Fuel Tank Cap Wrench 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 Exhaust System ................................................ 1F2-69
Diagnostic Information and Procedure ............. 1F2-4 Catalytic Converter ...........................................1F2-69
Failure Code Diagnosis ...................................... 1F2-4 Oxygen Sensor ................................................. 1F2-70
Clearing Failure Codes ....................................... 1F2-4 Engine Control Module .................................... 1F2-76
Failure Codes Table ........................................... 1F2-4 Serial Data Communication ............................... 1F2-78
Ignition System ................................................... 1F2-8 Internal Failure .................................................. 1F2-80
Ignition Coil ...................................................... 1F2-10 Electronic Throttle Controller Safety
Malfunction .................................................... 1F2-82
Crankshaft Position (CKP) Sensor .................... 1F2-12
Immobilizer ......................................................1F2-84
Camshaft Position (CMP) Sensor ....................... 1F2-16
Camshaft Actuator ............................................ 1F2-20 Maintenance and Repair ................................. 1F2-85
Knock Sensor (KS) ...........................................1F2-22 On-Vehicle Service ........................................... 1F2-85
Spark Plug ....................................................... 1F2-24 Discharging the Pressure in Fuel System .......... 1F2-85
System Voltage ................................................1F2-28 Fuel Pump ........................................................ 1F2-85
Ignition Switch .................................................. 1F2-29 Fuel Filter .......................................................... 1F2-86
Fuel System ...................................................... 1F2-30 Fuel Tank .......................................................... 1F2-87
Fuel Pump ........................................................ 1F2-32 Fuel Pressure Regulator .................................... 1F2-88
Fuel Injector...................................................... 1F2-36 Fuel Rail and Injector ........................................1F2-89
Purge Control Valve .......................................... 1F2-40 Engine Coolant Temperature Sensor .................. 1F2-90
Fuel Rail ........................................................... 1F2-42 Throttle Body (Integrated with the 91
Actuator) ....................................................... 1F2-91
Fuel Pressure Regulator .................................... 1F2-44
Hot Film Air Mass (HFM) Sensor ........................ 1F2-92
Induction System .............................................. 1F2-46
Knock Sensor ................................................... 1F2-92
Throttle Valve Actuator ...................................... 1F2-46
Pedal Position Sensor ....................................... 1F2-93
Hot Film Air Mass (HFM) Sensor ........................ 1F2-50
Oxygen Sensor ................................................. 1F2-93
Engine Coolant Temperature (ECT) Sensor ........ 1F2-54
Purge Control Valve .......................................... 1F2-94
Accelerator Pedal Module .................................1F2-58
Canister............................................................ 1F2-94
Cooling Fan ...................................................... 1F2-62
Camshaft Position Sensor .................................1F2-94
A/C Compressor Relay .....................................1F2-63
Crankshaft Position Sensor ............................... 1F2-95
Cruise Control Switch ........................................1F2-64
Engine Control Module ...................................... 1F2-95
Traction Control System (TCS) ...........................1F2-65
Schematic and Routing Diagrams ................... 1F2-96
Stop Lamp Switch............................................. 1F2-66
ECM Wiring Diagram
Engine RPM ..................................................... 1F2-67 (2.3L DOHC - MSE 3.53D) ..............................1F2-96
1F2-2 M161 ENGINE CONTROLS

Specifications ................................................. 1F2-103 Special Tools and Equipment ........................ 1F2-106

Engine Data Display Table .............................. 1F2-103 Special Tools Table .........................................1F2-106
Fastener Tightening Specifications .................. 1F2-104
Fuel System Specification ............................... 1F2-105
Temperature vs Resistance ............................. 1F2-105

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-3

ENGINE AND ECM PROBLEM CHECK REPORT

VEHICLE AND CUSTOMER INFORMATION
Date Problem Occurred
Customer Name Vehicle Model
Driver Name VIN
Purchase date Engine Model
Km
License No. Mileage
miles

MIL INFORMATION
Condition of MIL o Remains on o Sometimes illuminates o Does not illuminate
DTC inspection o Normal o Malfunction code(s) (code )
(if available) o Freeze frame data ( )

CONDITION WHEN PROBLEM OCCURS

SSANGYONG Y200
1F2-4 M161 ENGINE CONTROLS

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

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-5

FAILURE CODES TABLE (Cont’d)

Failure See Page Description

code
44 1F1-62 Cooling fan (HI) relay short circuit to power
45 1F1-62 Cooling fan (HI) relay short circuit to ground or open
54 1F1-41 Purge control circuit malfunction
56 1F1-23 No.1 knock sensor signal failure
58 1F1-17 Camshaft position sensor signal : No.1 cylinder synchronization failure
59 1F1-79 CAN communication failure : MSR data transmission not plausible
60 1F1-79 CAN communication failure : ASR data transmission not plausible
64 1F1-11 No ignition voltage output (No.1 ignition coil)
65 1F1-11 No ignition voltage output (No.2 ignition coil)
67 1F1-13 Crankshaft position sensor adaptation failure
68 1F1-25 Random/Multiple Misfire
71 1F1-29 Starter signal recognition failure
72 1F1-37 No.1 injector short circuit to battery
73 1F1-37 No.1 injector short circuit to ground or open
74 1F1-37 No.2 injector short circuit to battery
75 1F1-37 No.2 injector short circuit to ground or open
76 1F1-37 No.3 injector short circuit to battery
77 1F1-38 No.3 injector short circuit to ground or open
78 1F1-38 No.4 injector short circuit to battery
79 1F1-38 No.4 injector short circuit to ground or open
80 1F1-72 Oxygen sensor high voltage
81 1F1-73 Bank 1 system short term fuel trim adaptation below lean threshold
82 1F1-72 Oxygen sensor no activity detected
83 1F1-72 Oxygen sensor not lean after overrun fuel shut -off
84 1F1-72 Oxygen sensor slow response
85 1F1-72 Oxygen sensor heater failure
86 1F1-72 Oxygen sensor heater short circuit to battery
87 1F1-72 Oxygen sensor heater short circuit to ground or open
89 1F1-72 Oxygen sensor low voltage
93 1F1-73 Bank 1 system short term fuel trim adaptation above rich threshold
96 1F1-73 Bank 1 system short term fuel trim at rich stop
97 1F1-73 Bank 1 system short term fuel trim at lean stop
98 1F1-73 Bank 1 system idle adaptation failure (above rich threshold)
99 1F1-73 Bank 1 system idle adaptation failure (below lean threshold)
100 1F1-73 Bank 1 system learning control failure (rich, low load)
101 1F1-73 Bank 1 system learning control failure (lean, low load)
102 1F1-73 Bank 1 system learning control failure (rich, high load)
103 1F1-73 Bank 1 system learning control failure (lean, high load)
104 1F1-47 Throttle position sensor 1 low voltage
105 1F1-47 Throttle position sensor 1 high voltage

SSANGYONG Y200
1F2-6 M161 ENGINE CONTROLS

FAILURE CODES TABLE (Cont’d)

Failure See Page Description

code
108 1F1-47 Throttle position sensor 2 low voltage
109 1F1-47 Throttle position sensor 2 high voltage
110 1F1-82 Throttle actuator learning data fault
116 1F1-47 Throttle actuator learning control failure
117 1F1-82 Exceed fuel-cut safety time
119 1F1-47 Throttle valve return spring failure
120 1F1-82 Cruise control interruption memory failure
121 1F1-47 Throttle actuator failure
122 1F1-59 Accelerator pedal position sensor signal failure
123 1F1-47 Different Mass air flow sensor signal with throttle position sensor
125 1F1-47 Both throttle position sensors failure
126 1F1-48 Throttle position sensor 1 not plausible with throttle position sensor 2
127 1F1-48 High permanent throttle signal
129 1F1-64 Cruise control “OFF” due to message counter failure
130 1F1-64 Vehicle speed signal failure
131 1F1-64 Vehicle speed signal failure
132 1F1-64 Cruise control lever failure
133 1F1-64 Cruise control acceleration failure
134 1F1-64 Cruise control deceleration failure
135 1F1-66 Stop lamp switch failure
136 1F1-80 ECU failure (RAM)
137 1F1-80 ECU failure (EPROM)
138 1F1-82 Call monitoring
139 1F1-82 Servo motor control output interruption memory failure
140 1F1-82 Servo motor open/short
141 1F1-84 Unprogramed ECU with immobilizer
142 1F1-80 Uncoded/unprogramed ECU
143 1F1-80 ECU failure (EEPROM/Flash-EPROM checksum failure)
144 1F1-80 ECU failure (coding ID checksum failure)
145 1F1-80 ECU failure (coding checksum failure)
146 1F1-80 ECU failure (programing checksum failure)
150 1F1-65 TCS input signal short circuit to battery
151 1F1-65 TCS input signal short circuit to ground or open
160 1F1-59 Accelerator pedal position sensor 1 low voltage
161 1F1-59 Accelerator pedal position sensor 1 high voltage
162 1F1-59 Accelerator pedal position sensor 2 low voltage
163 1F1-59 Accelerator pedal position sensor 2 high voltage
164 1F1-59 Accelerator pedal position sensor 1 not plausible with pedal position sensor 2
167 1F1-59 Both setpoint accelerator pedal position sensor defective
185 1F1-48 Mass air flow sensor and throttle position sensor failure
186 1F1-82 ECU failure (incompatible CPU)

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-7

FAILURE CODES TABLE (Cont’d)

Failure See Page Description

code
187 1F1-82 ECU failure (CPUs communication failure)
188 1F1-82 ECU failure (CPU 2 configuration failure)
189 1F1-82 ECU failure (CPU 2 fault)
190 1F1-82 ECU failure (CPU run time failure between CPUs)
226 1F1-21 Camshaft actuator short circuit to battery
227 1F1-21 Camshaft actuator short circuit to ground or open
228 1F1-63 A/C compressor relay short circuit to battery
229 1F1-63 A/C compressor relay short circuit to ground or open
231 1F1-82 ECU failure (CPU 2 cruise control message counter failure)
232 1F1-82 Over decceleration limit (CPU 2)
233 1F1-82 Over acceleration limit (CPU 2)
234 1F1-82 Cruise control lever dual operation (CPU 2)
235 1F1-82 Cruise control lever safety terminal failure (CPU 2)
236 1F1-82 Unusual pedal position variation (CPU 2)
237 1F1-82 Unusual throttle position variation (CPU 2)
238 1F1-82 Unusual throttle controller monitor data comparison fault (CPU 2)
239 1F1-83 Unusual accelerator pedal position sensor comparison fault (CPU 2)
240 1F1-83 Throttle potentiometer comparision fault (CPU 2)
241 1F1-83 Unusual CPU communication (CPU 2)
242 1F1-83 Unusual CPU configuration (CPU 2)
243 1F1-83 A/D converter failure (CPU 2)
244 1F1-83 Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2
245 1F1-83 Position controller setpoint fault between CPU 1 and CPU 2
246 1F1-83 MSR setpoint fault between CPU 1 and CPU 2
247 1F1-83 Idle control setpoint fault between CPU 1 and CPU 2
248 1F1-83 A/D converteroverflow (CPU 2)
249 1F1-83 ROM f aul t (CPU 2)
250 1F1-83 RAM f aul t (CPU 2)
251 1F1-83 Cycle monitor fault (CPU 2)

SSANGYONG Y200
1F2-8 M161 ENGINE CONTROLS

IGNITION SYSTEM
This ignition system does not use a conventional the available energy to fire the spark plug. The remaining
distributor and coil. It uses a crankshaft position sensor energy is available to the spark plug in the cylinder on
input to the Engine Control Module (ECM). The ECM the compression stroke.
then determines Electronic Spark Timing (EST) and These systems use the EST signal from the ECM to
triggers the electronic ignition system ignition coil. control the EST. The ECM uses the following
This type of distributorless ignition system uses a information:
‘‘waste spark” method of spark distribution. Each • Engine load (mass air flow sensor).
cylinder is paired with the cylinder that is opposite it
(2-3 or 1-4). The spark occurs simultaneously in the • Engine temperature.
cylinder coming up on the compression stroke and in • Intake air temperature.
the cylinder coming up on the exhaust stroke. The • Crankshaft position.
cylinder on the exhaust stroke requires very little of • Engine speed (rpm).

YAA1F910

SSANGYONG Y200
1F2-10 M161 ENGINE CONTROLS

IGNITION COIL

YAA1F920

1 Control Cable Connection 5a, 5b Secondary Voltage Connection

2 Ignition Cable E Iron Core
3 Spark Plug Connector L1 Secondary Ignition Coil
4 Coupling Plug L2 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
M161 ENGINE CONTROLS 1F2-11

YAD1F0E0

Failure
Description Trouble Area Maintenance Hint
Code
• Inspection the ECM pin 71 and 72 about
No ignition voltage short circuit or open with bad contact
64 output • Inspection the power source to ignition
(No. 1 ignition coil) coil
Malfunction of ignition circuit
Primary current values or • Inspection the ignition coil, high tension
cords etc.
secondary short circuit
No ignition voltage • Inspection the spark plug (wet, cracks,
65 output wear, improper gap, burned electrodes,
(No. 2 ignition coil) 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
1F2-12 M161 ENGINE CONTROLS

CRANKSHAFT POSITION (CKP) SENSOR

YAA1F940

1 Crankshaft Position Sensor Connector 3 Crankshaft Position Sensor

2 Bolt

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
M161 ENGINE CONTROLS 1F2-13

YAD1F120

Failure
Description Trouble Area Maintenance Hint
Code
Crankshaft position Even through cam position
sensor signal failure recognition is normal, no
17
(no engine revolution crankshaft position signal
signal) recognition • Monitoring the actual rpm through or
scan tool
When more than applicable
Crankshaft position • Inspection the ECM pin 100, 99 about
revolution values or
18 sensor signal failure short circuit with bad contact
implausible to 60-2 teeth.
(rpm > max. value)
• Inspection the CKP sensor
When implausible recogni- • Inspection the air gap between sensor
Crankshaft position tion of cam and crank angle and drive plate
20 sensor signal failure signal or intermittent sens-
(gap recognition failure) ing the signal or error count • Inspection the drive plate (teeth condi-
of undetected gap. tion)

Crankshaft position When faulty crank angle • Inspection the ECM

67 sensor adaptation sensor adaption
failure

Notice: Measure the insulator resistance of the CKP sensor if out of the specified value.

SSANGYONG Y200
1F2-14 M161 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

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 kΩ

Notice: Measure the check and ground terminal of

the CKP sensor if out of the specified value.

SSANGYONG Y200
1F2-16 M161 ENGINE CONTROLS

CAMSHAFT POSITION (CMP) SENSOR

YAA1F950

1 Camshaft Position Sensor Connector 3 Camshaft Position Sensor

2 Bolt 4 O-Ring

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-17

YAD1F150

Failure
Description Trouble Area Maintenance Hint
Code
Camshaft position When no cam recognition • Inspection the source voltage of CMP
sensor signal : No. 1 signal during TN 24 counts sensor
19 cylinder recognition more.
failure (maintain the constant low or • Inspection the ECM pin 106, 104 about
short circuit or open with bad contact
high level)
Camshaft position When synchronization fault • Inspection the CMP sensor
sensor signal : No. 1 of cylinder 1 • Inspection the damage of sensor or
58 cylinder synchronization (TDC recognition) sprocket
failure
• Inspection the ECM

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
1F2-18 M161 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
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

Notice: If the measured value is not within the

specified value, check the cable.

SSANGYONG Y200
1F2-20 M161 ENGINE CONTROLS

CAMSHAFT ACTUATOR

YAA1F970

1 Bolt 4 Armature
2 Camshaft Actuator 5 Roll Pin
3 Bolt 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 Camshaft Position Effect
Engine stop Retard -
0 ~ 1,740 rpm Retard Idle speed is improved
Blow-by gas is decreased
Valve overlap is decreased
1,740 ~ 3,540 rpm Advanced Torque is increased
Fuel loss is decreased
NOx is decreased
Above 3,540 rpm Retard Engine overrun is prohibited

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-21

YAD1F150

Camshaft actuator short • Inspection the power source short circuit

circuit to ground or or open to cam actuator
227 open • Inspection the magnet and hardware
• Inspection the ECM

Camshaft Actuator Current Consumption Inspection

Notice: If the measured value is not within the specified value, check the cable.

SSANGYONG Y200
1F2-22 M161 ENGINE CONTROLS

KNOCK SENSOR (KS)

YAD1F180

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-23

YAD1F0F0

Failure
Description Trouble Area Maintenance Hint
Code
No. 1 knock sensor When recognition in more • Inspection the ECM pin 118, 117 about
signal failure than control gain threshold short circuit or open with bad contact
at normal operational
56 condition of other system • Inspection the KS 1 malfunction
during over 75 and • Inspection the ECM
3,000 rpm running area
(cylinder 1, 2, 3, 4)

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.

SSANGYONG Y200
1F2-24 M161 ENGINE CONTROLS

SPARK PLUG

YAA1F990

1 Screw 6 Bolts
2 Adaptor 7 Ignition Coil (T 1/1)
3 Ignition Coil Cable Cover 8 Coupling Plug
4 Spark Plug Connector 9 Spark Plug
5 Ignition Coil Connector 10 Ignition Coil (T 1/2)

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-25

YAD1F0G0

Failure
Description Trouble Area Maintenance Hint
Code
Random / Multiple When detection misfire of • Inspection the ignition system
Misfire multiple cylinder for source
of over the emission • Inspection the injection system
threshold or catalyst • Inspection the fuel pressure
damage
• Inspection the compression pressure
• Inspection the valve timing or clearance
68
• Inspection the air flow sensor
• Inspection the crankshaft position sensor
and air gap
• Inspection the engine wiring system
• Inspection the Engine Control Module
(ECM)

SSANGYONG Y200
1F2-26 M161 ENGINE CONTROLS

Spark Plug Cable Resistance Inspection

Notice: Replace the spark plug cable if the measured values is out of the specified values.

SSANGYONG Y200
1F2-28 M161 ENGINE CONTROLS

SYSTEM VOLTAGE

YAD1F220

Failure
Description Trouble Area Maintenance Hint
Code
System voltage too low Malfunction in recognition of • Monitoring the actual battery voltages
system source voltage. through the scan tool
Less than minimum 8 volts
in 2,000 rpm below, or less • Inspection the Engine Control Module
(ECM) pin 12, 11, 10, 5 about short
than 10 volts in 2,000 rpm
08 circuit or open with bad contact
above.
• Inspection the over voltage protection
relay
• Inspection the battery
• Inspection ECM

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-29

IGNITION SWITCH

YAD1F230

Failure
Description Trouble Area Maintenance Hint
Code
Starter signal recogni- When not detection of • Inspection the Engine Control Module
tion failure starter signal (ECM) pin 2 circuit short or open with
71 bad contact
• Inspection ECM

SSANGYONG Y200
1F2-30 M161 ENGINE CONTROLS

FUEL SYSTEM
The function of the fuel metering system is to deliver of fuel delivered in the starting mode by changing how
the correct amount of fuel to the engine under all long the fuel injector is turned on and off. This is done
operating conditions. by ‘‘pulsing” the fuel injectors for very short times.
The fuel is delivered to the engine by the individual Run Mode
fuel injectors mounted into the intake manifold near
The run mode has two conditions called ‘‘open loop”
each cylinder.
and ‘‘closed loop”.
The main fuel control sensors are the Mass Air Flow
(MAF) sensor and the oxygen (O2) sensors. Open Loop
The MAF sensor monitors the mass flow of the air being When the engine is first started and it is above 690
drawn into the engine. An electrically heated element rpm, the system goes into “open loop” operation. In
is mounted in the intake air stream, where it is cooled “open loop”, the ECM ignores the signal from the HO2S
by the flow of incoming air. Engine Control Module and calculates the air/fuel ratio based on inputs from
(ECM) modulates the flow of heating current to maintain the ECT sensor and the MAF sensor. The ECM stays
the temperature differential between the heated film in “open loop” until the following conditions are met:
and the intake air at a constant level. The amount of • The O2 has a varying voltage output, showing that
heating current required to maintain the temperature it is hot enough to operate properly.
thus provides an index for the mass air flow. This
concept automatically compensates for variations in
• The ECT sensor is above a specified temperature
(22.5 °C).
air density, as this is one of the factors that determines
the amount of warmth that the surrounding air absorbs • A specific amount of time has elapsed after starting
from the heated element. MAF sensor is located the engine.
between the air filter and the throttle valve. Closed Loop
Under high fuel demands, the MAF sensor reads a The specific values for the above conditions vary with
high mass flow condition, such as wide open throttle. different engines and are stored in the Electronically
The ECM uses this information to enrich the mixture, Erasable Programmable Read-Only Memory (EEPROM).
thus increasing the fuel injector on-time, to provide When these conditions are met, the system goes into
the correct amount of fuel. When decelerating, the mass “closed loop” operation. In “closed loop”, the ECM
flow decreases. This mass flow change is sensed by calculates the air/fuel ratio (fuel injector on- time)
the MAF sensor and read by the ECM, which then based on the signals from the O2 sensors. This allows
decreases the fuel injector on-time due to the low fuel the air/fuel ratio to stay very close to 14.7 to 1.
demand conditions.
Acceleration Mode
The O2 sensors are located in the exhaust pipe before
catalytic converter. The O2 sensors indicate to the ECM The ECM responds to rapid changes in throttle position
the amount of oxygen in the exhaust gas, and the ECM and airflow and provides extra fuel.
changes the air/fuel ratio to the engine by controlling Deceleration Mode
the fuel injectors. The best air/fuel ratio to minimize
The ECM responds to changes in throttle position and
exhaust emissions is 14.7 to 1, which allows the
airflow and reduces the amount of fuel. When
catalytic converter to operate most efficiently. Because
deceleration is very fast, the ECM can cut off fuel
of the constant measuring and adjusting of the air/fuel
completely for short periods of time.
ratio, the fuel injection system is called a “closed loop”
system. Battery Voltage Correction Mode
The ECM uses voltage inputs from several sensors to When battery voltage is low, the ECM can compensate
determine how much fuel to provide to the engine. The for a weak spark delivered by the ignition module by
fuel is delivered under one of several conditions, called using the following methods:
“modes”. • Increasing the fuel injector pulse width.
Starting Mode • Increasing the idle speed rpm.
When the ignition is turned ON, the ECM turns the fuel • Increasing the ignition dwell time.
pump relay on for 1 second. The fuel pump then builds
Fuel Cut-Off Mode
fuel pressure. The ECM also checks the Engine Coolant
Temperature (ECT) sensor and the Throttle Position (TP) No fuel is delivered by the fuel injectors when the
sensor and determines the proper air/fuel ratio for ignition is off. This prevents dieseling or engine run-
starting the engine. This ranges from1.5 to 1 at -36 °C on. Also, the fuel is not delivered if there are no reference
(-33 °F) coolant temperature to 14.7 to 1 at 94 °C (201 pulses received from the CKP sensor. This prevents
°F) coolant temperature. The ECM controls the amount flooding.

SSANGYONG Y200
1F2-32 M161 ENGINE CONTROLS

FUEL PUMP

YAD1F240

1 Flange and Harness Assembly 5 Thermistor

2 Spring 6 Float Arm
3 Fuel Pump 7 Thermistor Housing
4 Float 8 Resistor Card and Wiper

Requirements for Fuel Pump

Item Specified Value Item Specified Value
System Pressure 3.8 bar Minimum Delivery at 8V 30 Litre/ Hr
Maximum Pressure 8.5 bar (12 V) Operating Voltage 8V
Minimum Pressure 5.0 bar (12 V) Maximum Allowable
7.5 A
Current
Nominal Voltage 12 V Ambient Temperature -30 ~ +70° C
Minimum Amount 114 Liter/ Hr Maximum Amount of Fuel 165 Liter/ Hr
of Fuel Supply (12 V, 3.8 bar, -30 ~ +70° C) Supply (12 V, 3.8 bar, -30 ~ +70° C)

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-33

YAD1F250

Failure
Description Trouble Area Maintenance Hint
Code

34 Fuel pump relay short When short circuit to power • Inspection the Engine Control Module
circuit to battery source (ECM) pin 33 about short circuit or open
with bad contact
Fuel pump relay short When short circuit to ground
35 circuit to ground or or open • Inspection the fuel pump relay
open
• Inspection the ECM

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 0 V (for 1 ~ 2 sec.)

Cranking 0V

SSANGYONG Y200
1F2-34 M161 ENGINE CONTROLS

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

Notice: Replace the fuel pump relay if the measured value is over 9 A.

SSANGYONG Y200
1F2-36 M161 ENGINE CONTROLS

FUEL INJECTOR

YAA1F0C0

1 O-Ring 4 O-Ring
2 Injector 5 Fuel Rail
3 Injector Bracket

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 injector’s 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.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-37

YAD1F0H0

Failure
Description Trouble Area Maintenance Hint
Code
No. 1 injector short When malfunction of injector • Inspection the power to injector #1 or
circuit to battery circuit bad contact
72
Injector #1 short circuit to • Inspection the injector
power
• Inspection the ECM
No. 1 injector short When malfunction of injector • Inspection the ECM pin 63 about short
circuit to ground or circuit circuit or open with bad contact
73 open
Injector #1 short circuit to • Inspection the injector
ground or open
• Inspection the ECM
No. 2 injector short When malfunction of injector • Inspection the power to injector #2 or
circuit to battery circuit bad contact
74
Injector #2 short circuit to • Inspection the injector
power
• Inspection the ECM
No. 2 injector short When malfunction of injector • Inspection the ECM pin 64 about short
circuit to ground or circuit circuit or open with bad contact
75 open
Injector #2 short circuit to • Inspection the injector
ground or open
• Inspection the ECM
No. 3 injector short When malfunction of injector • Inspection the power to injector #3 or
circuit to battery circuit bad contact
76
Injector #3 short circuit to • Inspection the injector
power
• Inspection the ECM
SSANGYONG Y200
1F2-38 M161 ENGINE CONTROLS

Failure
Description Trouble Area Maintenance Hint
Code
No. 3 injector short When malfunction of injector • Inspection the ECM pin 65 about short
circuit to ground or circuit circuit or open with bad contact
77 open
Injector #3 short circuit to • Inspection the injector
ground or open
• Inspection the ECM
No. 4 injector short When malfunction of injector • Inspection the power to injector #4 or
circuit to battery circuit bad contact
78
Injector #4 short circuit to • Inspection the injector
power
• Inspection the ECM
No. 4 injector short When malfunction of injector • Inspection the ECM pin 66 about short
circuit to ground or circuit circuit or open with bad contact
79 open
Injector #4 short circuit to • Inspection the injector
ground or open
• Inspection the ECM

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-39

Injector Spray Pattern Check

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.
YAD1F280
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 Ω

Notice: Replace the fuel injector if the measured

YAD1F290 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 8.0 ms
Engine Idle 3 ~ 5 ms
Wide Open Throttle 14 ms
(WOT)

SSANGYONG Y200
1F2-40 M161 ENGINE CONTROLS

PURGE CONTROL VALVE

YAA1F440

1 Purge Control Valve 3 Line to Canister

2 Line to Engine 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

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-41

YAD1F310

Failure
Description Trouble Area Maintenance Hint
Code

40
Purge control valve When short circuit to power • Inspection the ECM pin 34 about short
short circuit to battery source circuit or open with bad contact
Purge control valve When short circuit to ground • Inspection the source power of valve
41 short circuit to ground or open
or open • Inspection the purge control solenoid
vale
54 Purge control circuit When malfunction of purge
malfunction control : not work • Inspection the ECM

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.)
Specified Value purge control valve
operates at this time

Notice: Test while at normal temperature and at

idling state by operating the engine.

SSANGYONG Y200
1F2-42 M161 ENGINE CONTROLS

FUEL RAIL

YAA1F0E0

1 O-Ring 9 Combination Bolt

2 Fuel Pressure Regulator 10 Bolt
3 Circlip 11 Clamp
4 Vacuum Hose 12 Fuel Return Line
5 O-Ring 13 Hollow Bolt
6 Injector 14 Seal Ring
7 Injector Bracket 15 Seal Ring
8 Fuel Rail 16 Fuel Pressure Test Connector

SSANGYONG Y200
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.
Vacuum Hose
YAA1F700 3.2 ~ 3.6
Connected (bar)
Vacuum Hose
3.7 ~ 4.2
Disconnected (bar)

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 • Fuel leakage at the injector
drops slowly
• Faulty fuel pressure
regulator’s diaphragm
and O-ring
YAA1F0K0
Fuel pressure • Faulty check valve in
drops rapidly the fuel pump

3. If there is no change in fuel pressure and maintain

the following pressure over 30minutes, it is normal.
Fuel pressure (bar) 2.5

SSANGYONG Y200
1F2-44 M161 ENGINE CONTROLS

FUEL PRESSURE REGULATOR

YAA1F0F0

1 Vacuum Hose 4 O-Ring

2 Circlip 5 O-Ring
3 Fuel Pressure Regulator

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).
YAD1F360
When the fuel pressure goes up, the diaphragm forces
2. Fuel return line A. Valves Closed the compression spring (6) in the direction of
3. Valve B. Valves Opened compression. At this moment, the valve (3) sticks to
5. Diaphragm the diaphragm by the fuel pressure, and the fuel return
6. Compression Spring line (2) opens. The fuel over supplied returns to the
8. Fuel Chamber fuel tank through the return line.
9. Spring Chamber

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-45

The pressure difference between the fuel pressure and

the intake manifold is about 3.8 bars during the full
load.

YAD1F390

1. Fuel Pressure Regulator

2. Intake Manifold
YAD1F370
3. Fuel Return (to fuel tank)
1. Fuel Pressure Regulator 4. Fuel Supply (from fuel pump)
2. Intake Manifold 7. Fuel Pressure (approx. 3.2 bars)
3. Fuel Return (to fuel tank) 8. Intake Manifold Negative Pressure (0.6 bars)
4. Fuel Supply (from fuel pump)
5. Fuel Pressure (approx. 3.8 bars) <Fuel Pressure Diagram>
6. Intake Manifold Negative Pressure (0 bar)

<Operating at Idle and partial load>

YAD1F400

A. Fuel pressure
B. Intake Manifold Negative Pressure
LL. Idling
TL. Partial load
VL. Full load

YAD1F380

Consequently, the fuel pressure in the fuel distributor

SSANGYONG Y200
1F2-46 M161 ENGINE CONTROLS

INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR

YAA1F540

The throttle actuator is actuated by the Engine Control the spring capsule.
Module (ECM) according to the position of the Consequently, the throttle valve opening is a constant
accelerator pedal position. 10-12 °approximately.
It has two potentiometers which signal the position of At no load, this produces an engine speed of about
the throttle valve to the ECM to enable it to recognize 1,800 rpm
the various engine load states.
Driving
Ignition “Off”
When driving (part/full throttle), the servo motor controls
In the de-energized states the throttle valve position the throttle valve in line with the various load states
is determined to be spring capsule. and according to the input signals from the pedal value
Ignition “On” sensor according to the input signals from the pedal
value sensor according to the position of the
When the ignition S/W on the servo motor in the throttle
accelerator pedal.
actuator is operated by the ECM. The throttle valve
adopts a position in line with the coolant temperature. The function of the EA (electronic accelerator) in the
ECM determines the opening angle of the throttle valve
Closed position through the throttle actuator. Further functions are;
In the closed throttle position, the servo motor controls • Idle speed control
engine speed by operating the throttle valve further
(greater mixture) or closing it further (reduced mixture),
• Cruise control
depending on coolant temperature and engine load. • Reducing engine torque for ASR/ABS operation
When this is done, the throttle valve can be closed • Electronic accelerator emergency running
further by the servo motor overcoming the force of the • Storing faults
spring capsule (mechanical end stop). If the actuator
• Data transfer through CAN
is de-energized, the throttle valve is resting against

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-47

YAD1F420

Failure
Description Trouble Area Maintenance Hint
Code

104
Throttle position sensor TPS 1 short circuit to ground • Monitoring the actual values through
1 low voltage or open scan tool

105
Throttle position sensor TPS 1 short circuit to power • Inspection the ECM pin 84, 85, 87, 112,
1 high voltage 67, 68 about short circuit or open with
bad contact
Throttle position sensor TPS 2 short circuit to ground
108
2 low voltage or open • Inspection the throttle valve actuator

109
Throttle position sensor TPS 2 short circuit to power • Inspection the ECM
2 high voltage
Throttle actuator When actuat or adaption
116 learning control failure fluctuation or not meet the
condition
Throttle valve return When return spring
119
spring failure defective of actuator
Throttle act uator failure When supply voltage of the
121 actuat or short circuit to
power
Different mass air flow When shut down of out put
123 sensor signal with driver
throttle position sensor
Both throttle position When defective of both
125
sensor failure potentiometers

SSANGYONG Y200
1F2-48 M161 ENGINE CONTROLS

Failure
Description Trouble Area Maintenance Hint
Code
Throttle position sensor When difference between • Monitoring the actual values through
126 1 not plausible with TPS 1 and TPS 2 scan tool
Throttle position sensor 2
• Inspection the ECM pin 84, 85, 87, 112,
High permanent throttle When failure of wiring 67, 68 about short circuit or open with
127 signal harness or actuator bad contact
Mass air flow sensor When difference between • Inspection the throttle valve actuator
185 and throttle position MAF and TPS signal
sensor failure • Inspection the ECM

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 Specified Value

Closed 0.3 ~ 0.9 v
TPS 1
Opened 4.0 ~ 4.6 v
Closed 4.0 ~ 4.6 v
TPS 2
Opened 0.3 ~ 0.9 v

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 Specified Value

Ignition “ON” 0.8 ~ 2.3 v
Engine 1.0 ~ 2.5 v
Status Idling (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 Ω

SSANGYONG Y200
1F2-50 M161 ENGINE CONTROLS

HOT FILM AIR MASS (HFM) SENSOR

YAD1F430

1 Housing 4 Connector
2 Protector Net 5 Hot Film Air Mass Sensor
3 Electronic Housing 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 over-
temperature 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.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-51

Mass Air Flow (kg/h) Voltage (V) Mass Air Flow (kg/h) Voltage (V)
0 0.95 ~ 1.05 250 3.51
10 1.28 370 3.93
15 1.41 480 4.23
30 1.71 640 4.56
60 2.16 800 4.82
120 2.76

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.

SSANGYONG Y200
1F2-52 M161 ENGINE CONTROLS

YAD1F440

Failure
Description Trouble Area Maintenance Hint
Code

03
Intake air temperature IAT sensor short circuit to • Monitoring the actual air temperature
sensor low voltage ground or open through scan tool

04
Intake air temperature IAT sensor short circuit to • Inspection the ECM pin 80, 79 about
sensor high voltage power short circuit or open with bad contact
Intake air temperature Malfunction in recognition of • Inspection the IAT sensor (integrated in
05 sensor plausibility IAT HFM sensor)
When functional problem • Inspection the ECM
Mass air flow sensor Malfunction in recognition of • Monitoring the actual air mass flow
09 plausibility MAF through scan tool
When air mass not plausible • Inspection the ECM pin 81, 105 about
short circuit or open with bad contact
Mass air flow sensor MAF sensor short circuit to
10
low voltage ground or open • Inspection the MAF sensor (integrated in
HFM sensor)
Mass air flow sensor MAF sensor short circuit to
11
high voltage power • Inspection the ECM

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-53

Mass Air Flow Sensor Input Voltage Inspection

1. Turn the ignition switch to “ON” position.
2. Measure the signal voltage between the ECM pin No. 103 and No. 104.
Application Specified Value
Ignition “ON” 0.9 ~ 1.1 V
Engine 1.3 ~ 1.7 V
Status Idling (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

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

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).

SSANGYONG Y200
1F2-54 M161 ENGINE CONTROLS

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

YAA1F590

1 Artificial Resin Housing 4 Connector

2 Metal Housing 5 Engine Coolant Temperature Sensor
3 NTC (Negative Temperature Coefficient)
Resistor

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-55

SSANGYONG Y200
1F2-56 M161 ENGINE CONTROLS

YAD1F470

Failure
Description Trouble Area Maintenance Hint
Code
Engine coolant ECT sensor short circuit to • Monitoring the actual coolant temperature
00 temperature sensor low ground or open through scan t ool
voltage
• Inspection the ECM pin 78, 79 about
Engine coolant ECT sensor short circuit to short circuit or open with bad contact
01 temperature sensor high power
voltage • Inspection the ECT sensor

Engine coolant Malfunction in recognition of • Inspection the ECM

temperature sensor ECT
02 plausibility
When drop to about 50° C
below after warm up
Engine coolant Malfunction in recognition of
temperature insufficient ECT
06 for closed loop fuel
When minimum temperature
control
for lambda control after
warm up

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-57

3. Turn the ignition switch to “OFF” position.

4. Disconnect the ECT sensor connector.
5. Turn the ignition switch to “ON” position.
6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4.
Temperature (°C) Ω)
Specified Value (Ω
20 2,500
80 322
100 185

Notice: Replace wiring and coolant temperature sensor if out of specified value.

SSANGYONG Y200
1F2-58 M161 ENGINE CONTROLS

ACCELERATOR PEDAL MODULE

YAD1F480

1 Accelerator Pedal 4 6-Pin Connector

2 Accelerator Pedal Sensor 5 Kick-down Switch
3 Bolts 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.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-59

YAD1F490

Failure
Description Trouble Area Maintenance Hint
Code
Acceleration pedal When malfunction of APP • Monitoring the actual values through
122 position sensor signal sensor scan tool
failure
• Inspection the ECM pin 31, 47, 32, 48,
Acceleration pedal APP 1 sensor short circuit to 59, 51 about short circuit or open with
160 position 1 sensor low ground or open bad contact
voltage
• Inspection the APP sensor
Acceleration pedal APP 1 sensor short circuit to
161 position sensor 1 high power • Inspection the ECM
voltage
Acceleration pedal APP 2 sensor short circuit to
162 position sensor 2 low ground or open
voltage
Acceleration pedal APP 2 sensor short circuit to
163 position sensor 2 high power
voltage
Accelerator pedal When difference between
position sensor 1 not APP 1 sensor and APP 2
164 plausible with sensor
accelerator pedal
position sensor 2
Both setpoint When defective of both APP
167 accelerator pedal sensor
position sensor defective

SSANGYONG Y200
1F2-60 M161 ENGINE CONTROLS

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 Specified Value (V)
Valve
Closed Throttle Valve 0.3 ~ 0.7
Fully Depressed Throttle
4.3 ~ 4.8
Valve

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 Specified Value (V)
Valve
Closed Throttle Valve 0.1 ~ 0.4
Fully Depressed Throttle
2.1 ~ 2.5
Valve

Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply
voltage to APP sensor 2.

SSANGYONG Y200
1F2-62 M161 ENGINE CONTROLS

COOLING FAN

YAD1F510

Failure
Description Trouble Area Maintenance Hint
Code

44
Cooling fan (HI ) relay Cooling fan short circuit to • Inspection the Engine Control Module
short circuit to power power (ECM) pin 35 about short circuit or open
with bad contact
Cooling fan (HI ) relay Cooling fan short circuit to
short circuit to ground ground or open • Inspection the power source
45 or open
• Inspection the cooling fan
• Inspection the ECM

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.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-63

A/C COMPRESSOR RELAY

YAD1F520

Failure
Description Trouble Area Maintenance Hint
Code

228
A/C compressor relay When malfunction of A/C • Monitoring the actual operation through
short circuit to battery compressor control scan tool
A/c compressor relay • Inspection the Engine Control Module
short circuit to ground (ECM) pin 44 about short circuit or open
or open with bad contact
229
• Inspection the relay short circuit or open
• Inspection the ECM

SSANGYONG Y200
1F2-64 M161 ENGINE CONTROLS

CRUISE CONTROL SWITCH

YAD1F530

130
Vehicle speed signal When malfunction of • Inspection the Engine Control Module
failure auto-cruise system (ECM) pin 52, 53, 54, 55, 57 about short
Implausible condition of circuit or open with bad contact
Vehicle speed signal
131 vehicle speed signal.
failure • Inspection the CAN and ABS

132
Cruise control lever Cruise control lever defective • Inspection the cruise control lever switch
failure
• Inspection the ECM
Cruise control system
Cruise control
133 Implausible condition of
acceleration failure
acceleration signal
Cruise control Cruise control system
134 deceleration failure Implausible condition of
deceleration signal

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.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-65

TRACTION CONTROL SYSTEM (TCS)

YAD1F540

Failure
Description Trouble Area Maintenance Hint
Code

150 TCS input signal short TCS short circuit to power • Inspection the Engine Control Module
circuit to battery (ECM) pin 45 about short circuit or open
with bad contact
TCS input signal short TCS short circuit to ground
151 circuit to ground or or open • Inspection the TCS lamp of I/P cluster.
open
• Inspection the ECM

SSANGYONG Y200
1F2-66 M161 ENGINE CONTROLS

STOP LAMP SWITCH

YAD1F550

Failure
Description Trouble Area Maintenance Hint
Code

135
Stop lamp switch failure When malfunction of stop • Monitoring the actual operational status
lamp switch-implausible and vehicle speed signal through scan
condition of stop lamp tool
signal input
• 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

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-67

ENGINE RPM

YAD1F560

Failure
Description Trouble Area Maintenance Hint
Code
Engine rpm output When short circuit to battery • Monitoring the actual rpm in cluster
32 circuit short circuit to
battery • Inspection the Engine Control Module
(ECM) pin 60 about short circuit or open
Engine rpm output When short circuit to ground
33 circuit short circuit to or open • Inspection the cluster panel board circuit
ground or open • Inspection the ECM

SSANGYONG Y200
1F2-68 M161 ENGINE CONTROLS

EXHAUST SYSTEM
CATALYTIC CONVERTER These catalysts in the 3-way catalytic converter are
the rare metals platinum (Pt) and rhodium (Rh).
The purpose of the catalytic converter is to convert
The catalytic converter consists essentially of three
the three pollutants of carbon monoxide (CO),
main elements. The exhaust gases flow through the
hydrocarbons (HC) and oxides of nitrogen (NOx)
catalytic converter and, in so doing, coming into
contained in the exhaust of gasoline engines, into the
contact with rare metals (Pt and Rh).
harmless compounds of water (H2O), carbon dioxide
(CO2) and nitrogen (N2). The following chemical reaction are produced.
The catalytic converter contains acatalyst, a word CO + O 2 → CO2
coming from the Greek and which designates the HC + O2 → CO2 + H 2O
element essential for catalyst which triggers chemical NO x → N 2 + O2
reactions without itself being consumed.

SSANGYONG Y200
1F2-70 M161 ENGINE CONTROLS

OXYGEN SENSOR

YAD1F570

The oxygen sensor is unique amongthe engine control When the exhaust gas is rich (below 14.7:1), the voltage
sensors because is acts like a battery and is able to output is high, above 450 mv. When the exhaust gas
generate its own low voltage signal. It is located the is lean (above 14.7:1 air/fuel ratio), the sensor’s
exhaust system and monitors the amount of oxygen in voltage output is low, below 450 mv.
the exhaust stream and provides feedback to the The ECM uses oxygen sensor information for:
Engine Control Module (ECM).
• Open loop / closed loop criteria
The electrically heated oxygen sensor warms up quickly
and remains hot, even at idle when the exhaust manifold • Ideal air / fuel ratio
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.
YAD1F580

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-71

YAD1F590

SSANGYONG Y200
1F2-72 M161 ENGINE CONTROLS

YAD1F600

Failure
Description Trouble Area Maintenance Hint
Code
Oxygen sensor high When recognition the output • Monitoring the actual output signal
voltage that more than nominal through scan tool
80 threshold, malfunction of
sensing voltage. • Inspection the ECM pin 16, 17 about
short circuit or open with bad contact
Oxygen sensor low When recognition the output
voltage that more than nominal • Inspection the oxygen sensor
89
threshold, malfunction of • Inspection the ECM
sensing voltage.
Oxygen sensor no When recognition the output
82
activity detected that not active the sensor etc.
Oxygen sensor not lean When recognition the output
83 after overrun fuel that no lean signal after
shut-off overrun fuel shut-off
Oxygen sensor slow When slow response of sensor
84
response signal

85
Oxygen sensor heater When recognition the heating • Monitoring the heating status through
failure circuit scan tool
Oxygen sensor heater When recognition the heating • Inspection the ECM pin 9 about short
short circuit to battery currents that more or less than circuit or open with bad contact
86 set values (less than 0.2 A or
more than 2 A) • Inspection the heating power source

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-73

Failure
Description Trouble Area Maintenance Hint
Code
Bank 1 system short When recognition the value • Inspection the intake air leakage
term fuel trim less than nominal control
adaptation below lean threshold, it means that when • Inspection the injection quantities with
81 injector block or leakage
threshold big deviation in control range
of adaptation values through • Inspection the exhaust leakage
fuel and air mixture formation
• Inspection the ECM
Bank 1 system short When recognition the value
term fuel trim more than nominal control
adaptation above rich threshold, it means that when
93 threshold big deviation in control range
of adaptation values through
fuel and air mixture formation
Bank 1 system short When recognition the short
96 term fuel trim at rich term fuel trim that more than
stop nominal threshold
Bank 1 system short When recognition the short
97 term fuel trim at lean term fuel trim that less than
stop nominal threshold
Bank 1 system idle When recognition the long
98 adaptationfailure term fuel trim exceeds rich
(above rich threshold) threshold
Bank 1 system idle When recognition the long
99 adaptation failure term fuel trim exceeds lean
(below rich threshold) threshold
Bank 1 system learning When recognition the long
100 control failure term fuel trim exceeds rich
(rich, low load) threshold
Bank 1 system learning When recognition the long
101 control failure term fuel trim exceeds lean
(lean, low load) threshold
Bank 1 system learning When recognition the long
102 control failure term fuel trim exceeds rich
(rich, high load) threshold
Bank 1 system learning When recognition the long
103 control failure term fuel trim exceeds lean
(rich, low load) threshold

SSANGYONG Y200
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 catalyst’s
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

Notice: If the measured value is not within the specified value, the possible cause may be in cable, oxygen
sensor or ECM

SSANGYONG Y200
1F2-76 M161 ENGINE CONTROLS

ENGINE CONTROL MODULE

YAD1F610

1 Cover 5 Pin
2 Plate Vehicle Side : No. 13-60
3 Connector Engine Side : No. 73-120
4 Plat Pin A Vehicle Side Connector : Black
Vehicle Side : No. 1-12 B Engine Side Connector : Gray
Engine Side : No. 61-72

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.

SSANGYONG Y200
1F2-78 M161 ENGINE CONTROLS

SERIAL DATA COMMUNICATION

YAD1F620

Failure
Description Trouble Area Maintenance Hint
Code
CAN communication When CAN signal message • Inspection the ASR unit with CAN
failure: ASR/MSR missing or implausibility for connection
ASR/MSR unit or not
23 initialized condition • Inspection the Engine Control Module
(ECM) pin 38, 37 about short circuit or
open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ABS unit with CAN
failure: ABS missing or implausibility for connection
ABS unit or not initialized
24 • Inspection the ECM pin 38, 37 about
condition
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the TCM unit with CAN
failure: TCU (A/T only) missing or implausibility for connection
TCU unit or not initialized
26
condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-79

Failure
Description Trouble Area Maintenance Hint
Code
CAN communication When CAN signal message • Inspection the ABS/ABD unit with CAN
failure: ID 200h not missing or implausibility for connection
plausible ABS/ABD unit or not initialized
29 condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ABS/ABD unit with CAN
failure: ID 208h not missing or implausibility for connection
plausible ABS/ABD unit or not initialized
30 condition • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the each control unit with CAN
failure: communication missing or implausibility for connection
initialization failure each unit (ABS, ASR, TCM,
31
TOD etc.) or not initialized • Inspection the ECM pin 38, 37 about
short circuit or open with bad contact
condition
• Inspection the ECM
CAN communication When CAN signal message • Inspection the MSR unit with CAN
failure: MSR data missing or implausibility for connection
transmission not MSR unit or not initialized
59 plausible condition • Inspection the Engine Control Module
(ECM) pin 38, 37 about short circuit or
open with bad contact
• Inspection the ECM
CAN communication When CAN signal message • Inspection the ASR unit with CAN
failure: ASR data missing or implausibility for connection
transmission not ASR unit or not initialized
60 plausible condition • Inspection the Engine Control Module
(ECM) pin 38, 37 about short circuit or
open with bad contact
• Inspection the ECM

SSANGYONG Y200
1F2-80 M161 ENGINE CONTROLS

INTERNAL FAILURE
Failure
Description Trouble Area Maintenance Hint
Code
Transmission coding When faulty of variant coding • Inspection the coding condition through
failure of transmission scan tool

21 • InspectiontheEngine ControlModule
(ECM)
• Inspection the CAN line
• Inspection the TCM
ECM failure (RAM) When malfunction of random • Inspection the ECM
136 access memory - ECM
internal error
Uncoded/ unprogramed When malfunction of ECM • Fulfill the ECM variant coding
142 ECM coding-required ECM
encoding
137 ECM failure (EPROM) When malfunction of ECM • Inspection the ECM
internal
ECM failure (EEPROM/
143 Flash-EPPOM
checksum failure)
ECM failure (coding ID
144
checksum failure)
ECM failure (coding
145
checksum failure)
ECM failure (program-
146 ming checksum failure)

SSANGYONG Y200
1F2-82 M161 ENGINE CONTROLS

ELECTRONIC THROTTLE CONTROLLER SAFETY MALFUNCTION

Failure
Description Trouble Area Maintenance Hint
Code

187 ECM failure (CPUs

communication failure)
ECM failure (CPU 2
188
configuration failure)
ECM failure
189
(CPU 2 fault)
ECM failure
190 (CPU run time failure
between CPUs)
ECM failure (CPU 2
231 cruise control message
counter failure)
Over deceleration limit
232
(CPU 2)
Over acceleration limit
233
(CPU 2)
Cruise control lever dual
234
operation (CPU 2)
Cruise control lever
235 safety terminal failure
(CPU 2)
Unusual pedal position
236
variation (CPU 2)
Unusual throttle position
237
variation (CPU 2)
Unusual throttle
controller monitoring
238
data comparison fault
(CPU 2)

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-83

Failure
Description Trouble Area Maintenance Hint
Code
Unusual accelerator System internal failure • Inspection the Engine Control Module
pedal position sensor (ECM)
239
comparison fault
(CPU 2)
Throttle potentiometer
240 comparison fault
(CPU 2)
Unusual CPU
241 communication (CPU 2)
Unusual CPU
242
configuration (CPU 2)
A/D converter failure
243
(CPU 2)
Accelerator pedal
position sensor setpoint
244 fault between CPU 1
and CPU 2
Position controller
245 setpoint fault between
CPU 1 and CPU 2
MSR setpoint fault
246 between CPU 1 and
CPU 2
Idle control setpoint
247 fault between CPU 1
and CPU 2
A/D converter overflow
248
(CPU 2)
249 ROM fault (CPU 2)
250 RAM fault (CPU 2)
Cycle monitor fault
251
(CPU 2)

SSANGYONG Y200
1F2-84 M161 ENGINE CONTROLS

IMMOBILIZER

YAD1F630

Failure
Description Trouble Area Maintenance Hint
Code
Communication with When missing the transpon- • Inspection the Engine Control Module
transponder missing der signal (ECM) pin 13, 14 about short circuit or
open with bad contact
• Inspection the power source or ground
25 short circuit or open of immobilizer unit
• Inspection the transponder condition
(broken etc.)
• Inspection the ECM
Unprogramed ECM with When malfunction of • Fulfill the immobilizer pairing
immobilizer immobilizer
141 Required immobilizer
encoding, no paired
condition of immobilizer even
through start trial

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-85

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)

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 doesn’t stain
around.

3. Installation should follow the removal procedure

in the reverse order.

YAA1F710

1. Relieve the fuel system pressure. Refer to

SSANGYONG Y200
1F2-86 M161 ENGINE CONTROLS

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
Removal and Installation Procedure
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 “Dis-

charging the Pressure in Fuel System” in this sec-
tion.
YAA1F190 3. Disconnect the fuel lines from the fuel filter.
Installation Notice
Tightening Torque 28 N•m (21 lb-ft)

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. Remove the fuel filter.

6. Install the fuel filter.
7. Perform a leak test of the fuel filter.
8. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-87

1. Relieve the fuel pressure. Refer to “Discharging

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

SSANGYONG Y200
1F2-88 M161 ENGINE CONTROLS

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

FUEL PRESSURE REGULATOR

Removal and Installation Procedure
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.

YAA1F730

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-89

FUEL RAIL AND INJECTORS

Removal and Installation Procedure
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
YAA1F710 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)

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

SSANGYONG Y200
1F2-90 M161 ENGINE CONTROLS

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.

ENGINE COOLANT TEMPERATURE

SENSOR
Removal and Installation Procedure
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
YAA1F780 system.

4. Remove the engine coolant temperature sensor

from the pump hosing.
Installation Notice
Tightening Torque 30 N•m (22 lb-ft)

5. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-91

THROTTLE BODY (INTEGRATED

WITH THE ACTUATOR)
Removal and Installation Procedure
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 12 N•m (106 lb-in)

8. Remove the vacuum hose.

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
1F2-92 M161 ENGINE CONTROLS

HOT FILM AIR MASS (HFM) SENSOR

Removal and Installation Procedure
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 sepa-
rated from the contact surface.
Notice: Make sure the HFM sensor coupling
KAC1F270
connects completely with the contact surface
installation.

5. Remove the HFM sensor.

6. Installation should follow the removal procedure
in the reverse order.

KAA1F180 4. Remove the knock sensor.

5. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-93

PEDAL POSITION SENSOR

Removal and Installation Procedure
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.

5. Installation should follow the removal procedure
KAA1F410 in the reverse order.

2. Disconnect the electrical connector.

YAA1F820 3. Carefully remove the oxygen sensor from the
exhaust pipe.
Installation Notice
Tightening Torque 55 N•m (41 lb-ft)

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 anti-

seize compound, if needed.
5. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200
1F2-94 M161 ENGINE CONTROLS

PURGE CONTROL VALVE

CANISTER
Removal and Installation Procedure
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

Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the cam-
shaft position sensor.
3. Remove the camshaft position sensor retaining
bolt.
Installation Notice
Tightening Torque 10 N•m (89 lb-in)

YAA1F810

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-95

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

Removal and installation Procedure
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)

4. Installation should follow the removal procedure

KAA1F160 in the reverse order.

ENGINE CONTROL MODULE

Removal and installation Procedure
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 10 N•m (89 lb-in)

KAA1F200 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
1F2-96 M161 ENGINE CONTROLS

ECM WIRING DIAGRAM (2.3L DOHC - 1 OF 7) (MSE 3.53D) SCHEMATIC AND ROUTING DIAGRAMS

YAD1F010

SSANGYONG Y200
SSANGYONG Y200

ECM WIRING DIAGRAM (2.3L DOHC - 2 OF 7) (MSE 3.53D)

M161 ENGINE CONTROLS 1F2-97

YAD1F0A0
1F2-98 M161 ENGINE CONTROLS
ECM WIRING DIAGRAM (2.3L DOHC - 3 OF 7) (MSE 3. 53D)
SSANGYONG Y200

YAD1F030
SSANGYONG Y200

ECM WIRING DIAGRAM (2.3L DOHC - 4 OF 7) (MSE 3.53D)

M161 ENGINE CONTROLS 1F2-99

YAD1F040
1F2-100 M161 ENGINE CONTROLS
ECM WIRING DIAGRAM (2.3L DOHC - 5 OF 7) (MSE 3.53D)
SSANGYONG Y200

YAD1F0B0
SSANGYONG Y200

ECM WIRING DIAGRAM (2.3L DOHC - 6 OF 7) (MSE 3.53D)

M161 ENGINE CONTROLS 1F2-101

YAD1F0C0
1F2-102 M161 ENGINE CONTROLS
ECM WIRING DIAGRAM (2.3L DOHC - 7 OF 7) (MSE 3.53D)
SSANGYONG Y200

YAD1F0D0
M161 ENGINE CONTROLS 1F2-103

SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter Unit Value
Engine Coolant Temp. °C greater than 95 °C after warm up
-40 ~ 130 °C (varies with ambient
Intake Air Temp. °C
temp. or engine mode)
Engine RPM rpm 700 ± 50 (P/N), 600 ± 50 (D)
Regular RPM rpm 700 ± 50 (P/N), 600 ± 50 (D)
Engine Load % 18 ~ 25 %
Mass Air Flow Meter Kg/h 16 ~ 25 Kg/h
0 °TA (up to 100 °TA at the wide
Throttle Position Angle °TA open throttle)
Spark Advance °CA °CA (6 ~ 9 °CA)
Indicated Engine Torque Nm Varies with engine condition
Injection Time ms 3 ~ 5 ms
Battery Voltage V 13.5 ~ 14.1 V (engine running)
Front Axle Speed Km/h 0 ~ 265 Km/h
Rear Axle Speed Km/h 0 ~ 265 Km/h
Accel. Pedal Position 1 V 0.4 ~ 4.8 V
Accel. Pedal Position 2 V 0.2 ~ 2.4 V
Throttle Position 1 V 0.3 ~ 4.6 V
Throttle Position 2 V 0.3 ~ 4.6 V
Fuel Integrator 0.8 ~ 1.2
Oxygen Sensor mv 100 ~ 900 mv
A/C S/W Condition 1=ON/0=OFF -
Full Load State 1=ON/0=OFF -
Shift Gear State (A/T) 1=ON/0=OFF -
A/C Control State 1=ON/0=OFF -
Clutch Switch (M/T) 1=ON/0=OFF -
Cam Actuator State 1=ON/0=OFF -
Knocking Control 1=ON/0=OFF -
Protect Mission 1=ON/0=OFF -
Purge Control Valve 1=ON/0=OFF -
Lambda Function 1=ON/0=OFF -
Catalyst Heating 1=ON/0=OFF -
Overrun Fuel Cut 1=ON/0=OFF -
Full Fuel Cut 1=ON/0=OFF -
Brake Switch 1=ON/0=OFF -
Cruise Control Status 1=ON/0=OFF -

* Condition : Warmed up, idle, P/N or neutral

SSANGYONG Y200
1F2-104 M161 ENGINE CONTROLS

FASTENER TIGHTENING SPECIFICATIONS

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

SSANGYONG Y200
M161 ENGINE CONTROLS 1F2-105

FUEL SYSTEM SPECIFICATION This type of fuel can reduce vehicle performance and
damage components of the fuel system.
Use Only Unleaded Fuel Rated at 89 Octane
Caution: Use of methanol may damage the fuel sys-
or Higher tem.
Fuel quality and additives contained in fuel have a
significant effect on power output, drivability, and life Vehicle Fueling from Drums or Storage
of the engine. Containers
Fuel with too low an octane number can cause engine For safety reasons (particularly when using noncom-
knock. mercial fueling systems) fuel containers, pumps and
Caution: Use of fuel with an octane number lower hoses must be properly earthed.
than 89 may damage engine and exhaust system. Static electricity build up can occur under certain atmo-
spheric and fuel flow conditions if unearthed hoses,
Notice: To prevent accidental use of leaded fuel, the particularly plastic, are fitted to the fuel-dispensing
nozzles for leaded fuel are larger, and will not fit the pump.
fuel filler neck of your vehicle. It is therefore recommended that earthed pumps with
integrally earthed hoses be used, and that storage
Do Not Use Methanol containers be properly earthed during all
Fuels containing methanol (wood alcohol) should not noncommercial fueling operations.
be used in vehicle.

SSANGYONG Y200
1F2-106 M161 ENGINE CONTROLS

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

661 589 00 46 00 103 589 00 21 00

Fuel Tank Cap Wrench 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 Repair Instructions ............................................ 1F3-41
Fuel System ...................................................... 1F3-2 On-Vehicle Service ........................................... 1F3-41
Governor ........................................................... 1F3-4 Vacuum Pump .................................................. 1F3-41
Absolute Metering Manifold Pressure Vacuum Unit Replacement ................................ 1F3-43
Compensator (ALDA) .....................................1F3-10 Fuel Pump ........................................................ 1F3-44
Pneumatic Idle Speed Increase (PLA) ............... 1F3-11 Injection Nozzles ..............................................1F3-46
Pneumatic Shut-Off Device (PNAB) ................... 1F3-12 Injection Nozzle Repair .....................................1F3-48
Exhaust Gas Recirculation (EGR) Valve .............1F3-13 Injection Timing Device Assembly .................... 1F3-51
Component Locator ......................................... 1F3-15 Injection Timing Device .....................................1F3-56
Fuel Injection Pump .......................................... 1F3-15 Fuel Injection Pump .......................................... 1F3-58
Vacuum Pump (Sectional View) .........................1F3-16 Fuel Tank .......................................................... 1F3-64
Diagnostic Information And Procedure ........... 1F3-17 Specifications ................................................... 1F3-66
Vacuum Control System Test ............................ 1F3-17 General Specifications ......................................1F3-66
Vacuum Shut-Off Leak Test ............................... 1F3-21 Fastener Tightening Specifications .................... 1F3-67
Idle Speed Adjustment .....................................1F3-23 Schematic and Routing Diagrams ................... 1F3-68
Fuel Pump Test ................................................. 1F3-25 EGR System................................................... 1F3-68
Injection Nozzle Test ........................................1F3-28 Special Tools and Equipment .......................... 1F3-69
Checking and Adjusting Start Of Delivery .......... 1F3-31 Special Tools Table ...........................................1F3-69
1F3-2 DIESEL ENGINE CONTROLS

DESCRIPTION AND OPERATION

FUEL SYSTEM
Fuel Injection System

YAD1FAA0

1 Fuel Injection Pump 6 Fuel Return Hoses

2 Fuel Feed Pump 7 Injection Line
3 Overflow Valve 8 Fuel Tank
4 Injection Nozzle 9 Fuel Filter
5 Pre-filter 10 Choke Orifice

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-3

Fuel Injection Pump Coding

PES 5M 55C 320 RS 167

P Injection Pump
E Self - Driven
S End Flange Mounting
5 Number of Cylinders (5EA)
M Pump Size (Flange Stroke)
M - 7 mm
A - 8 mm
M, W - 8 mm, 10 mm
YAD1FAB0
P - 10 mm, 11 mm, 12 mm
Z - 12 mm
O - 15 mm

55 Element Diameter
C Modification Letter
320 Assembly Number
R Direction of Rotation (clockwise)
S167 Special Version

SSANGYONG Y200
1F3-4 DIESEL ENGINE CONTROLS

GOVERNOR control requirements are restricted to low idle and high

idle (maximum) speeds.control requirements are
RSF Minimum-maximum-speed governor restricted to low idle and high idle (maximum) speeds.
The RSF mechanical governor was developed In the uncontrolled range between these two speed,
specifically as a minimum-maximum-speed governor. the driver uses the accelerator pedal to directly adjust
It is suitable for use in those on-road vehicles the setting of the injection-pump control rack so that
(passenger cars and commercial vehicles) in which the engine develops the right torque.

YAD1FAC0

a Idle Range (Working Range of the Idle Spring) S Start Setting With Accelerator Pedal fully
b Extended Idle Range at No-Load and Minimum Depressed (Cold-Start)
Part Load (Working Range of the Idle Spring S ’ Start Setting With Accelerator Pedal Released
and the Auxiliary Idle Spring) (Hot/ Warm Start)
c Uncontrolled Range L Low-Idle-Speed Setting
d Torque-Control Range (Working Range of the O High-Idle-Speed Setting
Torque-Control Spring) n1u Low Idle Speed
e Torque-Control Travel n1o High Idle Speed
f Speed-Regulation Range (Working Range of the nvo Maximum Full-Load Speed
Governor Spring) n1 Speed at Start of Torque Control
g Full-Load Speed Regulation to the High Idle n2 Speed at End of Torque Control
Speed
h Start of the Auxiliary Idle-Spring Shutoff

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-5

Speed-sensing mechanism stage 1 (low idle) The flyweights (22) are fastened directly to the injection-
The force path starts at flyweights (22) and travels pump camshaft and when they move outward,
through sliding sleeve (20) and guide lever (9) to idle governor sliding sleeve (20) is moved axially. The
spring (12) and auxiliary idle spring (14). Both springs sliding sleeve does not move except in the idle, full-
are leaf springs. load torque-control, and speed-regulation breakaway
ranges. The fuel delivery quantity needed for the
Speed-sensing machanism, stage 2 required engine torque is selected by the actuator-
(until full-load speed regulation) mechanism control lever.
After completion of idle-speed sleeve travel, the force The guide lever (9) is movably connected at pivot point
path is from governor sliding sleeve (20) through B with the governor sliding sleeve. In addition, guide
torque-control spring retainer (18) and tensioning lever lever and tensioning lever (16) also pivot at point A.
(16) to governor spring (17).

YAD1FAD0

1 Stop(Shutoff) Lever 14 Auxiliary Idle Spring

2 Strap 15 Adjusting Screw for Auxiliary Idle Spring
3 Stop Lever 16 Tensioning Lever
4 Control Rack 17 Governor Spring
5 Linkage Lever (Inner) 18 Spring Retainer
6 Control Lever (Outer) (Torque Control)
7 Full-Load Stop 19 Full-Load Adjusting Screw
8 Adjusting Screw For Idle Speed 20 Governor Sliding Sleeve
9 Guide Lever 21 Auxiliary-Idle-Spring
10 Idle Stop Switch-Off Device
11 Reverse-Transfer Lever 22 Flyweight
12 Idle-Speed Spring
13 Variable-Fulcrum Lever

SSANGYONG Y200
1F3-6 DIESEL ENGINE CONTROLS

Actuator mechanism Starting the engine

Input of the desired valve is through control lever (6) The engine is to be started according to the vehicle
linkage lever (5) and reverse-transfer lever (11) to manufacturer’s operating instructions. Normally, it can
variable fulcrum lever (13), and from there through strap be started without pressing the accelerator pedal. Only
(2) to injection-pump control rack (4). The strap is with a cold engine at low temperatures is the accelerator
spring-loaded, and compensates for the extra pedal to be pushed to the floor so that control lever (6)
movement of the fulcrum lever. Similar to the guide is shifted up against full-load stop(7) – a fixed stop on
lever, the reverse-transfer lever is also flexibly mounted the governor housing. Reverse- transfer lever (11)
at pivot point B of the sliding sleeve, and is also swivels around pivot point B, and in doing so shifts
attached to the fulcrum lever (13) via a shaft and fulcrum lever (13) in the “Start” direction. The result is
bushing. Full-load delivery at the fulcrum lever’s lower that the control rack (4) is moved to the start setting
bearing point, which also acts as the spring-loaded and the engine receives the required start quantity.
yield point for the fulcrum lever for absorbing the Rapid speed regulation from the governor start setting
sliding sleeve’s additional travel in case of excessive is made possible by lifting the auxiliary idle spring
speed. The bearing shaft of the stop lever (3) protrudes (14) away from fulcrum lever (9) by a switch-off device
from the governor housing. Attached to its end is a (21) when the control lever is in the full-load position.
stop (shutoff) lever (1) which switches off the engine,
whereby the stop lever pulls the control rack in the
stop (shoutoff) direction.

YAD1FAE0

4 Control Rack 11 Reverse-Transfer Lever

6 Control Lever (Outer) 13 Variable-Fuicrum Lever
7 Full-Load Stop 14 Auxiliary-Idle Spring
9 Guide Lever 21 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 Intermediate speed

After passing through the idle stage (a), governor
Low idle speed
sliding sleeve (20) and spring retainer (18) for torque
Once the engine starts and the accelerator pedal is control come into contact with each other. In the
released, a return spring pulls control lever (6) back to uncontrolled range between idle and maximum speed,
the low-idle position. Linkage lever (5) is now up against the position of the flyweights (22) remains constant up
idle-speed stop screw(10). to high idle (maximum) speed, the only exception being
During warm-up, low idle speed follows the idle-speed for minor adjustments necessary for torque control.
control curve and stabilizes at Point L. Control-rack setting and therefore delivery quantity are
When speed increases, flyweights (22) move outward, selected directly through control lever (6).
and shift governor sliding sleeve (20) to the right. During That is, the driver uses the accelerator pedal to select
operation within the idle range, sliding sleeve the delivery quantity necessary to increase speed or
movement is transmitted through reverse-transfer lever climb hills (control-lever position between idle stop and
(11) and fulcrum lever (13); moving the control rack (4) full-load stop).
toward Stop (shutoff). At the same time, sliding-sleeve If the driver depresses the accelerator pedal fully, the
movement causes guide lever (9) to swivel about pivot control rack shifts to the full-load delivery setting.
point A, compressing the idle leaf spring (12). This
spring’s 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).

YAD1FAF0

4 Control Rack 12 Idle-Speed Spring

5 Linkage Lever (Inner) 13 Variable-Fulcrum Lever
6 Control Lever 14 Auxiliary Idle Spring
8 Adjusting Screw For Idle Speed 15 Adjusting Screw for Auxiliary Idle Spring
9 Guide Lever 18 Spring Retainer (Torque Control)
10 Idle Stop 20 Governor Sliding Sleeve
11 Reverse-Transfer Lever 22 Flyweight

Idle-speed setting.
(only the components concerned in the governing process are shown)

SSANGYONG Y200
1F3-8 DIESEL ENGINE CONTROLS

Torque control load speed nvo is reached. If engine speed increases

If torque control is fitted, full-load delivery quantity is beyond full-load speed, the force exerted by the
flyweights (22) suffices to overcome the force of
reduced when a given speed n 1 is exceeded, because
governor spring (17) and full-load-speed regulation
centrifugal force acting on sliding sleeve (20) exceeds starts.
the force of the torque-control spring fitted in spring
Engine speed increases slightly, and rack travel is
retainer (18). The torque-control spring yields to this
reduced due to the rack being moved towards stop
force. As a result, if speed increases further, control
(shutoff) and the delivery quantity decreases.
rack (4) shifts by the torque-control travel distance.
Torque control ends at speed n 2. Breakaway depends upon governor spring pretension.
The engine adjusts to high idle (maximum) speed n10
Instead of positive torque control, the RDF governor
when all load is removed.
can have negative torque control. Here the control-rack
setting is controlled by a spring combination. When driving downhill with the accelerator released,
the vehicle drives the engine (overrun) and accelerates
High idle (maximum) speed it.
With the accelerator pedal pressed to the floor, the No fuel is injected during this operating mode (overrun
full-load quantity is injected until the maximum full- fuel shutoff).

YAD1FAG0

4 Control Rack 20 Governor Sliding Sleeve

17 Governor Spring 22 Flyweight
18 Spring Retainer (Torque Control)

Full-load setting
(only the components concerned in the governing process are shown)

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-9

Stopping the engine As a result, the diaphragm of the vacuum unit is pulled
When Stop (shutoff) lever (1) is moved by hand, stop against the compression spring.
lever (3) shifts control rack (4) to the Stop (shutoff) The vacuum unit (6) is connected with a stop lever
position. The fuel supply is interrupted and the engine (2r). This lever pivots around the fulcrum “D” pulling
stops. A pneumatic shutoff device can also be used the control rod of the injection pump into the “stop
for engine switchoff. position”. The bypass spring of the fulcrum lever is
overcome in this process. Via the emergency stop lever
Switching off (2s) the control rod can likewise be pulled into “stop
The vacuum unit (6) is connected to vacuum from the position” on the outside of the governor.
vacuum pump via the glow starter switch of the vehicle.

YAD1FAM0

a Start
b Stop

SSANGYONG Y200
1F3-10 DIESEL ENGINE CONTROLS

ABSOLUTE METERING MANIFOLD Because the engine’s turbocharger further compresses

the prevailing atmospheric pressure, the absolute
PRESSURE COMPENSATOR pressure in the engine’s intake manifold is a
(ALDA) combination of the atmospheric pressure and the
charge-air pressure. The absolute-metering manifold-
On a pressure-charged engine, the cylinder air charge
pressure compensator registers this absolute pressure
depends upon the boost pressure, which in turn is
and adapts the fuel-delivery quantity accordingly.
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.

YAD1FAJ0

1 Adjusting Screw 4 Aneroid Capsule

2 Aneroid Box 5 Adaptation
3 Connection for the Line to the Engine Manifold 6 Guide Plate

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-11

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

SSANGYONG Y200
1F3-12 DIESEL ENGINE CONTROLS

PNEUMATIC SHUT-OFF DEVICE This device can only be installed on vehicle which are
equipped with a vacuum pump.
(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.

YAD1FAK0

1 Pneumatic Shut-Off Device 4 Spring-Loaded Strap

2 Shut-Off Lever for Manual Operation 5 Control Rack
3 Stop Lever

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-13

EXHAUST GAS RECIRCULATION

(EGR) VALVE
The Exhaust Gas Recirculation (EGR) system is the
device to lower the NOx (oxides of nitrogen) emission
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level caused by high combustion temperature. ;;;;;;;;;;;;;;
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Because the combustion process of the diesel engine ;;;;;;;;;;;;;;
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always needs excessive air, the exhaust gas contains ;;;;;;;;;;;;;;
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large amount of NOx. ;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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The EGR valve restricts NOx generation by recirculating ;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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some amount of the exhaust gas into the combustion
chamber to reduce the combustion temperature.
But the recirculated gas results in reduced charging YAD1FAL0

efficiency of mixture so that the engine performance

drops down. Because of this fact, EGR valve is tuned • Condition of working the EGR valve
to operate in the area where oxidized substances are - 100 seconds after starting the engine
generated much.
- More than 200 RPM

YAD1FAM0

1 Injection Pump 6 Lever

2 Micro Switch 7 Micro Switch
3 Bolt 8 Adjusting Disc “A” Setting Indicator (10 inch)
4 Screw ....................................... 5 N•m (44 lb-in) 9 Adjusting Disc “B” Setting Indicator (11 inch)
5 Cam

SSANGYONG Y200
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. Hold the injection with clamp (special) on the work bench.

2. Install the micro switch setting device 017 589 08 21 01 in the injection pump.
3. Adjust and fix the lever (6) at 10° ± 1 °
4. Insert the harness into the micro switch setting device 617 589 08 21 01.
5. Install the cam on the injection pump when the both lamps are “on”.
6. Install the screw.
7. At this moment, loosen the clamp and insert the adjusting disc “A” to the lever and check again.
8. 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
DIESEL ENGINE CONTROLS 1F3-15

COMPONENT LOCATOR
FUEL INJECTION PUMP

YAD1FAN0

1 Delivery Valve Holder 9 Governor Assembly

2 Control Lever 10 Hinge Lever
3 Engine Stop Unit 11 Spring Retainer (Torque Control)
4 Idle Speed Adjustment (ALDA) 12 Fly Weight
5 Stop Lever 13 Clamping Piece
6 Adjusting Screw for Idle Speed 14 Plunger Driving Cam
7 Guide Lever 15 Fuel Pump Driving Cam
8 Adjusting Screw for Auxiliary Idle Speed

SSANGYONG Y200
1F3-16 DIESEL ENGINE CONTROLS

VACUUM PUMP (SECTIONAL VIEW)

YAD1FAP0

2 Suction Valve 16 Roller Cam

4 Piston 17 Piston Rod
5 Pressure Valve 21 Inner Return Spring
6 Safety Valve 23 Upper Spring Retainer
7 O-Ring 28 Piston Ring
8 Pump Housing 30 Seal Ring
9 Pump Cover 31 Oil Return Valve
12 Lever 32 Restrictor
14 Outer Return Spring SB To Brake Booster
15 Inner Spring Retainer SK To Vacuum Lines

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-17

DIAGNOSTIC INFORMATION AND PROCEDURE

VACUUM CONTROL SYSTEM TEST

YAD1FAQ0

1 Rubber Hose 7 Distributor

2 Air Filter 8 Molding Hose
3 Distributor 9 Connector
4 Chock 10 Chock Filter
5 Rubber Hose 11 Molding Hose
6 Molding Hose

Service Data

Idle Speed Increase At least 100 rpm at approx. 500 mbr

Permissible Pressure Drop of System 400 - 500 mbar approx. 1 min

SSANGYONG Y200
1F3-18 DIESEL ENGINE CONTROLS

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

e.g Bosch MOT 001.03

Digital tester
Sun DIT 9000
e.g Ahlborm, Therm 2263 - 2
Temperature measuring instrument with test probe
Eichenfeldstrabe 1 - 3
WB24
D - 8150 Holzkirichen

Tester Connection

YAD1FAR0

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-19

Test step 1 (Coolant Temp. ≤ 0°C)

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.
YAD1FAS0
Faulty PLA vacuum unit.
(Remove the connection hose from vacuum pump)

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

SSANGYONG Y200
1F3-20 DIESEL ENGINE CONTROLS

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. ± 3°C of the thermovalve.

YES NO

Faulty thermovalve.
Defective filter with
YAD1FAS0 restriction.

Stop the engine. Detach the filter with restriction.

Filter with restriction is clear.

YES NO

Defective filter with

restriction.

YAD1FAW0 OK

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-21

VACUUM SHUT-OFF LEAK TEST

YAD1FAX0

1 Vacuum Pump 5 Check Valve (to Brake Booster)

2 Fuel Injection Pump 6 Engine Shut-Off Valve
3 Engine Stop Unit 7 Suction Line
4 Control Line 8 Vacuum Tester

Service Data

Model Permissible loss of vacuum

Entire System at 400 + 50 mbar Vacuum 6 mbar / min.
Individual Part at 300 + 50 mbar Vacuum 5 mbar / min.

SSANGYONG Y200
1F3-22 DIESEL ENGINE CONTROLS

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 6 mbar / min
vacuum
If a vacuum drop is more than sperified value,
YAD1FAY0
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 5 mbar / min
vacuum
If a vacuum drop is more than specified value,
replace the engine shut-off valve (6)

Notice: Before replacing the valve for the glow

YAD1FAZ0 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
5 mbar / min
vacuum
- If a vacuum drop is more than specified valve,
replace the vacuum stop unit.

YAD1FB00

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-23

IDLE SPEED ADJUSTMENT

Service Data

Engine Idle Speed

OM662LA Engine 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
1F3-24 DIESEL ENGINE CONTROLS

6. Ensure not to damage the idle spring in the

governor and adjust idle speed by turning the PLA
unit (5) slowly.
Clockwise RPM Decrease
Counterclockwise RPM Increase

Notice: Do not rotate the PLA unit over ½ 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
DIESEL ENGINE CONTROLS 1F3-25

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 Fuel Filter Housing 5 Tester ............................ At Idle Speed > 0.3 bar
2 Fuel Line ......................................... At Full Load > 0.5 bar
3 Seal ........................................................ Replace 6 Fuel Injection Pump
4 Bolt ........................................... 13 N•m (10 lb-ft) 7 Fuel Pump

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-27

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 > 0.3 bar
At Full Load > 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
1F3-28 DIESEL ENGINE CONTROLS

INJECTION NOZZLE TEST

Preceding Work: Removal of fuel injection nozzle

YAD1FBB0

1 Fuel Injection Nozzle ...........New : 135 - 143 bar 2 Tester

............................................ Used : min. 120 bar 3 Valve
A Closed Spray = good
B Stringy Spray = poor

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-29

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
YAD1FBC0
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.

YAD1FBD0

• Poor
The spray pattern shows split, too wide and
stringy.
(Repair the fuel injection nozzle)

YAD1FBE0

SSANGYONG Y200
1F3-30 DIESEL ENGINE CONTROLS

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 135 - 143 bar
Used Nozzle Min. 120 bar
Difference Between Nozzles Max. 5 bar

Notice: If out of standard, repair the injection

nozzle.

6. Leak test
YAD1FBC0
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
DIESEL ENGINE CONTROLS 1F3-31

CHECKING AND ADJUSTING START OF DELIVERY

Governor Impulse Method (RIV)
In order to be able to register the relationship of the In order to obtain a measuring signal the sensor pins
injection pump relative to the engine two signals are must be moved past the pulse generators with a
required. minimum speed (idle speed). A measuring instrument
measures the time interval of the two impulses,
• TDC impulse from the crankshaft. converting the result into an angular value which is
• Governor impulse from the injection pump. then indicated.
Both impulses are supplied by pulse generators.

YAD1FBF0

1 Fuel Injection Pump 4 TDC Pluse Sender Unit

2 Rl Sensor 5 Battery
3 Digital Testor

SSANGYONG Y200
1F3-32 DIESEL ENGINE CONTROLS

Position Sensor, RIV Method

YAD1FBG0

1 Position Sensor 4 Seal ........................................................ Replace

2 Battery 5 Screw Plug ............................... 30 N•m (22 lb-ft)
3 Fuel Injection Pump

Service Data

Start of Delivery (RIV) ATDC 14° - 16°

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-33

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 ATDC 14° - 16°
0 T 10 20 30 40
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 4 TDC Pulse Generator

2 Rl Sensor 5 Battery
3 Digital Tester

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-35

(Connection Diagram for Testers With Adapter)

YAD1FBK0

1 Fuel Injection Pump 4 TDC Pulse Sender Unit

2 Rl Sensor 5 Battery
3 Digital Tester 6 Rl Pulse Generator

Service Data

Start of Delivery (RIV) ATDC 14° - 16°

Idle Speed 720 - 820 rpm

SSANGYONG Y200
1F3-36 DIESEL ENGINE CONTROLS

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 Tools
Digital Tester With Pluse Generator Bosch, MOT 001.03
Hartmann & Braun. EOMT3
Without Pulse Generator 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.

YAD1FBM0 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)

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 4 Bolt........................................... 23 N•m (17 lb-ft)

2 Bolt........................................... 23 N•m (17 lb-ft) 5 Scale ....... Rl start of delivery = 14° - 16° ATDC
3 Fuel Injection Pump

SSANGYONG Y200
1F3-38 DIESEL ENGINE CONTROLS

Tools Required
617 589 08 21 00 Position Sensor

Adjustment Procedure
1. Position the No. 1 cylinder at ATDC 15°
Notice: Do not rotate the engine in opposite
0 T 10 20 30 40 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 Start of Delievery Retarded
To the left 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) 3 Bolt........................................... 23 N•m (17 lb-ft)

2 Adjusting
Screw .... To the right : start of delivery retarded
To the left : start of delivery advanced

Service Data

Start of Delivery (RIV) ATDC 14° - 16°

Ldling Speed 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 Tools
Digital Tester With Pulse Generator Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Without Pulse Generator 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 Start of Delivery Retarded
To the Left Start Delivery Advanced

YAD1FBV0

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-41

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
VACUUM PUMP
Preceding Work: Removal the poly V-belt

YAD1FBX0

1 Bolt........................................... 10 N•m (89 lb-in) 3 Vacuum Line

2 Vacuum Pump 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
DIESEL ENGINE CONTROLS 1F3-43

VACUUM UNIT REPLACEMENT

YAD1FC10

1 Bracket 4 Vacuum Line

2 Bolt 5 Seal ........................................................ Replace
3 Vacuum Unit

SSANGYONG Y200
1F3-44 DIESEL ENGINE CONTROLS

FUEL PUMP

YAD1FC20

1 Fuel Injection Pump 5 Gasket ................................................... Replace

2 Pressure Line ........................... 13 N•m (10 lb-ft) 6 Spring Lock Washer
3 Suction Line 7 Hexagon Nuts .......................... 18 N•m (13 lb-ft)
4 Hose Clip ............................................... Replace 8 Fuel Pump

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-45

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

4. Installation should follow the removal procedure

in the reverse order.

YAD1FC50

SSANGYONG Y200
1F3-46 DIESEL ENGINE CONTROLS

INJECTION NOZZLES

YAD1FC60

1 Fuel Injection Nozzle . 35 - 40N•m (26 - 30 lb-ft) 4 Nozzle Washer ..................................... Replace
2 Fuel Return Hose 5 Fuel Injection Pipe ................... 18 N•m (13 lb-ft)
3 Plug

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-47

Tools Required
001 589 65 09 00 Serration Wrench

Removal & Installation Procedure

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
35 - 40 N•m
Tightening Torque
(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
1F3-48 DIESEL ENGINE CONTROLS

INJECTION NOZZLE REPAIR

Preceding Work: Removal of fuel injection nozzle

YAD1FCA0

1 Nozzle Holder 5 Intermediate Disc

2 Steel Washer 6 Nozzle Needle
3 Compression Spring 7 Nozzle Body
4 Thrust Pin 8 Nozzle Tensioning Nut ............ 80 N•m (59 lb-ft)

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-49

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
1F3-50 DIESEL ENGINE CONTROLS

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
DIESEL ENGINE CONTROLS 1F3-51

INJECTION TIMING DEVICE ASSEMBLY

Preceding Work : Removal of vacuum pump

YAD1FCF0

1 Cylinder Head Cover 10 Washer

2 Bolt........................................... 10 N•m (89 lb-in) 11 Bolt (Left-Hand Thread) ........... 46 N•m (34 lb-ft)
3 Gasket ................................................... Replace 12 Camshaft Sprocket
4 Fuel Injection Pump 13 Washer
5 Seal ........................................................ Replace 14 12-Sided Stretch Bolt ..........................................
6 Screw Plug ............................... 30 N•m (22 lb-ft) ........................... Check, 25 N•m (18 lb-ft)+ 90°
7 Oil Pan 15 Timing Chain
8 Locking Pin 16 Seal
9 Injection Timing Device 17 Chain Tensioner ....................... 80 N•m (59 lb-ft)

SSANGYONG Y200
1F3-52 DIESEL ENGINE CONTROLS

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

Removal & Installation Procedure

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 46 N•m (34 lb-ft)

Do not remove the bolt.

YAD1FCH0

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-53

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 30 N•m (22 lb-ft)

Replace the seal.

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
1F3-54 DIESEL ENGINE CONTROLS

8. Remove the chain tensioner (17).

Installation Notice
Tightening Torque 80 N•m (59 lb-ft)

Replace the seal (16).

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
DIESEL ENGINE CONTROLS 1F3-55

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
1F3-56 DIESEL ENGINE CONTROLS

INJECTION TIMING DEVICE

Preceding Work: Removal of injection timing device assembly

YAD1FCR0

1 Cam Sprocket ............................................ Check 4 Segment Flange and Drive Hub

2 Bushing ...................................................... Check 5 Compression Springs
3 Governor Weights

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-57

Removal & Installation Procedure

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
1F3-58 DIESEL ENGINE CONTROLS

FUEL INJECTION PUMP

Preceding Work: Removal of vacuum pump
Removal of air cleaner housing
Removal of intake manifold

YAD1FCV0

18 Chain Tensioner ....................... 80 N•m (59 lb-ft) 24 Oil Pan

19 Seal ........................................................ Replace 25 Fuel Injection Pump
20 Bolt(Left-Hand Thread) ............ 46 N•m (34 lb-ft) 26 Seal ........................................................ Replace
21 Washer 27 Screw Plug ............................... 30 N•m (22 lb-ft)
22 Bolt ........................................... 23 N•m (17 lb-ft) 28 Square Nut
23 Seal ........................................................ Replace

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-59

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
1F3-60 DIESEL ENGINE CONTROLS

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
DIESEL ENGINE CONTROLS 1F3-61

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
1F3-62 DIESEL ENGINE CONTROLS

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) 13 N•m (10 lb-ft)
Fuel Injection Line (15) 18 N•m (13 lb-ft)
Fuel feed Line (3) 13 N•m (10 lb-ft)
Suction and Pressure Line (4) 13 N•m (10 lb-ft)

Replace the seal.

11. Assemble the plastic clip (8).

YAD1FD90

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-63

12. Connect the vacuum line (13, 14).

13. Connect the connecting rod (15).
14. connect the accelerator control damper (16).
(Manual transmission vehicle)

15. Install the chain tensioner.

16. Install the vacuum pump.
17. Check the start of delivery.
18. Adjust the idle speed.

YAD1FDA0

SSANGYONG Y200
1F3-64 DIESEL ENGINE CONTROLS

FUEL TANK

YAD1FDB0

1 Fuel Tank Mounting Bracket 7 Fuel Pump

2 Fuel Return Line 8 Fuel Tank Rear Pipe
3 Fuel Supply Line 9 Fuel Tank Air Cap
4 Fuel Filter 10 Fuel Filler Assembly
6 Fuel Tank

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-65

Removal & Installation Procedure

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
1F3-66 DIESEL ENGINE CONTROLS

SPECIFICATIONS
GENERAL SPECIFICATIONS
Fuel Distribution Type Individual Injection Type (Same Number of Cylinder and Plunger)
Number of Cylinders 5 Cylinder
Mounting Type End Flange Mounting
Drive Type Inside Chain Connected with Camshaft
Flange Stroke 7 mm
Flange Outside Diameter 5.5 mm
Rack Movement 21 mm
Max. Speed 2,500 rpm
Injected Fuel Quantity / Stroke 35 mm3 / Stroke
Lubrication Type Sump Lubrication Type (Connected with Engine Oil Passage)

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-67

FASTENER TIGHTENING SPECIFICATIONS

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

SSANGYONG Y200
1F3-68 DIESEL ENGINE CONTROLS

EGR SYSTEM SCHEMATIC AND ROUTING DIAGRAMS

YAD1FDF0

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-69

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

000 589 14 27 00
000 589 00 68 00
Fuel Injection Nozzle
Cleaning Set
Tester

YAD1FDU0 YAD1FDK0

000 589 77 03 00 001 589 65 09 00

Box Wrench Insert Serration Wrench

YAD1FDT0 YAD1BKB0

001 589 73 21 00 116 589 02 34 00

Vacuum Pump Threaded Bolt

YAD1A190 YAD1BLH0

116 589 20 33 00 201 589 13 21 00

Sliding Hammer Vacuum Tester

YAD1B580 YAD1FDG0

SSANGYONG Y200
1F3-70 DIESEL ENGINE CONTROLS

SPECIAL TOOLS TABLE (Cont’d)

601 589 05 21 00
601 589 05 14 00
Locking Sensor
Assembly Cage

YAD1FDS0 YAD1FDQ0

610 589 00 08 00
617 589 00 21 00
Flange
Ri Sensor

YAD1FDP0 YAD1FDN0

617 589 08 21 01
617 589 04 21 00
Micro Switch Setting
Tester
Device

YAD1FDJ0 YAD1FDL0

617 589 08 21 00
617 589 09 21 00
Position Sensor
Ri Adapter

YAD1FDL0 YAD1FDM0

SSANGYONG Y200
DIESEL ENGINE CONTROLS 1F3-71

SPECIAL TOOLS TABLE (Cont’d)

667 589 04 63 00
667 589 00 21 00
Retaining Plate
TDC Pulse Generator

YAD1FDH0 YAD1FDR0

SSANGYONG Y200
SECTION 2C

FRONT SUSPENSION
TABLE OF CONTENTS
Description and Operation ................................... 2C-2 Repair Instructions ................................................ 2C-9
Front Suspension ................................................. 2C-2 On-vehicle Service ............................................... 2C-9
Specifications ...................................................... 2C-4 Stabilizer ........................................................... 2C-11
Component Locator ............................................. 2C-5 Shock Absorber Assembly ................................ 2C-12
Front Suspension Assembly ................................. 2C-5 Upper/Lower Arm Assembly .............................. 2C-14
Cross-Sectional View ........................................... 2C-6 Unit Repair .......................................................... 2C-16
Suspension Assembly ......................................... 2C-6 Front Coil Spring ................................................ 2C-16
Shock Absorber ................................................... 2C-7 Hub and Bearing ............................................... 2C-18
Diagnostic Information and Procedures ................ 2C-8 Special Tool and Equipment.............................. 2C-20
Special Tools Table ........................................... 2C-20
2C-2 FRONT SUSPENSION

DESCRIPTION AND OPERATION

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 YAD2C020

design, with the control arms that pivot from the engine
frame. The frame has isolation mounts on the body The telescopic shock absorber is consist of the tube
and a conventional rubber bushing is used on the lower with the piston and the rod, and the other cylinder tube.
control arm pivot. The front lower control arm bushing The piston section has the orifice and valve and the
is mounted horizontally. The upper end of the strut is cylinder is filled fully with oil.
isolated by a rubber mount which contains a bearing This double tube type enables to control the vibration
to allow for wheel turning. The lower end of the steering properly because oil resistance forces are generated
knuckle pivots on a ball joint riveted to the control on compression and expansion of shock absorber.
arm. The ball joint is fastened to the steering knuckle Thus, this double type is better than the mono tube
with a castellated nut and cotter pin. 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
vehicle’s 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 YAD2C030

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, it’s difficult to make a effect
on vibration damping because there is not any friction
between coils.

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
2C-4 FRONT SUSPENSION

SPECIFICATIONS
Application Specification
Suspension System Double Wishbone
Spring Type Coil spring
Shock Absorber Telescopic Double Tube Type(GAS)
Stabilizer Torsion Bar Type
Wheel Alignment Toe-In 2 ± 2 mm
Camber 0° ± 30´ (Both side difference must be below 30´)
Caster 2° 45 ± 30´ (Both side difference must be below 30´)

SSANGYONG Y200
FRONT SUSPENSION 2C-5

COMPONENT LOCATOR
FRONT SUSPENSION ASSEMBLY

YAD2E050

1 Stabilizer Bar 5 Stabilizer Bar Link

2 Cam bolt 6 Knuckle
3 Lower arm 7 Upper arm
4 Yoke 8 Shock Absorber Assembly
(Including coil spring)

SSANGYONG Y200
2C-6 FRONT SUSPENSION

CROSS-SECTIONAL VIEW
SUSPENSION ASSEMBLY

YAD2C060

SSANGYONG Y200
FRONT SUSPENSION 2C-7

SHOCK ABSORBER

YAD2C070

1 Lower Spring Sheet 10 Bump Stopper

2 Yoke Bracket 11 Spring Sheet Rubber
3 Rebound Stopper 12 Upper Spring Sheet
4 Cylinder 13 Rubber
5 Piston 14 Rubber
6 Shock-Absorber assembly 15 Spacer
7 Spring 16 Washer
8 Yoke 17 Nut
9 Boot 18 Bolt

SSANGYONG Y200
2C-8 FRONT SUSPENSION

DIAGNOSTIC INFORMATION AND PROCEDURES

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

SSANGYONG Y200
FRONT SUSPENSION 2C-9

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE

YAD2C080

SSANGYONG Y200
2C-10 FRONT SUSPENSION

1 Nut 15 Nut
2 Nut 16 Bolt
3 Washer 17 Bolt
4 Rubber 18 Bolt
5 Bushing 19 Bushing
6 Upper Spring Sheet 20 Nut
7 Rubber 21 Upper Arm
8 Spring Sheet Rubber 22 Nut
9 Boot 23 Bushing
10 Boot 24 Washer
11 Spring 25 Bolt
12 Shock Absorber 26 Lower Arm
13 Lower Spring Sheet 27 Bushing
14 Yoke 28 Bushing

SSANGYONG Y200
FRONT SUSPENSION 2C-11

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

Installation Procedure
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 it’s original
position.
Installation Notice
60 - 80 N•m
Tightening Torque
(44 - 59 lb-ft)

YAD2C120

SSANGYONG Y200
2C-12 FRONT SUSPENSION

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 (1) 110 - 120 N•m

Torque (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
FRONT SUSPENSION 2C-13

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

Installation Procedure
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
40 - 60 N•m
Tightening Torque
(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
60 - 70 N•m
Tightening Torque
(44 - 52 lb-ft)

YAD2C200

SSANGYONG Y200
2C-14 FRONT SUSPENSION

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
FRONT SUSPENSION 2C-15

3. Remove mounting bolts and nuts of the lower arm

(both front and rear) and separate the lower arm.

YAD2C250

Installation Procedure
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 160 - 170 N•m
YAD2C260

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 Upper side (1) 110 - 120 N•m

Tightening
Torque Lower side (2) 110 - 130 N•m

YAD2C280

SSANGYONG Y200
2C-16 FRONT SUSPENSION

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.
YAD2C290

3. Remove the shock absorber mounting nut and

remove the lock nut of the special tool in order to
separate the shock absorber.

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
FRONT SUSPENSION 2C-17

Installation Procedure
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 334 N•m
Tightening torque of 25 - 40 N•m
lock nut (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
2C-18 FRONT SUSPENSION

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
FRONT SUSPENSION 2C-19

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
2C-20 FRONT SUSPENSION

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

DW340 - 050 661 589 13 33 00

Sliding Hammer Ball joint remover

YAD2C400 YAD2C440

DW 340 - 060 DW 340 - 021 - 01

Front hub cap remover/ Handle
installer

YAD2C410 YAD2C450

DW340 - 070 DW 340 - 021 - 02

Front hub flange Front inner bearing race
remover installer

YAD2C420 YAD2C460

661 589 01 07 00 DW 340 - 021 - 03

Front hub adjust nut Front outer bearing race
remover/installer installer

YAD2C430 YAD2C470

SSANGYONG Y200
SECTION 2D

REAR SUSPENSION
TABLE OF CONTENTS
Description and Operation ................................... 2D-2 Wheel Bearing End Play ...................................... 2D-7
Rear Suspension ................................................. 2D-2 Wheel Bearing Free load ...................................... 2D-7
Specifications ...................................................... 2D-3 Repair Instructions ................................................ 2D-8
Component Locator ............................................. 2D-4 On-Vehicle Service ............................................... 2D-8
Rear Suspension Assembly ................................. 2D-4 Rear Suspension Assembly ................................. 2D-9
Shock Absorber ................................................... 2D-5 Special Tools and Equipment ............................ 2D-16
Diagnostic Information and Procedures .............. 2D-6 Special Tools Table ............................................ 2D-16
Rear Suspension ................................................. 2D-6
2D-2 REAR SUSPENSION

DESCRIPTION AND OPERATION

REAR SUSPENSION
The rear suspension system is to keep the ride comfort 1. Stabilizer:
or safety and this vehicle is applied to 5 link
It enables to keep the balance on turning and to
suspension system. This system consists of both coil
minimize the vehicle’s slope when both right and
spring, upper/lower arm, the lateral rod, stabilizer,
left wheels move differently.
connecting rod and bumper.
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:
It is installed between the rear axle and body frame.
YAD2D010
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 5 Links (Two Upper Arm, Two Lower Arm, One Lateral Rod)
Spring Type Coil Spring
Stabilizer Type Torsion Bar Type
Shock Absorber Type Telescopic Double Tube Type
Max. Length 495 mm
Min. Length 308 mm
Engine Type GSL 3.2, DSL(A/T) DSL(M/T)
Coil O.D. 13.1 mm 13.0 mm
Coil I.D(A) Ø 114 mm Ø 114 mm
Free-load Height(B) 405.7 mm 386.8 mm
Compression Height(C) 260.0 mm 250.0 mm
O.D(D) Ø 127.1 mm Ø 127.0 mm
YAD2D020 Constant 2.45 ± 5% 2.45 ± 5%

SSANGYONG Y200
2D-4 REAR SUSPENSION

COMPONENT LOCATOR
REAR SUSPANSION ASSEMBLY

YAD2D030

1 Coil Spring Seat(upper) 6 Lower Arm (link)

2 Coil Spring 7 Stabilizer Link
3 Lateral Rod 8 Stabilizer
4 Shock Absorber 9 Pump Stopper
5 Upper arm(link)

SSANGYONG Y200
REAR SUSPENSION 2D-5

SHOCK ABSORBER

YAD2D040

SSANGYONG Y200
2D-6 REAR SUSPENSION

DIAGNOSTIC INFORMATION AND PROCEDURES

REAR SUSPENSION

Symptom Possible Cause Action

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

SSANGYONG Y200
REAR SUSPENSION 2D-7

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

0 mm
end play

4. If the wheel bearing end play is excessive,

retighten the castle nut.
5. If the wheel bearing end play continues to be
YAD2D050 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 1.4 ~ 4.3 kg.cm
6. Retighten the castle nut as specified torque when
YAD2D060 the measured value is not within the specified
value.
7. Replace the wheel bearing as needed.

SSANGYONG Y200
2D-8 REAR SUSPENSION

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE

YAD2D070

1 Rear Suspension Assembly 6 Stabilizer

2 Rubber 7 Coil Spring
3 Upper Arm 8 Shock Absorber
4 Lower Arm 9 Lateral Rod
5 Stabilizer Link

SSANGYONG Y200
REAR SUSPENSION 2D-9

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
2D-10 REAR SUSPENSION

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
REAR SUSPENSION 2D-11

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
2D-12 REAR SUSPENSION

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

Installation Procedure
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
REAR SUSPENSION 2D-13

3. Insert the upper side of the shock absorber to the

frame and tighten nuts manually. And then install
the lower side’s to the axle and tighten nuts as
specified torque.
Installation Notice

Tightening Torque : 30 - 45 N•m

Upper side (1) (22 - 33 lb-ft)

Tightening Length : 6 - 9 mm
Tightening Torque : 50 - 65 N•m
Lower side (2)
(37 - 48 lb-ft)
YAD2D220

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)) 165 N•m
Tightening Torque(axle(2)) 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)) 165 N•m
Tightening Torque(axle(2)) 165 N•m

YAD2D240

6. Install the lateral rod to both the frame and axle

side.
Installation Notice
Tightening Torque(frame(1)) 165 N•m
Tightening Torque(axle(2)) 165 N•m

YAD2D250

SSANGYONG Y200
2D-14 REAR SUSPENSION

7. Install the connecting rod to the frame bracket.

Notice: Follow the tightening length for installing
the nut.

Installation Notice
Tightening Torque 38 N•m (28 lb-ft)
Tightening Length(A) 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
30 - 45 N•m
Tightening Torque
(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
REAR SUSPENSION 2D-15

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
2D-16 REAR SUSPENSION

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

661 589 12 33 00 Torque Wrench

Rear spring compressor

YAD2D300 YAD2D310

SSANGYONG Y200
SECTION 2E

TIRES AND WHEELS

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

DESCRIPTION AND OPERATION

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

Caution: Remove stones from the tread in order to

avoid operator injury during spin balancing.

Inspect the tire for any damage. Balance the tire

a c c o r d i n g t o t h e e q u i p m e n t m a n u f a c t u r e r’ s
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
YAD2E020
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.

SSANGYONG Y200
TIRES AND WHEELS 2E-3

Convention for Radial Tire The Relation Between Load and Tire
P 225 / 75 R - 15 102 T

Max Speed :
190 km/h

Load Index :
850 kg

Rim Diameter : 15 inch.

Radial Tire

Aspect Ratio = (Section Height ÷

YAD2E040
Section Width) x 100 : 75 %

Section Width : 225 mm

TIRE’S ABNORMAL ACTION
Passenger Car
Standing Wave
Max Speed Symbol Load Index

Limit Speed Limit Speed

Symbol Symbol
(km/h) (km/h)
F 80 94 670
M 130 95 690
N 140 96 710
P 150 97 730
Q 160 98 750
R 170 99 775
S 180 100 800
YAD2E050
T 190 101 825
U 200 102 850 During running the rotating tire repeats deformation
and restoring movement generated in tread. But when
H 210 103 875 the wheel rotating speed reaches high, the next
V 240 104 900 deformation applied to tire before restoring last
Z Above 240 105 925 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
2E-4 TIRES AND WHEELS

The condition of driving a vehicle fast on the road Camber

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.

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 YAD2E080
geometrically with the body mass.
The steering and suspension systems require that the Camber is the tilting of the top of the tire from the
front wheels self-return and that the tire rolling effort vertical when viewed from the front of the vehicle. When
and the road friction be held to a negligible force in the tires tilt outward, the camber is positive. When the
order to allow the customer to direct the vehicle with tires tilt inward, the camber is negative. The camber
the least effort and the most comfort. angle is measured in degrees from the vertical. Camber
influnces both directional control and tire wear.
A complete wheel alignment check should include
measurements of the rear toe and camber. If the vehicle has too much positive camber, the
outside shoulder of the tire will wear. If the vehicle has
Toe-in 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 YAD2E090
wheels.
The toe serves to offset the small deflections of the Caster is the tilting of the uppermost point of the
wheel support system which occur when the vehicle is steering axis either forward or backward from the
rolling forward. vertical when viewed from the side of the vehicle. A
backward tilt is positive and a forward tilt negative.
The specified toe angle is the setting which achieves-
Caster influences directional control of the steering but
degrees “0¡Æ” of toe when the vehicle is moving.
does not affect tire wear.
Incorrect toe-in or toe-out will cause tire wear and
Weak springs or overloading a vehicle will affect
reduced fuel economy. As the individual steering and
caster. One wheel with more positive caster will pull
suspension components wear from vehicle mileage,
toward the center of the car. This condition will cause
additional toe will be needed to compensate for the
the car to move or lean toward the side with the least
wear. Always correct the toe dimension last.
amount of positive caster. Caster is measures in
degrees and is not adjustable.

SSANGYONG Y200
TIRES AND WHEELS 2E-5

SPECIFICATIONS
Wheel Size Aluminum Type 7JJ x 16
Steel Type 6.5JJ x 16
Wheel Nut Tightening Aluminum Wheel 8 - 12 kgf.m
Torque Steel Wheel 11 - 13 kgf.m
Tire Type Radial Tire Radial Tire
Inflation Pressure (psi) P225/75R15 30 psi
P235/70R16 30 psi
P255/65R16 30 psi
Wheel Alignment Toe-in 2 ± 2 mm
Camber 0° ± 30’ (Below 30' the difference between right and left)
Caster 2° 45 ± 30’ (Below 30' the difference between right and left)

SSANGYONG Y200
2E-6 TIRES AND WHEELS

DIAGNOSTIC INFORMATION AND PROCEDURES

Condition Cause Action
Irregular tires wear Improper tire inflation pressure Adjust
Poor wheel balance Adjust
Improper tire rotation Rotation tires on the maintenance
schedule
Poor toe-in Adjust
Poor adjusting the pre-load of the wheel bearing Adjust
Poor braking performance Adjust
Driving noise, Vibration Low tire inflation pressure Adjust
Poor balance of wheels, tires Adjust
Severe vibration due to wheels, tires Adjust or replacement
Irregular tires wear Check and adjust
Rapid wear Excessive tire inflation pressure Adjust
High speed driving with low tire pressure Adjust
Excessive vehicle weight Proper weight

SSANGYONG Y200
TIRES AND WHEELS 2E-7

GENERAL INSPECTION
INSPECTION THE APPEARANCE

Condition Cause Action

Rapid wear at Under inflation or lack of rotation Adjust inflation
shoulders 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 Adjust camber

Incorrect toe-in

YAD2E160 YAD2E110

SSANGYONG Y200
2E-8 TIRES AND WHEELS

Inspection The Appearance (Cont’d)

Condition Cause Action

Feathered edge Incorrect toe-in Adjust toe-in

YAD2E170 YAD2E180

Bold spot Unbalanced wheel Adjust wheel balance

YAD2E190 YAD2E200

Sharply wear at the tread outside Unbalanced wheel Adjust

Wheel bearing play Check play

Check pre-load

Ball joint play Check

YAD2E210
Faulty shock absorber Check

SSANGYONG Y200
TIRES AND WHEELS 2E-9

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
2E-10 TIRES AND WHEELS

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
YAD2E260
aluminum wheels requires the use of the special
nylon-coated, clip-on wheel weights.

Balance Weight

10 g 20 g 30 g 40 g 50 g 60 g
0.4 oz 0.7 oz 1.10 oz 1.40 oz 1.80 oz 2.10 oz

YAD2E270

SSANGYONG Y200
TIRES AND WHEELS 2E-11

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.

Caution at replacement tires

YAD2E280
• 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
2E-12 TIRES AND WHEELS

COMPONENT LOCATOR
TIRE AND WHEEL ASSEMBLY

YAD2E290

1 Wheel Nut 5 Wheel Cap

2 Wheel 6 Wheel Cap
3 Balance Weight 7 Wheel Cap
4 Tire 8 Wheel Cap

SSANGYONG Y200
TIRES AND WHEELS 2E-13

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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

4. Installation should follow the removal procedure

in the reverse order.

YAD2E320

SSANGYONG Y200
2E-14 TIRES AND WHEELS

General Instruction
• 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).
3 1
5
• Raise the tires 3 cm off the ground using the
6 jacket.
2 4 • Tighten the wheel nuts diagonally as shown.

Tightening Steel Wheel: 80 - 120 N•m

Torque 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.
• If the spare tire may move after installation,
YAD2E350 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
TIRES AND WHEELS 2E-15

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 tire’s bead from the rim flange using

the approved lubricant.
Notice: Do not use silicone, synthetic detergent
and gasoline, etc.

YAD2E380

SSANGYONG Y200
2E-16 TIRES AND WHEELS

5. Apply the lubricant between the rim and the bead.

YAD2E390

6. Insert the removal lever between the tire’s 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
TIRES AND WHEELS 2E-17

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
2E-18 TIRES AND WHEELS

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
2.1 kg•cm2 (30 psi)
tire pressure

YAD2E460

SSANGYONG Y200
SECTION 3A

FRONT AXLE

TABLE OF CONTENTS
General Description and Operation ............... 3A-2 Front Axle Shaft .............................................. 3A-11
Front Axle Housing Assembly ......................... 3A-2 Vacuum Line ................................................... 3A-18
Axle Shaft Assembly ........................................ 3A-3 Axle Housing .................................................. 3A-19
Specifications ................................................... 3A-4 Unit Repair ....................................................... 3A-20
Diagnosis Information and Procedures .......... 3A-5 Axle Housing Assembly ................................. 3A-20
Component Locator ......................................... 3A-6 Differential Joint Assembly ............................ 3A-26
Front Axle Shaft ................................................ 3A-6 Wheel Joint Assembly ................................... 3A-28
Front Axle Housing ........................................... 3A-7 Special Tools And Equipment ....................... 3A-30
Vacuum Line ................................................... 3A-10 Special Tools Table ........................................ 3A-30
Maintenance and Repair .................................3A-11
On-Vehicle Service ............................................ 3A-11
3A-2 FRONT AXLE

GENERAL DESCRIPTION AND OPERATION

FRONT AXLE HOUSING ASSEMBLY

YAD3A020

1 Axle Tube Assembly 7 Inner Shaft (LH)

2 Snap Ring 8 Inner Shaft (RH)
3 Ball Bearing 9 Bolt
4 Oil Seal 10 Front Axle Bracket (LH)
5 Protector 11 Front Axle Bracket (RH)
6 Retainer

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 Drive Shaft 7 Boot Band

2 Housing (Inboard) 8 Boot Band
3 Boot (Outboard) 9 Boot Band
4 Boot (Inboard) 10 Seal
5 Shaft 11 Ball Joint
6 Boot Band

SSANGYONG Y200
3A-4 FRONT AXLE

SPECIFICATIONS

Drive Shaft Type CV Joint

Axle Housing Type Build up
Differential Type Conventional
Gear Type Hypoid Gear
Reduction Ratio Gaso. Gasoline + M/T 3.73
(E32 or E23) Diesel + M/T 4.27
Gasoline + M/T 4.56
Diesel + M/T 4.89
Oil Capacity 1.4 L
Specification SAE 80W / 90 or API Gl-5

SSANGYONG Y200
FRONT AXLE 3A-5

DIAGNOSIS INFORMATION AND PROCEDURES

Phenomena Checks Action
Noise (During Straight Lack of Oil Replenish
Driving) Low Viscosity of Oil Replace
Inferior Oil Replace
Excessive Backlash of Ring Gears Adjust
Worn or Damaged Tooth of Ring and Pinion Gear Replace
Worn or Damaged Tooth of Drive Pinion Gear Replace
Wear of Side Bearing and Side Gear Spline Replace
Bending of Axle Housing Replace
Distortion of Differential Case Replace
Wear of Pinion Shaft Replace
Incorrect Drive Pinion Preload. Adjust
Incorrect Contact of Ring Gear and Pinion Reassembly
Oil Leakage Excessive Oil Adjust
Fault Seal of Carrier Contact Surface Correct
Axle Housing Crack Replace
Worn or Damaged Oil Seal Replace
Noise (During Turning) Worn or Damaged Tooth of Pinion or Side Gear Replace
Wear of Pinion Shaft Replace
Excessive Backlash of Pinion Gear and Side Gear Replace
Excessive End-Play of Rear Axle Shaft Adjust
Incorrect Contact of Side Gear and Differential Case Replace
Axle Housing Crack Replace
Distortion or Poor Installation of Drive pinion Oil Seal Replace
Damaged of Torn Drive Pinion Oil Seal Replace
Loosened Bearing Collar Replace
Worn or Damaged Universal Joint Replace
Worn or damaged Axle Shaft Bearing Replace
Heating Lack of Oil Replenish
Insufficient Backlash of Gears Adjust
Excessive Preload of Bearing Adjust

SSANGYONG Y200
3A-6 FRONT AXLE

COMPONENT LOCATOR
FRONT AXLE SHAFT

YAD3A040

1 Front Axle Inner Shaft Mounting (Axle Housing) 9 Outboard Boot

2 Front Axle Drive Shaft 10 Boot Clamp
3 Washer 11 Shaft
4 Bolt 12 Boot Clamp
5 Steering Knuckle 13 Inboard Boot
6 Dust Seal 14 Boot Clamp
7 Outboard Joint Assembly 15 Inboard Joint Assembly
8 Boot Clamp

SSANGYONG Y200
FRONT AXLE 3A-7

FRONT AXLE HOUSING

YAD3A330

1 Axle Mounting Bracket 10 Nut

2 Breather Hose 11 Front Axle Housing
3 Bolt 12 Nut
4 Nut 13 Bolt
5 Cross Member 14 Washer
6 Bolt 15 Inner Shaft (Left)
7 Bushing 16 Inner Shaft (Right)
8 Spacer 17 Washer Plain
9 Spacer

SSANGYONG Y200
3A-8 FRONT AXLE

YAD3A380

SSANGYONG Y200
FRONT AXLE 3A-9

1 Front Axle Housing Mounting Bracket 20 Bearing

2 Inner Shaft (Left) 21 Oil Slinger
3 Bolt 22 Driver Pinion
4 Oil Seal ................................................................ 23 Oil Filler Plug
........ Replace, Apply Grease to the Sealing Rib 24 Bolt
5 Snap Ring 25 Axle Housing Cover........... Apply Liquid Gasket
6 Bearing 26 Ring Gear
7 Snap Ring 27 Bearing
8 Oil Drain Plug 28 Shim
9 Front Axle Housing 29 Shaft Lock Pin
10 Breather Nipple 30 Differential Case
11 Inner Shaft (Right) 31 Bolt
12 Pinion Lock Nut 32 Bolt
13 Washer 33 Washer
14 Companion Flange 34 Bearing Cap
15 Oil Seal ................................................................ 35 Thrust Washer
......... Replace, Apply grease to the sealing Rib 36 Side Gear
16 Bearing 37 Differential shaft
17 Shim 38 Differential Pinion
18 Bearing Baffle 39 Thrust Washer
19 Shim

SSANGYONG Y200
3A-10 FRONT AXLE

VACUUM LINE

YAD3A300

1 Vacuum Auto-locking Hub Assembly 10 Hose Molded

2 Bolt.................................. 50-60 N•m(37-44 lb-ft) 11 Check Valve
3 Washer 12 Corrugated Tube
4 Auto-locking Hub Cap 13 Auto-locking Hub Solenoid Valve
5 Retaining Ring 14 Bolt
6 Shim 15 Hose (L:2000/Yellow)
7 Locking Hub 16 Hose (L:3200/Red)
8 Hose and Tube Assembly 17 Hose (L:1500/White) (DSL)
9 T-Connector Hose (L:800/Blue) (GSL)

SSANGYONG Y200
FRONT AXLE 3A-11

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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 link-

knuckle 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. Inser t 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 Lower arm 140 - 160 N•m

Torque Upper arm 140 - 160 N•m

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 N•m

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.
Installation Notice
Tightening Torque 250 - 350 N•m

YAD3A230

6. With part time transfer case

• Install the brake disc assembly and tighten the
fixing bolts.
Installation Notice
Tightening Torque 100 - 130 N•m

• 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
YAD3A240
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 0.2, 0.3, 0.5, 1.0 mm

Max. clearance 0.2 mm

YAD3A250

• Install the hub cover to the body and tighten it

as the specified torque.
Installation Notice

50 - 60 N•m
Tightening torque
(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 N•m

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
35 - 45 N•m
Tightening torque
(26 - 33 lb-ft)

YAD3A280

9. Install the wheel speed sensor and connect the

vacuum line (with ABS only).
Installation Notice
ABS wheel speed 6 - 8 N•m
sensor mounting bolt (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
50 - 60 N•m
YAD3A320 Tightening Torque
(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
81 - 89 N•m
Tightening Torque
(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 N•m

5. Remove the frame and cross member mounting

nut (2) and pull off the cross member.
Installation Notice
62 - 93 N•m
Tightening Torque
YAD3A350
(45 - 69 lb-ft)

6. Support the axle housing on a suitable jack,

remove the axle housing mounting bracket nuts.
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
Installation Notice
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;; 62 - 93 N•m
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
Tightening Torque
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
(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

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 N•m

(21 - 30 lb-ft)

YAD3A400

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 Possible cause Remedy

1. Heel contact Excessive backlash Adjust backlash
• Noise can be occurred (Drecrease backlash)
• Select proper shin to
move the drive pinion
toward the ring gear
(toward toe)

YAD3A480 YAD3A490

2. Toe contact Insufficient backlash Adjust backlash

• Tooth can be damaged (Increase backlash)
or broken under heavy • Select proper shim to
load move the drive pinion
against the ring gear
(toward heel)

YAD3A500 YAD3A510

3. Face contact Excessive backlash Adjust backlash

• Drive pinion shaft is (Increase pinion shim)
apart from the ring gear • Move the drive pinion
• Noise can be occurred toward the ring gear
(toward center of ring
gear)

YAD3A520 YAD3A530

4. Flank contact Insufficient backlash Adjust backlash

• Gear contacts on the (Decrease pinion shim)
low flank • Move the ring gear
• Gear can be damaged toward the drive pinion
or worn (toward ring gear
center line)
• Noise can be occurred

YAD3A540 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 N•m

YAD3A570

3. Assemble the differential carrier assembly. Align

the ring gear to the mark of differential carrier,
tighten the fixing bolts.
Installation Notice
75 - 90 N•m
Tightening Torque
(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
48 - 69 N•m
Tightening Torque
(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 N•m

(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
80 - 100 N•m
Tightening Torque
(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 AND EQUIPMENT

SPECIAL TOOLS TABLE

661 589 13 33 00 Snap Ring Plier

Ball Joint Remover

YAD3A770 YAD3A780

Part Time Snap Ring

Remover / Installer

YAD3A790

SSANGYONG Y200
SECTION 3C

PROPELLER SHAFT
TABLE OF CONTENTS
General Description and Operation ..................... 3C-2 Maintenance and Repair ..................................... 3C-6
Specifications ...................................................... 3C-2 On-Vehicle Service ................................................. 3C-6
Diagnostic Information and Procedures .............. 3C-3 Propeller Shaft Assembly ..................................... 3C-6
Component Locator ............................................ 3C-4 Unit Repair ............................................................ 3C-9
Cross Sectional View ........................................... 3C-4 Propeller Shaft ..................................................... 3C-9
Propeller Shaft Assembly ..................................... 3C-5
3C-2 PROPELLER SHAFT

GENERAL DESCRIPTION AND OPERATION

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 Yoke & Spider Typed Universal Joint

Joint Type Spider (Needle Roller Bearing)
Number of Spider Front Shaft Full Time T/C 2
Part Time T/C 2
Rear Shaft 3
Outer Diameter of Spider (mm) Ø16.668
Tube Run-out (After Installation) Within 0.4 mm
Front Shaft Dimension (LXI.DXO.D) Diesel + M/T•A/T + 4408 T/C 607.1 × Ø59.5 × Ø63.5
Gasoline + M/T•A/T + 4421 T/C 591.1 × Ø59.5 × Ø63.5
Rear Shaft Dimension (LXI.DXO.D) Diesel + M/T•A/T + 4408 T/C (585.2+569.5) × Ø59.5 × Ø63.5
Gasoline + M/T•A/T + 4421 T/C (566.1+569.5) × Ø59.5 × Ø63.5
Unbalance Quantity (at 4,500 RPM) within 30 g·cm

SSANGYONG Y200
PROPELLER SHAFT 3C-3

DIAGNOSTIC INFORMATION AND PROCEDURES

Phenomena Checks Action
Vibration Incorrect Assembly of Sliding Joint Adjust
Bending of Propeller Shaft Replace
Poor Symmetry (Left/Right) of Universal Joint Snap Ring Adjust
Loosened Yoke connection bolt Tightening
Noise Worn or Damaged Universal Joint Bearing Replace
Separation of Universal Joint Snap Ring Adjust/Replace
Loosened Yoke connection part Tightening
Warn sliding Joint Spline pant Replace
Insufficient Grease Replenish

SSANGYONG Y200
3C-4 PROPELLER SHAFT

COMPONENT LOCATOR
CROSS SECTIONAL VIEW

Rear Propeller Shaft

YAD3C020

1 Flange Yoke 8 Split Washer

2 Journal Bearing Cap 9 Slip Tube Shaft
3 Cross Shaft Journal 10 Tube
4 Slip Yoke Assembly 11 Tube Yoke
5 Grease Nipple 12 Flange Yoke
6 Dust Cap 13 Center Bearing
7 Oil Seal

SSANGYONG Y200
PROPELLER SHAFT 3C-5

PROPELLER SHAFT ASSEMBLY

YAD3C030

1 Front Axle 6 Bolt

2 Bolt 7 Rear Propeller Shaft
3 Front Propeller Shaft 8 Bolt
4 Bolt 9 Rear Axle
5 Transfer Case

SSANGYONG Y200
3C-6 PROPELLER SHAFT

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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
PROPELLER SHAFT 3C-7

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 N•m

(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 N•m

(59 - 70 lb-ft)

YAD3C100

SSANGYONG Y200
3C-8 PROPELLER SHAFT

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 N•m

(52 - 59 lb-ft)

YAD3C110

SSANGYONG Y200
PROPELLER SHAFT 3C-9

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
3C-10 PROPELLER SHAFT

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 16.647 mm
Limit 16.668 mm

YAD3C180

3. Clearance between the spider and bearing

standard 0.03 ~ 0.098 mm
Limit 0.25 mm

YAD3C190

SSANGYONG Y200
PROPELLER SHAFT 3C-11

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 kg•cm

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
YAD3C210
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
3C-12 PROPELLER SHAFT

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 Maintenance and Repair .................................. 3D-8
Specifications ................................................... 3D-2 On-Vehicle Service .............................................. 3D-8
Diagnostic Information and Procedures ........ 3D-3 Axle Shaft Assembly (With Disc Brake) .......... 3D-8
Component Locator ......................................... 3D-4 Axle Shaft Assembly (With Drum Brake) ...... 3D-11
Rear Axle Assembly ......................................... 3D-4 Rear Axle Housing .......................................... 3D-13
Cross Sectional View ........................................ 3D-5 Unit Repair ....................................................... 3D-18
Rear Axle Shaft Assembly ............................... 3D-6 Axle Assembly ............................................... 3D-18
Differential Gear Assembly ............................ 3D-19
3D-2 REAR AXLE

GENERAL DESCRIPTION AND OPERATION

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

SSANGYONG Y200
REAR AXLE 3D-3

DIAGNOSTIC INFORMATION AND PROCEDURES

Phenomena Checks Action
Noise Lack of Oil Replenish
(During Straight Low Viscosity of Oil Replace
Driving) Inferior Oil Replace
Excessive Backlash of Ring Gears Adjust
Worn or Damaged Tooth of Ring and Pinion Gear Replace
Worn or Damaged Tooth of Drive Pinion Gear Replace
Wear of Side Bearing and Side Gear Spline Replace
Bending of Axle Housing Replace
Distortion of Differential Case Replace
Wear of Pinion Shaft Replace
Incorrect Drive Pinion Preload. Adjust
Incorrect Contact of Ring Gear and Pinion Reassembly
Oil Leakage Excessive Oil Adjust
Fault Seal of Carrier Contact Surface Correct
Axle Housing Crack Replace
Worn or Damaged Oil Seal Replace
Noise (During Turning) Worn or Damaged Tooth of Pinion or Side Gear Replace
Wear of Pinion Shaft Replace
Excessive Backlash of Pinion Gear and Side Gear Replace
Excessive End-Play of Rear Axle Shaft Adjust
Incorrect Contact of Side Gear and Differential Case Replace
Axle Housing Crack Replace
Distortion or Poor Installation of Drive pinion Oil Seal Replace
Damaged of Torn Drive Pinion Oil Seal Replace
Loosened Bearing Collar Replace
Worn or Damaged Universal Joint Replace
Worn or damaged Axle Shaft Bearing Replace
Heating Lock of Oil Replenish
Insufficient Backlash of Gears Adjust
Excessive Preload of Bearing Adjust

SSANGYONG Y200
3D-4 REAR AXLE

COMPONENT LOCATOR
REAR AXLE ASSEMBLY

YAD3D101

1 Axle Shaft/Tube 5 Shock Absorber

2 Stabilizer Bar 6 Lateral Rod
3 Spring Seat & Spring 7 Input Shaft
4 Upper Arm 8 Axle Housing

SSANGYONG Y200
REAR AXLE 3D-5

CROSS SECTIONAL VIEW

YAD3D020

1 Rear Axle Shaft Assembly 6 Coil Spring Seat (Lower)

2 Bracket Assembly 7 Caliper Assembly
3 Hub Oil Seal 8 Input Shaft/Flange
4 Bolt 9 Rod Mounting Bracket
5 Axle Shaft Tube 10 Wheel Speed Sensor

SSANGYONG Y200
3D-6 REAR AXLE

REAR AXLE SHAFT ASSEMBLY

With disc brake

YAD3D030

1 Brake Disc 7 Parking Brake Lining & Back Plate Assembly

2 Plug 8 Brake Caliper Assembly
3 Rear Axle Shaft 9 Spring Washer
4 Nut 10 Bolt
5 Washer 11 Rear Axle Housing
6 Parking Brake Cable

SSANGYONG Y200
REAR AXLE 3D-7

With drum brake

YAD3D150

1 Brake Drum 9 Bearing

2 Plug 10 Snap Ring
3 Rear Axle Shaft 11 Snap Ring
4 Wheel Bolt 12 Oil Seal
5 Nut 13 Brake Shoe & Back Plate Assembly
6 Washer 14 Bolt
7 Retainer Plate 15 Rear Axle Housing
8 Oil Seal

SSANGYONG Y200
3D-8 REAR AXLE

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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

50 - 65 N•m
Tightening torque
(37 - 48 lb-ft)

YAD3D120

3. Assemble the plastic plug n the rear axle flange

and install the dust shield.
Installation Notice

4 - 8 N•m
Tightening torque
(35 - 71 lb-in)

YAD3D130

4. Install the brake disc and caliper assembly.

Installation Notice
Tightening torque 85 - 105 N•m

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 service 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.

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YAD3D200

Installation
1. Check the rear axle shaft.
2. Insert the rear axle shaft into the axle housing and
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tighten the fixing nuts of axle shaft flange.

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Installation Notice

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(37 - 48 lb-ft)

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YAD3D210

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 N•m

3. Install the shock absorber in axle housing.

Installation Notice

Tightening Torque 30 - 45 N•m

(22 - 33 lb-ft)
YAD3D360

4. Install the stabilizer bar and upper/lower arm in

axle housing
Installation Notice
30 - 45 N•m
Stabilizer bar cap bolt
(22 - 33 lb-ft)
Upper arm nut 150 - 180 N•m
Lower arm nut 150 - 180 N•m

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
12 - 23 N•m
LCRV Mounting Bolt
(9 - 17 lb-ft)
6 - 8 N•m
Air Breather Hose Bolt
(53 - 71 lb-in)
15 - 19 N•m
Brake Oil Pipe (M10)
(11 - 14 lb-ft)
YAD3D390
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 Drive Pinion Lock Nut .................. 240 - 310 N•m 17 Bolt ................................................. 87 - 124 N•m
2 Washer 18 Bearing
3 Companion Flange 19 Shim
4 Pinion Oil Seal 20 Ring Gear
5 Bearing Slinger 21 Shaft Lock Pin
6 Bearing 22 Differential Case
7 Shim 23 Ring Gear Mounting Bolt ................. 75 - 90 N•m
8 Shim 24 Thrust Washer
9 Bearing Cup 25 Differential Pinion
10 Breather Nipple 26 Thrust Washer
11 Rear Axle Housing 27 Side Gear
12 Oil Drain Plug ................................... 28 - 42 N•m 28 Differential Shaft
13 Shim 29 Housing Cover
14 Bearing 30 Bolt ................................................... 38 - 46 N•m
15 Drive Pinion 31 Oil Filler Plug ................................... 28 - 42 N•m
16 Bearing Cap

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 Possible cause Remedy

1. Heel contact Excessive backlash Adjust backlash
• Noise can be occurred (Drecrease backlash)
• Select proper shin to
move the drive pinion
toward the ring gear
(toward toe)

YAD3D510 YAD3D520

2. Toe contact Insufficient backlash Adjust backlash

• Tooth can be damaged (Increase backlash)
or broken under heavy • Select proper shim to
load move the drive pinion
against the ring gear
(toward heel)

B
A
YAD3D530 YAD3D540

3. Face contact Excessive backlash Adjust backlash

(Increase pinion shim)
• Drive pinion shaft is
apart from the ring gear • Move the drive pinion
toward the ring gear
• Noise can be occurred (toward center of ring
gear)

YAD3D550 YAD3D560

4. Flank contact Insufficient backlash Adjust backlash

(Decrease pinion shim)
• Gear contacts on the
low flank • Move the ring gear
toward the drive pinion
• Gear can be damaged (toward ring gear
or worn
center line)
• Noise can be occurred

YAD3D570 YAD3D580

SSANGYONG Y200
3D-22 REAR AXLE

2. Assemble the drive pinion assembly to the axle

housing and then tighten the pinion lock nut.
Installation Notice
Tightening torque 240 - 310 N•m

YAD3D600

3. Assemble the differential carrier assembly. Align

the ring gear to the mark of differential carrier,
tighten the fixing bolts.
Installation Notice
75 - 90 N•m
Tightening Torque
(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
48 - 69 N•m
Tightening Torque
(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
SECTION 4A

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

DESCRIPTION AND OPERATION

BRAKING SYSTEM TESTING BRAKE PEDAL
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
YAD4A020
friction is present with a heavily braked, turning tire
than with a sliding tire. Brake pedal uses the principle of the leverage and
There are three major external conditions that affect increases the pressure into the master cylinder in order
brake performance: to generate the braking forces.

• Tires having unequal contact and grip of the road MASTER CYLINDER
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.

HYDRAULIC BRAKE SYSTEM

YAD4A030

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 non-
antilock braking system. The proportioning valves limit
the outlet pressures to the rear brakes after a
YAD4A010
predetermined master cylinder pressure has been
reached. The brake master cylinder sensor is attached
This system uses the principle of the leverage and under the body of the plastic brake master cylinder
PASCAL’s. When you pushes the brake pedal, the reservoir.
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.

SSANGYONG Y200
BRAKE SYSTEM 4A-3

BRAKE BOOSTER 2. Pressure Distribution After working

The brake booster is a double-diaphragm, vacuum-
suspended unit. In normal operating mode, with the
service brakes in the release position, a vacuum-
suspended 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.
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

MANDO Brake KDAC Brake

Application
Drum Type Disc Type Drum Type Disc Type
Brake Pedal Pedal Ratio 4.3 : 1 ← ← -
Pedal Stroke 138 mm ← ← -
Pedal Freeplay 1 ~ 4 mm ← ← -
Master Cylinder Tandem Type
Type ← ← -
(/W Lever Sensor)
Inner Diameter Ø 25.4 mm ← ← ←
Brake Booster Vacuum Booster
Type ← ← ←
Type
Ratio 7:1 ← ← ←
Front Brake Ventilated
Type - - ←
Disc Type
I.D. of Caliper
- Ø 60 mm - Ø 60 mm
Cylinder

Thickness of
- 10 mm - ←
Brake Pad
Thickness of
- 24 mm - ←
Disc Plate
Rear Brake Type Drum Type Solid Disc Drum Type ←
I.D of Drum Ø 254 mm - Ø 254 -
Leading End Leading End
Shoe Type - -
Trailing Type Trailing Type
Lining 55 x 243 x 5 mm - 55 x 243 -
I.D. of Wheel
Cylinder Ø 23.87 mm - Ø 23.81 mm -

I.D. of Caliper
- Ø 42.9 mm - Ø 42 mm
Cylinder
Thickness of
- 10 mm - 10 mm
Brake Pad

Thickness of
- 10.4 mm - 10.4 mm
Disc Plate
Parking Brake Type Rear Wheel Internal Expansion
Type Mechanical
Brake Fluid Spec. DOT4 or DOT3

SSANGYONG Y200
BRAKE SYSTEM 4A-5

DIAGNOSTIC INFORMATION AND PROCEDURES

Symptom Check Action
Noise Or Vehicle Vibration Incorrectly Mounted Back Plate or Caliper Repair
When Applied Brake Loosened Bolt of Back Plate or Caliper Retighten
Crack or Uneven Wear of Brake Drum or Disc Replace
Foreign Material Inside the Brake Drum Clean
Pad or Lining Sticking to Contact Surface Replace
Excessive Clearance Between Caliper and Pad Repair
Uneven Contact of Pad Repair
Lack of Lubrication Lubrication
Loosened Suspension Retighten
Pulls To One Side When Incorrect Tire Pressure Between Left and Right Adjust
Braking Poor Contact of Pad or Lining Repair
Oil or Grease is Applied to Pad or Lining Replace
Bent or Uneven Wear of Drum Replace
Incorrectly Mounted Wheel Cylinder Repair
Faulty Auto Adjuster Repair
Poor Braking Dirty or Lack of Fluid Replenish or Replace
Air in Brake System Bleeding
Faulty Brake Booster Repair
Poor Contact of Pad or Lining Repair
Oil or Grease on Pad Replace
Faulty Auto Adjuster Repair
Over Heated Rotor Due to Dragging Pad or Lining Repair
Clogging Brake Line Repair
Faulty Proportioning Valve Repair
Increasing Pedal Stroke Air in Brake System Bleeding
(Pedal Goes To Floor) Fluid Leaking Repair
Excessive Clearance Between Push Rod and M/Cylinder Adjust
Brake Dragging Parking Brake is not Fully Released Repair
Incorrect Adjustment of Parking Brake Adjust
Weak Return Spring of Brake Pedal Replace
Incorrect Pedal Free-play Repair
Broken Rear Drum Brake Shoe Return Spring Replace
Lack of Lubrication Lubrication
Damaged Master Cylinder Check Valve or Piston Replace
Return Spring
Insufficient Clearance Between Push Rod and Master Adjust
Cylinder
Poor Parking Brake Worn Brake Lining Replace
Dirty Brake Lining Surface by Grease or Oil Replace
Binding Parking Brake Cable Replace
Faulty Auto Adjuster Repair
Excessive Lever Stroke 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.
YAD4A070
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.

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.
YAD4A080
• 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.

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
YAD4A090
by depressing the pedal only after above air
bleeding.
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
YAD4A100
after above air bleeding.

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,
YAD4A110
loosen the lock nut of the brake booster push rod
and adjust the push rod length.

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
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
YAD4A130 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
14 - 18 N•m
Tightening Torque
(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
14 - 18 N•m
Tightening Torque
(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 Possible Cause Action

Poor Braking Performance Air in Brake System Bleeding
Poor Adjustment of Sensor Spring Adjust
Damaged Sensor Spring Replace
Fluid Leaking from LCRV Replace
Rear Wheels Lock Early Poor Adjustment of Sensor Spring Adjust
Internal Fluid Leaking of LCRV 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 Brake Booster 5 Hydraulic Pressure Control Valve (LCRV)

2 Brake Reservoir and Master Cylinder 6 3-way Connector
3 ABS Control Unit 7 Rear Drum (Disc) and Wheel Cylinder (Caliper)
4 Front Disc Brake and Caliper

SSANGYONG Y200
4A-12 BRAKE SYSTEM

BRAKE SYSTEM (W/CBS)

YAD4A200

1 Brake Booster 14 Pedal Assembly

2 Brake Booster Boot 15 Pedal Bracket Assembly
3 Cotter Pin 16 Clutch Pedal Pad
4 Clevis 17 Clutch Pedal
5 Clevis Pin 18 Brake Pedal Pad
6 Packing (1) 19 Brake Pedal
7 Master Cylinder Assembly 20 Brake Pedal Spring
8 Brake Oil Tank Assembly 21 Rear Brake Hose
9 Brake Oil Tank Cap 22 Clip
10 Brake Oil Tank 23 Front Brake Hose
11 Grommet Seal 24 Union Bolt
12 Master Cylinder 25 Plain Washer
13 Brake Stoplamp Switch

SSANGYONG Y200
BRAKE SYSTEM 4A-13

MASTER CYLINDER AND BOOSTER

KDAC (Delphi Korea)

YAD4A210

MANDO

YAD4A220

SSANGYONG Y200
4A-14 BRAKE SYSTEM

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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

Installation Procedure
1. Install the vacuum hose between the vacuum
pump and the power booster (Diesel Engine).
Tightening Torque
Bracket Mounting 35 - 45 N•m
Bolt (26 - 33 lb-ft)
Union Bolt to Vacuum 35 - 45 N•m
Pump (26 - 33 lb-ft)

YAD4A260

2. Install the vacuum hose between the vacuum

pump and the power booster. (Gasoline Engine)
Tightening Torque
Bracket Mounting 35 - 45 N•m
Bolt (26 - 33 lb-ft)
Union Bolt to Vacuum 35 - 45 N•m
Pump (26 - 33 lb-ft)

YAD4A270

BRAKE OIL LEVEL SWITCH

Removal & Installation Procedure
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

4. Installation should follow the removal procedure

in the reverse order.

YAD4A300

BRAKE FLUID RESERVOIR

Removal & Installation Procedure
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

Installation Procedure
1. Install the retainer ring using the snap ring plier.

YAD4A390

2. Install the master cylinder into the booster.

Installation Notice
8 - 12 N•m
Tightening Torque
(71 - 106 lb-in)

YAD4A400

3. Install the master cylinder completely and then

connect the brake pipe.
Installation Notice
15 - 18 N•m
Tightening Torque
(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

Installation Procedure
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
Removal & Installation Procedure
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.
21 - 35 N•m
Tightening Torque
(15 - 26 lb-ft)

YAD4A480

BRAKE PEDAL
Removal & Installation Procedure
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

Installation Procedure
1. Install the rear brake hose and tighten the union
bolts.
Tightening Torque 15 - 18 N•m
at the caliper (11 - 13 lb-ft)
Tightening Torque 15 - 19 N•m
at the wheel cylinder (11 - 13 lb-ft)

YAD4A590

YAD4A600

2. Install the front brake hose and tighten the union

bolts.
15 - 18 N•m
Tightening Torque
(11 - 13 lb-ft)

YAD4A610

SSANGYONG Y200
4A-24 BRAKE SYSTEM

3. Install the brake pipe to the correct position.

3-way Connector 15 - 19 N•m
(11 - 14 lb-ft)
LCRV System 15 - 19 N•m
(11 - 14 lb-ft)
ABS/ABD Control 15 - 19 N•m
Unit (11 - 14 lb-ft)
Port (M12) 20 - 24 N•m
(15 - 18 lb-ft)

4. Bleed the brake system after replacement of the

YAD4A620 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 14 - 18 N•m
Mounting nut (10 - 13 lb-ft)
Bracket Mounting 10 - 13 N•m
Bolt (89 - 115 lb-in)
Stud Mounting 14 - 18 N•m
Nut (10 - 13 lb-ft)

Notice: Bleed the brake system.

YAD4A660

SSANGYONG Y200
SECTION 4B

FRONT BRAKE
TABLE OF CONTENTS
Description and Operation ................................... 4B-2 Component Locator ............................................. 4B-6
Caliper ................................................................ 4B-2 Cross-Sectional View ........................................... 4B-6
Clearance Calibration ........................................... 4B-2 Front Caliper Brake .............................................. 4B-7
Specifications ...................................................... 4B-2 Repair Instructions ................................................ 4B-8
Diagnostic Information and Procedures .............. 4B-3 On-Vehicle Service ............................................... 4B-8
Inspection ............................................................. 4B-4 Front Brake .......................................................... 4B-8
Pad Thickness ..................................................... 4B-4 Brake Pad Replacement .................................... 4B-10
Brake Disc Thickness .......................................... 4B-4 Unit Repair .......................................................... 4B-13
Brake Disc Run Out ............................................. 4B-5 Brake Caliper .................................................... 4B-13
Caliper Housing I.D .............................................. 4B-5
4B-2 FRONT BRAKE

DESCRIPTION AND OPERATION

CALIPER However, as a part of the piston seal is fixed into a
grove in the cylinder shape of the seal is as shown in
This caliper has a single bore and is mounted to the below figure, distorted toward the piston moving
steering knuckle with two mounting bolts. Hydraulic direction.
pressure, created by applying the brake pedal, is
When the pressure is taken off from the brake pedal
converted by the caliper to a stopping force. This force
and the hydraulic pressure is released from the piston,
acts equally against the piston and the bottom of the
a restoring elastic force is generated at the seal and
caliper bore to move the piston outward and to slide
pushes the piston rightward and back it in original
the caliper inward, resulting in a clamping action on
position.
the rotor. This clamping action forces the linings against
the rotor, creating friction to stop the vehicle. 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 Delphi Korea
Application Ventilated Disc Type ←
Caliper Cylinder I.D. Ø 60 mm ←
Pad Thickness 10 mm ←
Disc Thickness 24 mm ←

SSANGYONG Y200
FRONT BRAKE 4B-3

DIAGNOSTIC INFORMATION AND PROCEDURES

Condition Possible Cause Action
Poor Braking Pad Wear, Hardening Replace
Oil Or Water Contamination On The Pad Replace and Repair
Inoperative Caliper Replace
Uneven Braking Pad Wear, Hardening Replace
Oil Or Water Contamination On The Pad Replace and Repair
Uneven Wear Or Twisted Of The Disc Replace
Inoperative Caliper Replace
Dragging Brake Inoperative Caliper Returning Replace
Excessive Pedal Travel Pad Wear Replace
Noise and Vibration When Pad Wear, Hardening Replace
Brake Applied Damage On The Disc Replace
Interference Of The Dust Cover Repair
Loose Caliper Mounting Bolts 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
• Boot’s damage and tear
• Disc plate’s scratch and bending

PAD THICKNESS
1. Remove the front wheel.
2. Measure the thickness and replace as needed.

yyyy
;;;;
Thickness Max wear Limit
yyyy
;;;;
;;;;;
yyyyy
yyyy
;;;;
10 mm 2 mm

;;;;;
yyyyy
yyyy
;;;;
;;;;;
yyyyy
yyyy
;;;;
;;;;;
yyyyy
yyyy
;;;;
;;;;;
yyyyy
;;;;;
yyyyy
;;;;;
yyyyy
YAD4B040

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 Max wear Limit
24 mm 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 pedal’s vibration at
braking.
0.03 mm (Disc only)
Run Out Limit
0.07 mm (On vehicle)

YAD4B060

CALIPER HOUSING I.D

Application Spec.
I.D Ø 60.0 mm
Non-ABS/ABS
Wear Limit Ø 61.0 mm

YAD4B070

SSANGYONG Y200
4B-6 FRONT BRAKE

COMPONENT LOCATOR
CROSS-SECTIONAL VIEW

YAD4B030

1 Brake Disc 6 Vacuum Hose Nipple

2 Wheel (Rim) 7 Caliper
3 Hub Range 8 Brake Fluid Nipple
4 Knuckle 9 Caliper Guide Bolt
5 Dust Shield 10 Caliper Bolt

SSANGYONG Y200
FRONT BRAKE 4B-7

FRONT CALIPER BRAKE

YAD4B080

1 Brake Caliper Assembly 6 Piston Seal

2 Guide Rod Set 7 Piston
3 Brake Pad 8 Piston Boot
4 Brake Pad Spring 9 Caliper Guide Rod Bolt
5 Caliper Mounting Bolt 10 Bleeder Screw

SSANGYONG Y200
4B-8 FRONT BRAKE

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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 (full-
time 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
85 - 105 N•m
Tightening Torque
(63 - 79 lb-ft)

YAD4B210

YAD4B220

SSANGYONG Y200
4B-12 FRONT BRAKE

3. Connect the brake hose to the caliper cylinder.

Installation Notice
7 - 13 N•m
Tightening Torque
(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
Disassembly Procedure
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
22 - 32 N•m
Tightening Torque
(16 - 24 lb-ft)

3. Fasten the bleeder screw as specified torque.

Installation Notice
7 - 13 N•m
Tightening Torque
(62 - 115 lb-in)

YAD4B290

SSANGYONG Y200
SECTION 4C

REAR BRAKE
TABLE OF CONTENTS
Description and Operation ................................... 4C-2 Component Locator ............................................. 4C-9
Drum Brake ......................................................... 4C-2 Drum Brake ......................................................... 4C-9
Wheel Cylinder .................................................... 4C-2 Disc Brake ........................................................ 4C-10
Brake Lining ........................................................ 4C-2 Rerair Instructions .............................................. 4C-11
Disc Brake .......................................................... 4C-3 On-Vehicle Service ............................................. 4C-11
Specifications ...................................................... 4C-3 Disc Brake Assembly ........................................ 4C-11
Diagnostic Information and Procedures .............. 4C-4 Drum Brake Assembly ....................................... 4C-16
Inspection ............................................................. 4C-5 Unit Repair .......................................................... 4C-21
Drum Brake Type................................................. 4C-5 Wheel Cylinder .................................................. 4C-21
Disc Brake Type .................................................. 4C-5 Parking Brake Lever ........................................... 4C-22
Cross Sectional View ........................................... 4C-7
Drum Brake (KDAC) ............................................. 4C-7
Disc Brake .......................................................... 4C-8
4C-2 REAR BRAKE

DESCRIPTION AND OPERATION

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

Disc Brake
Application Drum Brake
MANDO Delphi Korea
Drum I.D. Ø 254 mm - -
Shoe Type Leading and Trailing - -
Lining Width x Length x Thickness 55 x 243 x 4.7 mm - -
Wheel Cylinder I.D. Ø 23.81 mm - -
Caliper Cylinder I.D. - Ø 42.9 mm Ø 42 mm
Brake Pad Thickness - 10 mm 10 mm
Disc Thickness - 10.4 mm 10.4 mm

SSANGYONG Y200
4C-4 REAR BRAKE

DIAGNOSTIC INFORMATION AND PROCEDURES

Symptom Possible Cause Action

Poor Braking Lining Wear, Hardening Replace
Oil Or Water Contamination On The Lining Replace or Repair
Inoperative Wheel Cylinder Replace
Inoperative Clearance Automatic Control System Repair
Uneven Braking Lining Wear, Hardening Adjust
Oil Or Water Contamination On The Lining Replace or Repair
Inoperative Wheel Cylinder Replace
Inoperative Clearance Automatic Control System Repair
Dragging Brake Damage Of The Brake Shoe Return Spring Replace
Inoperative Wheel Cylinder Returning Replace
Excessive Pedal Travel Lining Wear Replace
Inoperative Clearance Automatic Control System Repair
Noise and Vibration When Lining Wear, Hardening Replace
Brake Applied Foreign Material Inside Drum Clean
Loosen The Brake Plate Bolt Tighten
Drum Deformation Or Surface Damage Replace
Inoperative Parking Brake Lining Wear, Hardening Replace
Oil Contamination On The Lining Replace
Inoperative Clearance Automatic Control System Repair

SSANGYONG Y200
REAR BRAKE 4C-5

INSPECTION
DRUM BRAKE TYPE
1. Inspect the drum for crack or damage or defor-
mation.
2. Measure the inside diameter.
Inside Diameter Wear Limit
Ø 254 mm Ø 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.

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2. If the measured value is below the limit value,
replace the pad.
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yyyy Wear Limit 2 mm
yyyyy
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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.
On-Vehicle Max. 0.07 mm
Run Out Limit
Disc only Max. 0.03 mm
2. If lateral run out exceeds the specification, replace
the brake disc to prevent the pedal’s vibration at
braking.

YAD4C100

SSANGYONG Y200
REAR BRAKE 4C-7

CROSS SECTIONAL VIEW

DRUM BRAKE (KDAC)

YAD4C040

1 Backing Plate 8 Retainer Spring Plate

2 Wheel Cylinder 9 Adjuster Assembly
3 Brake Shoe Lining 10 Adjuster Lever
4 Brake Shoe 11 Return Spring (Adjuster)
5 Lower Return Spring (Lower Shoe Spring) 13 Upper Return Spring (Upper Shoe Spring)
6 Retainer Spring Pin 14 Bolt
7 Compression Spring 15 Air Bleeder Nipple

SSANGYONG Y200
4C-8 REAR BRAKE

DISC BRAKE

YAD4C050

1 Backing Plate 5 Disc

2 Parking Cable 6 Wheel
3 Parking Cable Lever 7 Air Bleeder Nipple
4 Caliper Assembly 9 Shaft Assembly

SSANGYONG Y200
REAR BRAKE 4C-9

COMPONENT LOCATOR
DRUM BRAKE

YAD4C280

1 Bleeder Screw 9 Upper Return Spring

2 Bleeder Screw Cap 10 Brake Shoe Retaining Spring Pin
3 Rear Brake Assembly 11 Trailing Shoe
4 Rear Brake Plate 12 Brake Shoe Retaining Spring
5 Wheel Cylinder 13 Brake Shoe Retaining Spring Cap
6 Strut Assembly (Clearance Automatic Control 14 Lower Return Spring
System) 15 Hub Bolt
7 Brake Leading Shoe 16 Rear Brake Drum
8 Middle Return Spring

SSANGYONG Y200
4C-10 REAR BRAKE

DISC BRAKE

YAD4C110

1 Rear brake disc assembly 6 Gasket.................................................... Replace

2 Brake pad 7 Brake hose
3 Brake caliper 8 Gasket.................................................... Replace
4 Gasket.................................................... Replace 9 Hose bolt ........................................... 8 - 18 N•m
5 Bolt ........................................... 20 N•m (15 lb-ft)

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
• Boot’s damage and tear

YAD4C190

2. Inspect the brake pad thickness.

Pad Thickness Max wear Limit
10 mm 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 Max wear Limit
10.4 mm 8.5 mm

4. Inspect the disc plate’s 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

Installation Procedure
1. Install the brake lining between the backing plate
and the flange.
Installation Notice
4 - 8 N•m
Tightening Torque
(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
4 - 8 N•m
Tightening Torque
(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.

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yyyyyyy
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yyyyyyy
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yyyyyyy
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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. Wear Limit
Ø 254 mm Ø 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

Installation Procedure
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 Ø 253.08

- Ø 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
15 - 19 N•m
Tightening Torque
(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
Disassembly Procedure
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.
7 - 10 N•m
Bleeder Screw
(62 - 89 lb-in)
Wheel Cylinder 8 - 12 N•m
Mounting Bolt (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 Component Locator ............................................. 4D-5
Parking Brake ...................................................... 4D-2 Cross Sectional View ........................................... 4D-5
Parking Brake Switch and Indicator ...................... 4D-2 Parking Brake Lever and Cable ............................ 4D-6
Braking Inspection .............................................. 4D-2 Repair Instructions ................................................ 4D-7
Specifications ...................................................... 4D-3 On-Vehicle Service ............................................... 4D-7
Diagnostic Information and Procedure ............... 4D-4 Parking Brake ...................................................... 4D-7
4D-2 PARKING BRAKE

DESCRIPTION AND OPERATION

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

Application Spec.
Parking Brake Type Mechanical Rear-Wheel Drive Internal Expanded
Operation Manual

SSANGYONG Y200
4D-4 PARKING BRAKE

DIAGNOSTIC INFORMATION AND PROCEDURE

Symptom Possible Cause Action
Poor Braking Lining Wear, Hardening Replace
Oil Or Water Contamination On The Lining Replace Or Repair
Brake Cable Sticked Or Damage Replace
Excessive Pedal Travel Notch Adjustment
Inoperative Clearance Automatic Control System Repair

SSANGYONG Y200
PARKING BRAKE 4D-5

COMPONENT LOCATOR
CROSS SECTIONAL VIEW

YAD4D020

1 Parking Brake Lever 5 Cable

2 Parking Brake Cable Bracket (Rear) 6 With Drum Brake
3 Parking Brake Cable Bracket (Front) 7 With Disc Brake
4 Parking Brake Cable Bracket (Center)

SSANGYONG Y200
4D-6 PARKING BRAKE

PARKING BRAKE LEVER AND CABLE

YAD4D050

1 Parking Brake Lever 7 Nut

2 Parking Brake Warning Lamp Switch 8 Bolt
3 Bolt 9 Rear Parking Brake Cable
4 Bolt 10 Brake Disc (Rear Disc Brake Type)
5 Front Parking Brake Cable 11 Brake Drum (Rear Drum Brake Type)
6 Equalizer

SSANGYONG Y200
PARKING BRAKE 4D-7

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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
22 N•m
Tightening Torque
(16 lb-ft)

YAD4D140

4. Insert the parking brake cable to the lever hole

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

DESCRIPTION AND OPERATION

ABS(ANTI-LOCK BRAKE SYSTEM) The inlet valve and the outlet valve close/open by the
electrical signal and control the hydraulic pressure as
When wheel slip is noted during a brake application, increase, decrease and hold.
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
YAD4E010
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 ABS System Components
solenoid valves rapidly cycle. During antilock braking The ABS 5.3 Antilock Braking System (ABS) consists
on dry pavement, the tires may make intermittent of a conventional hydraulic brake system plus antilock
chirping noises as they approach slipping. These components. The conventional brake system includes
noises and pedal pulsations should be considered a vacuum booster, master cylinder, front disc brakes,
normal during antilock operation. rear disc brakes, interconnecting hydraulic brake pipes
The vehicle may be stopped by applying normal force and hoses, brake fluid level switch and the BRAKE
to the brake pedal. Brake pedal operation during indicator.
normal braking should be no different than previous The ABS components include a hydraulic unit, an
systems. Maintaining a constant force on the pedal electronic brake control module (EBCM), two system
will provide the shortest stopping distance while fuses, four wheel speed sensors (one at each wheel),
maintaining vehicle stability. interconnecting wiring, the ABS indicator, the EBD
indicator and the TCS indicator, See “ABS Component
Basic Knowledge Required Locator” in this section for the general layout of this
Before using this section, it is important that you have system.
a basic knowledge of the following items. Without this The basic hydraulic unit configuration consists of
knowledge, it will be difficult to use the diagnostic hydraulic check valves, two solenoid valves for each
procedures contained in this section. wheel, a hydraulic pump, and two accumulators. The
Basic Electrical Circuits - You should understand the hydraulic unit controls hydraulic pressure to the front
basic theory of electricity and know the meaning of calipers and rear calipers by modulating hydraulic
voltage, current (amps) And resistance (ohms). You pressure to prevent wheel lockup.
should understand what happens in a circuit with an Units equipped with TCS add two more valves for each
open or shorted wire. You should be able to read and drive wheel for the purpose of applying the brake to a
understand a wiring diagram. wheel that is slipping. This is done with pressure from
Use of Circuit Testing Tools - You should know how the hydraulic pump in the unit. There is also a TCS
to use a test light and how to bypass components to indicator lamp on the instrument panel to alert the driver
test circuits using fused jumper wires. You should be to the fact that the TCS system is active. The
familiar with a digital multimeter. You should be able components identified in the drawing are those added
to measure voltage, resistance, and current, and be to the basic ABS 5.3 system to provide traction control.
familiar with the controls and how to use them correctly. Nothing the hydraulic unit or the EBCM is serviceable.
In the event of any failure, the entire ABS unit with
Basic Hydraulic System attached EBCM must be replaced. For more information,
Each solenoid valve consists of one inlet valve and refer to “Base Braking Mode” and “Antilock Braking
one outlet valve in order to become the channel. Mode” in the section.

SSANGYONG Y200
ABS AND TCS 4E-3

TRACTION CONTROL SYSTEM The temperature of the brakes is calculated by a

mathematical model and TCS is switched passive if
(TCS) DESCRIPTION the calculated temperature is greater than a threshold
General Information value (500 °C). TCS is permitted again, when the
calculated temperature is less than 350 °C.
The traction control system (TCS) is a traction system
by means of brake intervention only, available in a low Lamp Concepts
speed range (< 60 kph). The system is equipped with an TCS information lamp,
It works on µ-split roads with sidewise different friction which is blinking during TCS operation.
coefficients. The activation of the EBD, TCS warning lamp and the
The spinning driven wheel is braked and the drive TCS info lamp is summarized in the following table:
torque can be transferred to the wheel on the high-µ
side. During TCS active, the TCS information lamp is
blinking.

System Failure (EBD,

ABS TCS TCS Passive Due to
Ignition ON ABS or TCS are Not
Operation Operation Temperature Model
Distinguished)
2 second on
ABS Warning
for lamp OFF OFF ON OFF
Lamp
check
2 second on
TCS Info Blinking
for lamp OFF OFF ON
Lamp (FLASHING)
check
2 second on
EBD Warning EBD
for lamp OFF ON OFF
Lamp operation/OFF
check

SSANGYONG Y200
4E-4 ABS AND TCS

Automatic Brake Differential (ABD) Control Algorithm

ABD (Automatic Brake Differential) system is a type The input signals for the control algorithm are the
of the TCS (ASR) system and substitutes the function filtered wheel speed signals from the ABS speed
of the mechanical LSD (Limited Slip Differential) processing.
system. With the speed difference of the driven wheels, the
ABD system operates by controlling the braking forces control deviation is calculated.
only under 60km/h.
If the control deviation exceeds a certain threshold
value, the wheel with the greater slip is braked actively.
TCS System Function
The threshold value depends on the vehicle speed:
Traction control does not have any effect on the
operation of the vehicle until the control module detects It is reduced with increasing vehicle speed down to a
one or both of the front wheels rotating faster than the constant value.
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 V = Faster rear wheel speed - Slower rear wheel

Depending on the control deviation and the wheel speed
acceleration of the spinning wheel, pressure increase, V = Vehicle speed
hold and decrease are made. * TCS is switched passive if the calculated temperature
The pressure modulation is done with the conventional is greater than a threshold value (500 °C).
control with the valves. Prime valve, inlet valve and • TCS (ABD) Indicator turns on but TCS is permitted
outlet valve according to the following table: again, when the calculated temperature is less than
350 °C.
Increase Hold Decrease
Prime Valve Open Open Open Temperature Model
Closed Closed Closed TCS operation is a high thermal load for the brakes.
Pilot Valve
To avoid any damages at the brakes, the disk
Inlet Valve Open Closed Closed
temperature is calculated with a mathematical model
Outlet Valve Closed Closed Open for each driven wheel separately, After ignition on, the
Speed Range calculation starts with 30 ° C and then three different
phases are evaluated separately and added:
TCS is available in the speed range ≤ 60 kph.
TCS operation, braking and cooling phase.
Above 60 kph vehicle speed, TCS is passive.
If the temperature is higher than 500 °C, TCS is disabled
It is possible to initiate TCS operation up to a vehicle for this wheel.
speed of 55 kph.
It is permitted again, if the model has calculated down
the 350 °C.

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
YAD4E030
reproducing a pressure-reduction function at the rear-
wheel brakes.
Service Precautions
ABS features an enhanced algorithm which includes
control of the brake force distribution between the front Observe the following general precautions during any
and rear axles. This is called Electronic Brake ABS/TCS service. Failure to adhere to these
Distribution. In an unloading car condition the brake precautions may result in ABS/TCS system damage.
efficiency is comparable to the conventional system 1. Disconnect the EBCM harness connector before
but for a fully loaden vehicle the efficiency of the EBD performing the electric welding procedures.
system is higher due to the better use of rear axle 2. Carefully note the routing of the ABS/TCS wiring
braking capability. and wring components during removal. The ABS/
TCS components are extremely sensitive to EMI
The Benefits of EBD (eletromagnetic interference). Proper mounting is
• Elimination of conventional proportioning valve EBD critical during component service.
utilizes the existing rear axle wheel speed sensor 3. Disconnect the EBCM connector with the ignition
to monitor rear wheel slip. OFF.
• Based on many variables in algorithm a pressure 4. Do not hang the suspension components from the
hold, increase and/or decrease pulsetrain may be wheel speed sensor cables. The cables may be
triggered at the rear wheels insuring vehicle damaged.
stability.
5. Do not use petroleum based fluids in the master
• Vehicle approaches the ideal brake force cylinder. Do not use any containers previously used
distribution (front to rear). for petroleum based fluids. Petroleum causes
• Constant brake force distribution during vehicle swelling and distortion of the rubber components
lifetime. in the hydraulic brake system, resulting in water
• EBD function is monitored via ABS safety logic entering the system and lowering the fluid boiling
(conventional proportioning valves are not point.
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 Front Wheel Speed Sensor Rings

The toothed ring mentioned above is pressed onto the
Replacement Tires
wheel-side (outer) constant velocity joint. Each ring
Tire size is important for proper performance of the contains 52 equally spaced teeth. Exercise care during
ABS system. Replacement tires should be the same service procedures to avoid prying or contacting this
size, load range, and construction as the original tires. ring. Excessive contact may cause damage to one or
Replace tires in axle sets and only with tires of the more teeth. If the ring is damaged, the wheel-side
same tire performance criteria (TPC) specification constant velocity joint must be replaced.
number.
The use of any other size or type of tire may seriously Rear Wheel Speed Sensors And Rings
affect the ABS operation. The rear wheel speed sensors operate in the same
manner as the front wheel speed sensor. They
Electronic Brake Control Module (EBCM) incorporate a length of flexible harness with the
Notice: There is on serviceable or removable connector attached to the end of the harness. The rear
EEPROM. The EBCM must be replaced as an assembly wheel speed rings are incorporated into the hub
(Only ABS). ABS/TCS is separated hydraulic modulator assemblies and cannot be replaced separately, require
and EBCM. replacement of the rear hub/bearing assembly.

The EBCM is attached to the hydraulic unit in the engine Valve Realy And Pump Motor Relay
compartment (ABS). The controlling element of ABS The valve relay and the motor pump relay are located
5.3 is a microprocessor-based EBCM. Inputs to the inside the electronic brake control module (EBCM) and
system include the four wheel speed sensors, the are not replaceable. If one should fail, replace the
stoplamp switch, the ignition switch, and the EBCM.
unswitched battery voltage. There is an output to a
be-directional serial data link, located in pin K of Wiring Harness
Assembly Line Diagnostic Link (ALDL) for service
The wiring harness is the mechanism by which the
diagnostic tools and assembly plant testing.
electronic brake control module (EBCM) is electrically
The EBCM monitors the speed of each wheel. If any connected to power and to ground, to the wheel speed
wheel begins to approach lockup and the brake switch sensors, the fuses, the switches, the indicators, and
is closed (brake pedal pressed), the EBCM controls the serial communications port. The components,
the solenoids to reduce brake pressure to the wheel considered part of the wiring harness, are the wires
approaching lockup. Once the wheel regains traction, that provide electrical interconnection, and connectors
brake pressure is increased until the wheel again (terminals, pins, contacts, or lugs) that provide an
begins to approach lockup. This cycle repeats until electrical/mechanical interface from the wire to a
either the vehicle comes to a stop, the brake pedal is system component.
released, or no wheels approach lockup.
Additionally, the EBCM monitors itself, each input Indicators
(except the serial data link), and each output for proper The electronic brake control module (EBCM)
operation. If it detects any system malfunction, the continuously monitors itself and the other ABS
EBCM will store a DTC in nonvolatile memory components If the EBCM detects a problem with the
(EERPOM) (DTCs will not disappear if the battery is system, the amber ABS indicator will light continuously
disconnected). Refer to “Self Diagnostics” in this to alert the driver to the problem. An illuminated ABS
section for more detailed information. indicator indicates that the ABS system has detected
a problem that affects the operation of ABS. On
Front Wheel Speed Sensors antilock braking will be available. Normal, non-antilock
The front wheel speed sensors are of a variable brake performance will remain. In order to regain ABS
reluctance type. Sensor is attached to the steering braking ability, the ABS must be serviced.
knuckle, close to a toothed ring. The result, as teeth The red BRAKE indicator will be illuminated when the
pass by the sensor, is an AC voltage with a frequency system detects a low brake fluid level in the master
proportional to the speed of the wheel. The magnitude cylinder or when the parking brake switch is closed
of the voltage and frequency increase with increasing (the parking brake is engaged).
speed. The sensor is not repairable, nor is the air gap
The EBD indicator will light continuously to alert the
adjustable.
driver to the problem in the basic brake system. The
EBD system must be serviced.

SSANGYONG Y200
4E-10 ABS AND TCS

HYDRAULIC CIRCUIT
ABS 5.3
Pressure Increase

YAD4E070

1 Master Cylinder 6 Accumulator

2 Hydraulic Modulator 7 Inlet Valve for each wheel
3 Damper 8 Outlet Valve for each wheel
4 Pump 9 Front Wheel
5 Pump Motor 10 Rear Wheel

SSANGYONG Y200
ABS AND TCS 4E-11

Pressure Hold

YAD4E080

1 Master Cylinder 6 Accumulator

2 Hydraulic Modulator 7 Inlet Valve for each wheel
3 Damper 8 Outlet Valve for each wheel
4 Pump 9 Front Wheel
5 Pump Motor 10 Rear Wheel

SSANGYONG Y200
4E-12 ABS AND TCS

Pressure Decrease

YAD4E090

1 Master Cylinder 6 Accumulator

2 Hydraulic Modulator 7 Inlet Valve for each wheel
3 Damper 8 Outlet Valve for each wheel
4 Pump 9 Front Wheel
5 Pump Motor 10 Rear Wheel

SSANGYONG Y200
ABS AND TCS 4E-13

ABS/TCS 5.3
Pressure Increase

YAD4E100

1 Master Cylinder 8 Outlet Valve for each wheel

2 Hydraulic Modulator 9 Wheel
3 Damper 10 Prime Valve
4 Pump 11 Pilot Valve
5 Pump Motor 12 Check Valve
6 Accumulator 13 ISD (Integrated Suction Damper)
7 Inlet Valve for each wheel

SSANGYONG Y200
4E-14 ABS AND TCS

Pressure Hold

YAD4E110

1 Master Cylinder 8 Outlet Valve for each wheel

2 Hydraulic Modulator 9 Wheel
3 Damper 10 Prime Valve
4 Pump 11 Pilot Valve
5 Pump Motor 12 Check Valve
6 Accumulator 13 ISD (Integrated Suction Damper)
7 Inlet Valve for each wheel

SSANGYONG Y200
ABS AND TCS 4E-15

Pressure Decrease

YAD4E120

1 Master Cylinder 8 Outlet Valve for each wheel

2 Hydraulic Modulator 9 Wheel
3 Damper 10 Prime Valve
4 Pump 11 Pilot Valve
5 Pump Motor 12 Check Valve
6 Accumulator 13 ISD (Integrated Suction Damper)
7 Inlet Valve for each wheel

SSANGYONG Y200
4E-16 ABS AND TCS

COMPONENT LOCATOR
ABS, ABS/TCS 5.3

1 3
2
4

YAD4E130

1 ABS/TCS Hydraulic Unit and Control Unit 4 Diagnosis connector

2 Rear Wheel Speed Sensor 5 Front Wheel Speed Sensor
3 ABS Warning Indicator

SSANGYONG Y200
4E-18 ABS AND TCS

DIAGNOSTIC INFORMATION AND PROCEDURES

YAD4E140

DIAGNOSTIC CIRCUIT CHECK

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

SSANGYONG Y200
ABS AND TCS 4E-19

Diagnostic Circuit Check

Step Action Value Yes No

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

SSANGYONG Y200
4E-20 ABS AND TCS

YAD4E150

Examine the wheel speed sensor.
1 - Go to Step 3 Go to Step 2
Are there any signs of physical damage?
1. Turn the ignition to LOCK.
2. Disconnect the left rear wheel speed sensor
connector.
2
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)? 1280 - 1920 Ω Go to Step 4 Go to Step 3
Replace the wheel speed sensor.
3
Is the repair complete? - System OK -
1. Switch the DVM to the AC mV.
2. Measure the voltage output between the wheel
4 speed sensor terminals while rotating the wheel
about 1 revolution per second.
Is the output within the specified value? ≈ 70 mV Go to Step 6 Go to Step 5
Replace the speed sensor or the toothed wheel, as
5 required.
Is the repair complete? - System OK -
1. Disconnect the from the EBCM.
2. Connect a DVM between ground and one terminal
of the wheel speed connector.
6 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? >1V Go to Step 7 Go to Step 8
Repair the short to voltage in the affected circuit.
7
Is the repair complete? - System OK -
1. Turn the ignition to LOCK.
2. Measure the resistance to ground from terminal 8
at the harness EBCM connector.
8 3. Measure the resistance to ground from terminal 9
at the harness EBCM connector.
Is the resistance at either circuit less than the speci-
fied value? ∞ Go to Step 9 Go to Step 10
Repair the short to ground in the affected circuit.
9
Is the repair complete? - System OK -
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
10 harness EBCM connector and the harness wheel
speed sensor connector.
Is the resistance on either circuit within the specified
value? >5Ω Go to Step 11 Go to Step 12
Repair the open or high resistance in the affected
11 circuit, as required.
Is the repair complete? - System OK -
Replace the ABS unit.
12
Is the repair complete? - System OK -

SSANGYONG Y200
4E-50 ABS AND TCS

YAD4E190

FREQUENCY ERROR
Circuit Description Test Description
The toothed wheel generates a voltage pulse as it The number(s) below refer to Step(s) on the diagnostic
moves past the wheel speed sensor. Each tooth-gap- table.
tooth series on the wheel generates the pulses. The 1. This step begins the examination of the front wheel
electronic brake control module (EBCM) uses the speed sensor sensors.
frequency of these pulses to determine wheel speed.
3. This step checks for a problem with one of the
The voltage generated depends on the air gap between
front toothed rings.
the wheel speed sensor and the toothed wheel, and
on the wheel speed. 5. This step checks the front wheel speed sensors.
7. This step checks for shorts in a front wheel speed
Diagnosis
sensor harness.
This DTC will set when the EBCM cannot identify which
9. This step checks for opens in a front wheel speed
wheel speed sensor is causing the malfunction. It is
sensor harness.
necessary to check all wheel speed sensors and
associated wiring to determine the cause of the DTC. 11. This step begins a check of the rear wheel speed
sensors.
Cause
13. This step checks for a problem with one of the
• Incorrect number of teeth on the toothed wheel. rear toothed rings.
• Damaged or broken teeth on the toothed wheel. 15. This step checks the rear wheel speed sensors.
• Open or short in speed wheel speed sensor wiring. 17. This step checks for shorts in a rear wheel speed
Action Taken When the DTC Sets sensor harness.
Antilock brake system (ABS) action is disabled and 19. This step checks for opens in a rear wheel speed
the ABS warning lamp is ON. sensor harness.

ABD 5.3 CIRCUIT

YAD4E290

SSANGYONG Y200
4E-90 ABS AND TCS

CONNECTOR END VIEWS

EBCM (HYDRAULIC MODULATOR/UNIT INTEGRATED)

YAD4E300

Pin Wire Color Circuit Pin Wire Color Circuit

1 WHT Right Rear Speed Sensor Ground 17 RED/WHT Battery
2 BLK/GRN Right Rear Speed Sensor 18 RED/WHT Battery
3 - Not Used 19 BLK Ground
4 BLK/RED Right Front Speed Sensor Ground 20 GRN/BRN ABS Warning Lamp
5 WHT/RED Right Front Speed Sensor 21 GRN/BLK EBD Warning Lamp
6 BRN Left Front Speed Sensor Ground 22 BLU TCS Warning Lamp
7 BLK/WHT Left Front Speed Sensor 23 YEL/GRN Acceleration Sensor Supply
8 BRN/BLK Left Rear Speed Sensor Ground Voltage (5V)

9 BRN/WHT Left Rear Speed Sensor 24 - Not Used

10 RED/BLK Acceleration Sensor Signal 25 - Not Used
11 BLU/BLK Data Link Connector 26 - Not Used
12 - Not Used 27 - Not Used
13 WHT/GRN TOD 28 RED/GRN Acceleration Sensor Ground
14 YEL Stoplamp SW 29 - Not Used
15 BRN/RED Ignition 30 - Not Used
16 BLK Ground 31 - Not Used

SSANGYONG Y200
ABS AND TCS 4E-91

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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 vehicle’s 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 vehicle’s
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
Removal & Installation Procedure
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 14 N•m (124 lb-in)

YAD4E320

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 N•m (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

Removal & Installation Procedure
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 N•m (62 lb-in)

6. Installation should follow the removal procedure

in the reverse order.
YAD4E350

REAR WHEEL SPEED SENSOR

Removal & Installation Procedure
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 N•m (62 lb-in)

5. Installation should follow the removal procedure

in the reverse order.

YAD4E370

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

Installation Procedure
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 AND EQUIPMENT

SPECIAL TOOLS TABLE

661 589 17 33 00
661 589 16 33 00
ABS Tooth Wheel
ABS Tooth Wheel Puller Installer

YAD4E420 YAD4E430

SSANGYONG Y200
SECTION 5A

AUTOMATIC TRANSMISSION
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 . . . . . . . . . . . . . . . . . 5A-2 Shift Quality Faults . . . . . . . . . . . . . . . . . . . . . . 5A-45
BTRA M74 4WD Automatic Transmission . . . . . . 5A-2 After Teardown Faults . . . . . . . . . . . . . . . . . . . 5A-47
Operators Interfaces . . . . . . . . . . . . . . . . . . . . . 5A-2 Trouble Code Diagnosis - Gasoline Vehicle . . 5A-50
Control Systems . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 TCM Diagnostic System Overview . . . . . . . . . . 5A-50
Electronic Control System . . . . . . . . . . . . . . . . . 5A-3 Clearing Trouble Codes . . . . . . . . . . . . . . . . . . 5A-50
Hydraulic Control System . . . . . . . . . . . . . . . . . 5A-10 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A-50
Hydraulic Control Circuit . . . . . . . . . . . . . . . . . . 5A-11 Trouble Code Diagnosis - Disel Vehicle . . . . . . 5A-52
Power Train System . . . . . . . . . . . . . . . . . . . . . 5A-15 TCM Diagnostic System Overview . . . . . . . . . . 5A-52
Power Flows . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-19 Clearing Trouble Codes . . . . . . . . . . . . . . . . . . 5A-52
Park and Neutral . . . . . . . . . . . . . . . . . . . . . . . 5A-20 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A-52
Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 5A-159
Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-24 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 5A-159
Drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-26 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-159
Drive 2 and Manual 2 . . . . . . . . . . . . . . . . . . . . 5A-28 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-162
Drive 3 and Manual 3 . . . . . . . . . . . . . . . . . . . . 5A-30 Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . . 5A-162
Drive 3 Lock Up and Manual 3 Lock Up . . . . . . 5A-32 Disassembly Procedure . . . . . . . . . . . . . . . . . . 5A-163
Drive 4 (Overdrive) . . . . . . . . . . . . . . . . . . . . . 5A-34 Assembly Procedure . . . . . . . . . . . . . . . . . . . . 5A-173
Drive 4 Lock Up . . . . . . . . . . . . . . . . . . . . . . . . 5A-36 Front and Rear Band Adjustment . . . . . . . . . . . 5A-201
Diagnostic Information and Procedures . . . . . 5A-38 Gear Shift Control Lever . . . . . . . . . . . . . . . . . . 5A-204
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-38 Kickdown Switch . . . . . . . . . . . . . . . . . . . . . . . 5A-205
Basic Knowledge Required . . . . . . . . . . . . . . . 5A-38 Transmission Control Module . . . . . . . . . . . . . . 5A-205
Functional Check Procedure . . . . . . . . . . . . . . . 5A-38 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-206
Transmission Fluid Level Service Procedure . . . 5A-38 General Specification . . . . . . . . . . . . . . . . . . . . 5A-206
Fluid Leak Diagnosis and Repair . . . . . . . . . . . 5A-39 Fastener Tightening Specifications . . . . . . . . . . 5A-210
Electrical / Garage Shift Test . . . . . . . . . . . . . . 5A-40 Schematic and Routing Diagrams . . . . . . . . . . 5A-211
Road Test Procedure . . . . . . . . . . . . . . . . . . . . 5A-40 TCM Wiring Diagrams (Gasoline Engine) . . . . . 5A-211
Electronic Adjustments . . . . . . . . . . . . . . . . . . 5A-41 TCM Wiring Diagrams (Diesel Engine) . . . . . . . 5A-213
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 5A-42 Connector End View . . . . . . . . . . . . . . . . . . . . . 5A-215
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-42 Special Tools and Equipment . . . . . . . . . . . . . 5A-216
Faulty Shift Pattern . . . . . . . . . . . . . . . . . . . . . . 5A-43 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-216
5A-2 AUTOMATIC TRANSMISSION

DESCRIPTION AND OPERATION

BTRA M74 4WD AUTOMATIC Of primary significance is the Transmission Control Mo-
dule (TCM) which is a microprocessor based control
TRANSMISSION system.
The BTR Automotive Model 74 Four Speed Automatic The TCM utilizes throttle position, rate of throttle open-
Transmission is an electronically controlled overdrive ing, engine speed, vehicle speed, transmission fluid
four speed unit with a lock-up torque converter. The temperature, gear selector position and mode selector
lock-up torque converter results in lower engine speeds inputs, and in some applications a Kickdown Switch
at cruise and eliminates unnecessary slippage. These to control all shift feel and shift schedule aspects.
features benefit the customer through improved fuel The TCM drives a single proportional solenoid multi-
economy and noise reduction. plexed to three regulator valves to control all shift feel
Max. aspects. The output pressure of this solenoid is con-
Power trolled as a function of transmission fluid temperature
Configuration
(kW) to maintain consistent shift feel throughout the
operating range.
260 mm Torque Shift scheduling is highly flexible, and several indepen-
Converter-Wide dent schedules are programmed depending on the ve-
320 160 Ratio Gear Set hicle.
Splined Output for Transfer
Typically the NORMAL schedule is used to maximize
Case
fuel economy and driveability, and a POWER schedule
is used to maximize performance. WINTER schedule
is used to facilitate starting in second gear.

KAA5A010

OPERATORS INTERFACES • P - Park position prevents the vehicle from rolling

either forward or backward by locking the
There are three operator interfaces as the following; transmission output shaft. The inhibitor switch
• Gear Shift Control Lever allows the engine to be started. For safety reasons,
• Driving Mode Selector the parking should be used in addition to the park
position. Do not select the Park position until the
• Indicator Light vehicle comes to a complete stop because it
Gear Shift Control lever mechanically locks the output shaft.
The transmission uses a conventional shift control lever. • R - Reverse allows the vehicle to be operated in a
The gear shift control lever can be moved from one rearward direction. The inhibitor switch enables re-
position to another within the staggered configuration verse lamp operation.
of the shift control lever gate to positively indicate the
• N - Neutral allows the engine to be started and oper-
gear selection. ated while driving the vehicle. The inhibitor switch

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-3

allows the engine to be started. There is no power When NORMAL mode is selected upshifts will occur
transferred through the transmission in Neutral. But to maximize fuel economy. When POWER mode is se-
the final drive is not locked by the parking pawl, so lected, upshifts will occur to give maximum
thewheels are free to rotate. performance and the POWER mode indicator light is
• D - Overdrive range is used for all normal driving switched ON.
conditions. 4th gear (overdrive gear) reduces the When WINTER mode is selected, starting in second
fuel consumption and the engine noise. Engine gear is facilitated, the WINTER mode indicator light is
braking is applied with reduced throttle. switched ON and the POWER mode indicator light is
First to second (1 → 2), first to third (1 → 3), second switched OFF.
to third (2 → 3), second to fourth (2 → 4), third to Indicator Light
fourth (3 → 4), fourth to third (4 → 3), fourth to
The indicator light is located on the instrument panel.
second (4 → 2), third to second (3 → 2), third to
first (3 → 1) and second to first (2 → 1) shifts are • Auto shift indicator light comes ON when the ignition
all available as a function of vehicle speed, throttle switch ON and shows the gear shift control lever
position and the time change rate of the throttle posi-tion.
position. • POWER mode indicator light comes ON when the
Downshifts are available for safe passing by POWER mode is selected and when the kickdown
depress-ing the accelerator. Lockup clutch may be switch is depressed.
enabled in 3rd and 4th gears depending on vehicle • WINTER mode indicator light comes ON when the
type. WINTER mode is selected.
• 3 - Manual 3 provides three gear ratios (first through
CONTROL SYSTEMS
third) and prevents the transmission from operating
in 4th gear. 3rd gear is used when driving on long BTRA M74 4WD automatic transmission consists of
hill roads or in heavy city traffic. Downshifts are two control systems. One is the electronic control
available by depressing the accelerator. system that monitors vehicle parameters and adjusts
• 2 - Manual 2 provides two gear ratios (first and the transmission performance. Another is the hydraulic
second). It is used to provide more power when control system that implements the commands of the
climbing hills or engine braking when driving down electronic control system commands.
a steep hill or starting off on slippery roads.
ELECTRONIC CONTROL SYSTEM
• 1 - Manual 1 is used to provide the maximum engine
braking when driving down the severe gradients. 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 regu-
lator valves to control shift feel.
KAA5A020
Transmission Control Module (TCM)
Driving Mode Selector The TCM is an in-vehicle micro-processor based trans-
The driving mode selector consists of a driving mode mission management system. It is mounted under the
selector switch and indicator light. The driving mode driver’s side front seat in the vehicle cabin.
selector is located on the center console and allows The TCM contains:
the driver to select the driving mode.
• Processing logic circuits which include a central mi-
The driving modes available to be selected vary with croprocessor controller and a back-up memory
vehicle types. Typically the driver should have the system.
option to select among NORMAL, POWER and
WINTER modes.
• Input circuits.

SSANGYONG Y200
5A-4 AUTOMATIC TRANSMISSION

• Output circuits which control external devices such the engine torque output, adjusts the variable pressure
as the Variable Pressure Solenoid (VPS) driver, On/ solenoid ramp pressure then executes the shift.
Off solenoid drivers, a diagnostics output and the The TCM continuously monitors every input and output
driving mode indicator light. circuit for short or open circuits and operating range.
Processing Logic When a failure or abnormal operation is detected the
Shift schedule and calibration information is stored in TCM records the condition code in the diagnostics
an Erasable Programmable Read Only Memory (EPROM). memory and implements a Limp Home Mode (LHM).
Throttle input calibration constants and the diagnostics The actual limp home mode used depends upon the
information are stored in Electrically Erasable Program- fail-ure detected with the object to maintain maximum
mable Read Only Memory (EEPROM) that retains the drive-ability without damaging the transmission. In
memory even when power to the TCM is disconnected. general input failures are handled by providing a
TCM continuously monitors the input values and uses default value. Output failures, which are capable of
these, via the shift schedule, to determine the required damaging the transmission, result in full limp mode
gear state. At the same time it monitors, via the giving only third or fourth gear and reverse. For further
solenoid outputs, the current gear state, whenever the details of limp modes and memory retention refer to
input conditions change such that the required gear the Diagnostic Trouble Code Diagnosis Section.
state is different to the current gear state, the TCM The TCM is designed to operate at ambient
initiates a gear shift to bring the two states back into temperatures between - 40 and 85 °C (- 40 and 185 °F).
line. It is also protected against electrical noise and voltage
Once the TCM has determined the type of gearshift spikes, however all the usual precautions should be
required the TCM accesses the shift logic, estimates observed, for example when arc welding or jump
starting.

KAA5A030

TCM Inputs
To function correctly, the TCM requires engine speed, and on/off solenoid states. This ensures the correct
vehicle speed, transmission fluid temperature, throttle gear selection and shift feel for all driving conditions.
position, gear position and Kickdown Switch inputs to The inputs required by the TCM are as follows;
determine the variable pressure solenoid current ramp

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-5

• Engine Speed Pin No. Codes and colors in Solenoid Loom

The engine speed signal is derived from the Control-
Pin No. Wire Color Connects to
ler Area Network (CAN) via Engine Control Module
(ECM). 1 Red Solenoid 1
• Vehicle Speed 2 Blue Solenoid 2
The vehicle speed sensor, which is located in the 3 Yellow Solenoid 3
transfer case, sends the output shaft speed signal 4 Orange Solenoid 4
to the Engine Control Module (ECM). The information
5 Green Solenoid 5
is then transferred to the TCM via the CAN.
6 Violet Solenoid 6
• Transmission Fluid Temperature
The transmission fluid temperature sensor is a 7 Brown Solenoid 7
thermistor located in the solenoid wiring loom within 8 Green Solenoid 5
the valve body of the transmission. This sensor is 9 White Temperature Sensor
a typical Negative Temperature Coefficient (NTC)
10 Red Temperature Sensor
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 Resistance (Ohms)

(°C) Minimum Maximum
KAA5A050
-20 13,638 17,287
0 5,177 6,616 Throttle Position Sensor
20 2,278 2, 723 Gasoline Engine:
100 117 196 The throttle position signal is sent from the ECM to the
135 (Overheat TCM via the CAN. Refer to Engine Section for further
75 85
Mode Threshold)
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
KAA5A040
of the TPS connentor.

SSANGYONG Y200
5A-6 AUTOMATIC TRANSMISSION

Maintaining good shift feel through the transmission Readings for Resistance / Shift Lever Positions
life span is dependant on having an accurate measure
of the engine throttle position. To achieve this the TCU Shift Lever Position Ω)
Resistance (kΩ
continuously monitors the maximum and minimum Manual 1 1 ~ 1.4
throttle potentiometer voltages and, if a change occurs, Manual 2 21.8 ~ 2.2
stores the new voltage values.
Manual 3 3 3 ~ 3.4
However these limits will be lost and will require
relearning should a new TCU be installed, or the throttle Drive 4.5 ~ 4.9
calibration data is cleared by the execution of a Neutral 6.8 ~ 7.2
particular sequence. This last instance depends on Reverse 10.8 ~ 11.2
the installation, and reference should be made to the
Diagnostics Section of this manual. The relearning will Park 18.6 ~ 19
happen automatically.
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 TCM’s
retentive memory. Connection to the diagnostic input
of the TCM is via a connector included in the vehicle’s
YAD5A250
wiring harness or computer interface.
Gear Position Sensor Battery Voltage Monitoring Input
The gear position sensor is incorporated in the inhibitor The battery voltage monitoring input is connected to
switch mounted on the side of the transmission case. 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 trans-
mission 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.
KAA5A060 TCM Outputs
The outputs from the TCM are supplied to the compo-
The gear position sensor is a multi-function switch pro- nents described below;
viding three functions;
• Solenoids
• Inhibit starting of the vehicle when the shift lever is
• Mode Indicator Light
in a position other than Park or Neutral
• Illuminate the reverse lamps when Reverse is se-
lected
• Indicate to the TCM which lever position has been
selected by way of a varying resistance.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-7

Solenoids • Solenoid 6: S6 is a normally open ON/OFF solenoid

The TCM controls seven solenoids. Solenoids 1 to 6 that sets the high/low level of line pressure. Solenoid
(S1 to S6) are mounted in the valve body, while OFF gives high pressure.
Solenoid 7 (S7) is mounted in the pump cover. • Solenoid 7: S7 is a normally open ON/OFF solenoid
• Solenoid 1 and 2: S1 and S2 are normally open ON/ that controls the application of the converter clutch.
OFF solenoids that set the selected gear. These Solenoid ON activates the clutch.
solenoids determine static gear position by Solenoid Logic for Static Gear States
operating the shift valves. Note that S1 and S2
Gear S1 S2
solenoids also send signal pressure to allow or
prohibit rear band engagement. 1st ON ON
• Solenoid 3 and 4: S3 and S4 are normally open ON/ 2nd OFF ON
OFF solenoids that combine to control shift quality 3rd OFF OFF
and sequencing. S3 switches the clutch regulator
4th ON OFF
valve OFF or ON. S4 switches the front band regula-
tor valve OFF or ON. S5 also provides the signal Reverse OFF OFF
pressure for the converter clutch regulator valve. Neutral OFF OFF
• Solenoid 5: S5 is a variable pressure solenoid that Park OFF OFF
ramps the pressure during gear changes. This sole-
noid provides the signal pressure to the clutch and
band regulator, thereby controlling the shift pres-
sures. S5 also provides the signal pressure for the
converter clutch regulator valve.

SSANGYONG Y200
5A-8 AUTOMATIC TRANSMISSION

Solenoid Operation during Gearshifts

Shift To Initiate Shift Typical S5 Current Ramp To Complete Shift

1-2 S1 OFF 750mA to 600mA S4 OFF
S4 ON
1-3 S1 OFF S3 OFF
S2 OFF 850mA to 750mA S4 OFF
S3 ON
S4 ON
1-4 S2 OFF S3 OFF
S3 ON 850mA to 750mA S4 OFF
S4 ON
2-3 S2 OFF 700mA to 500mA S3 OFF
S3 ON S4 OFF
S4 ON
3-4 S1 ON 750mA to 600mA S4 OFF
S4 ON
4-3 S4 ON 750mA to 900mA S1 OFF
S4 OFF
4-2 S3 ON S1 OFF
750mA to 950mA S2 ON
S3 OFF
4-1 S3 ON S2 ON
S4 ON 600mA to 1000mA S3 OFF
S4 OFF
3-2 S2 ON S4 OFF
S4 ON 600mA to 450mA @ 20 kph.
550mA to 400mA @ 60 kph.
800mA to 650mA @ 100 kph.
3-1 S3 ON S1 ON
S4 ON S2 ON
S3 OFF
700mA to 950mA S4 OFF
2-1 S4 ON 800mA to 950mA S1 ON
S4 OFF
Conv. Clutch
ON S7 ON 700mA to 400mA S7 OFF
OFF 600mA to 100mA

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-9

Solenoid Valve Symbols This applies full Line 500 pressure to the plunger and
because Line 500 pressure is always greater than S5
(ON/OFF Solenoids)
pressure it squeezes the S5 oil out between the
The solenoid symbol shown adjacent to each solenoid regulator valve and the plunger. The friction elements
on the hydraulic system schematics indicates the state are then fed oil pressure equal to Line 500 multiplied
of the oil flow through the solenoid valve with the power by the amplification ratio.
ON or OFF.
When a shift is initiated the required ON/OFF solenoid
Normally Open (NO) Solenoid is switched ON cutting the supply of Line 500 to the
POWER ON: Line 500 port is closed. The output port plunger.
is open to exhaust at the solenoid valve. At the same time the VPS pressure is reduced to the
POWER OFF: The exhaust port is closed. The output ramp start value and assumes control of the regulator
port is open to line 500. 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 se-
lected or if an overheat condition exists. The mode
indicator light is usually located on the instrument
cluster.
KAA5A070 Communication Systems
Variable Pressure Solenoid Multiplexing System CAN
Friction element shifting pressures are controlled by The Controller Area Network (CAN) connects various
the Variable Pressure Solenoid (VPS). control modules by using a twisted pair of wires, to
Line pressure is completely independent of shift pres- share common information. This results in a reduction
sure and is a function of throttle position, gear state of sensors and wiring. TCM obtains the actual engine
and engine speed. speed and throttle position, vehicle speed and
accelerator position etc. from ECM via CAN without
S5 is a proportional or variable pressure solenoid that
any additional sensors.
provides the signal pressure to the clutch and band
regulator valves thereby controlling shift pressures. K-Line
VPS pressure is multiplexed to the clutch regulator The K-line is typically used for obtaining diagnostic
valve, the band regulator valve and the converter clutch information from the TCM. A scan tool with a special
regulator valve during automatic gearshifts. interface is connected to the TCM via Data Link
A variable pressure solenoid produces a hydraulic Connector (DLC) and all current faults, stored faults,
pressure inversely proportional to the current applied. runtime parameters are then available. The stored
During a gearshift the TCM applies a progressively trouble codes can also be cleared by scan tool.
increasing or decreasing (ramped) current to the The K-line can be used for vehicle coding at the
solenoid. Current applied will vary between a minimum manufacturer’s plant or in the workshop. This allows
oaf 200 mA and a maximum of 1000 mA. Increasing for one TCM design to be used over different vehicle
current decreases output (S5) pressure. Decreasing mod-els.
current increases output (S5) pressure. The particular code is sent to the microprocessor via
Line 500 pressure, (approximately 440 to 560 kPa), is the K-line and this results in the software selecting the
the reference pressure for the VPS, and the VPS output correct shift and VPS ramp parameters.
pressure is always below line 500 pressure. Data Link Connector (DLC)
When the VPS is at standby, that is no gearshift is
The Data Link Connector (DLC) is a multiple cavity
taking place, the VPS current is set to 200 mA giving
connector. The DLC provides the means to access the
maximum output pressure.
serial data from the TCM.
Under steady state conditions the band and clutch The DLC allows the technician to use a scan tool to
regulator valve solenoids are switched OFF. monitor the various systems and display the Diagnostic
Trouble Codes (DTCs).

SSANGYONG Y200
5A-10 AUTOMATIC TRANSMISSION

The DLC connector is located within the driver’s The pump cover contains the following;
compartment, directly below the instrument panel on • Primary regulator valve for line pressure
the driver’s side.
• 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.
A103A321
All downshifts are accomplished by switching VPS pres-
sure to the band and/or clutch regulator valve and send-
HYDRAULIC CONTROL SYSTEM ing a ramped current to the VPS. The shift is completed
by simultaneously switching the regulators OFF,
The hydraulic controls are located in the valve body, switching the shift valves and at the same time causing
pump body and main case. the VPS to return to stand-by pressure.
The valve body contains the following; The primary regulator valve is located in the pump
• Manual valve cover and supplies four line pressures; high and low
• Three shift valves for forward gears, and high and low for reverse. This
pressure has no effect on shift quality and merely
• Sequence valve provides static clutch capacity during steady state
• Solenoid supply pressure regulator valve operation. Low pressure can be obtained by activating
• Line pressure control valve an ON/OFF solenoid with high line pressure being the
• Clutch apply feed regulator valve default mode.
• Band apply feed regulator valve Torque converter lock-up is initiated by toggling the
converter clutch control valve with an ON/OFF solenoid.
• Solenoid S1 to S6
The actual apply and release of the clutch is regulated
• Reverse lockout valve by the VPS via the converter clutch regulator valve.
The solenoid supply pressure regulator valve provides
reference pressure for all the solenoids.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-11
HYDRAULIC CONTROL CIRCUIT

KAA5A08A

SSANGYONG Y200
5A-12 AUTOMATIC TRANSMISSION

Valve Body

KAA5A110

KAA5A090
2-3 Shift Valve
Manual Valve The 2-3 shift valve is a two position valve. It is used
on all 2-3 and 3-2 gearshifts.
The manual valve is connected to the vehicle selector
mechanism and controls the flow of oil to the forward The switching of this valve is achieved by S2 which is
and reverse circuits. The manual valve function is located at the end of the valve spool.
identical in all forward gear positions except that in In the 1, 2 position, second gear oil from the 1-2 shift
the Manual 1 position an additional supply of oil is valve is prevented from entering the third gear circuit.
directed to the 1-2 shift valve for application of the When the valve is moved to the 3, 4 position, oil from
rear band and the C4 overrun clutch. The manual valve the second gear circuit is routed to the third gear circuit
directs the line pressure into the PRND fluid circuits. and the transmission is changed to third gear.

KAA5A100 KAA5A120

1-2 Shift Valve 3-4 Shift Valve

The 1-2 shift valve is a two position valve that must be The 3-4 shift valve is a two position valve. It is used
switched to the 2, 3 and 4 position in order to get any for all 3-4 and 4-3 gearshifts.
forward gear other than first gear. It is used for all 1-2
The switching of this valve is achieved by S1 which is
and 2-1 gearshifts.
located at the end of the valve spool.
The switching of this valve is achieved by using S1
During a 3-4 gearshift the 3-4 shift valve:
and/ or S2.
During a 1-2 gearshift drive oil from the manual valve • Exhausts the front band release (B1R) circuit
thereby allowing the application of the front band
passes through to the second gear circuit. During a 2-
(B1).
1 gearshift the band apply feed oil is allowed to exhaust
via the 1-2 shift valve. • Connects the inner apply area of the front servo
(B1AI) to the Band Apply Feed (BAF) circuit thus
The 1-2 shift valve works in conjunction with the 3-4
allowing greater apply forces to the front band.
shift valve to disengage the C4 clutch in first gear,
and engage C4 in second gear. When Manual 1 is • Exhausts the Overrun Clutch (OC) circuit which al-
selected the C4 clutch and rear band (B2) are engaged. lows the C4 clutch to disengage.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-13

During a 4-3 gearshift, the C4 clutch is engaged and line pressure control valve. When S6 pressure is applied
the front band (B1) is released. These actions are se- to the end of the Primary Regulator Valve (PRV), it is
quenced by the 4-3 sequence valve. opposed by spring force and causes LOW line
The 3-4 shift valve also switches during 1-2 and 2-1 pressure for light throttle application and cruising.
gearshifts where its function is to apply the overrun Heavy throttle application causes the normally open
clutch (C4) in second gear but to release it in first S6 to open (switch Off) thus closing line 500 and
gear. opening S6 to exhaust. Removal of S6 pressure from
Note that the C4 clutch is applied in Manual 1 by virtue the PRV results in HIGH line pressure.
of the manual valve and the 1-2 shift valve. Refer to
“1-2 Shift Valve” in this section.

KAA5A150

Clutch Apply Feed Regulator Valve

KAA5A130
The clutch apply feed regulator valve is a fixed ratio
4-3 Sequence Valve (2.25:1) valve. This valve provides a regulated pressure
The 4-3 sequence valve is a two position spring loaded to the C1 clutch and controls the change rate of the
valve. It switches during 3-4 and 4-3 gearshifts although clutch state to give the desired shift quality.
it performs no function during the 3-4 shift. Third gear oil supplied to the valve is regulated to pro-
During the 4-3 shift the 4-3 sequence valve delays the vide an output pressure, Clutch Apply Feed (CAF) pres-
connection of the Clutch Apply Feed (CAF) circuit to sure, of 2.25 times the S5 signal pressure when S3 is
the B1R circuit until the B1R circuit has been fully ON. When S3 is OFF, the output pressure is 2.25 times
pressurized by using the third gear circuit. This the line 500 pressure.
prevents objectionable engine flare on completion of
the 4-3 gearshift.

KAA5A160

KAA5A140
Band Apply Feed Regulator Valve
The band apply feed regulator valve is a fixed ratio
Solenoid Supply Pressure Regulator Valve (1.4:1) valve. It provides a regulated pressure to the
The solenoid supply pressure regulator valve supplies front servo, and controls the change rate of the front
a constant pressure to all solenoids (S1 to S7). Line band (B1) state to give the desired shift quality.
pres-sure is used as the feeding oil to this regulator Second gear oil supplied to the valve is regulated to
and the output is termed line 500. provide an output pressure, Band Apply Feed (BAF)
Line Pressure Control Valve pressure, of 1.4 times the S5 signal pressure when S4
is ON. When S4 is OFF the output pressure is 1.4 times
Line pressure is controlled by S6, which acts as the the line 500 pressure.

SSANGYONG Y200
5A-14 AUTOMATIC TRANSMISSION
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 con-
tained in the upper valve body. This valve uses S1-S2
pressure as a signal pressure and controls the applica-
tion 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 KAA5A190

of B2 in any of the forward driving gears except M1.

Primary Regulator Valve
The Primary Regulator Valve (PRV) regulates the trans-
mission 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 applica-
tions and cruising. Heavy throttle will cause S6 to switch
OFF and thereby cause high line pressure.
This stepped line pressure control has no detrimental
KAA5A180 effect on shift feel because all shifting pressures are
When the manual valve is in P, R or N positions, drive controlled by separate band and clutch regulator
oil is exhausted and the reverse lockout valve may be valves, and the output of S5.
toggled by S1-S2 pressure. When reverse gear is selected, both the low and high
line pressure values are boosted to guard against slip-
B2 is applied in P, R, and N if the following conditions
page. This is achieved by applying reverse oil line
are satisfied;
pressure to the PRV to assist the spring load. The
• In P or N, vehicle speed = 3 km/h. other end of the valve contains ports for line pressure
• In R, vehicle speed = 10 km/h. feedback and S6 pressure.
• Engine speed = 1600 rpm. The PRV also regulates the supply of oil to the
• Throttle position = 12 %. converter via the converter feed port. The cascade
Under these conditions, the TCM switches solenoids effect of the PRV ensures the first priority of the valve
S1 and S2 to OFF. The reverse lockout valve toggles is to maintain line pressure at very low engine speeds.
under the influence of the S1-S2 pressure, to connect When the engine speed increases and the pump
the line pressure to the B2 feed. Oil is fed to both the supplies an excess of oil the PRV moves to uncover
inner and outer apply areas of the rear servo piston, the converter feed port thereby pressurizing the
applying B2. converter. If there is an excess of oil for the
transmission’s needs then the PRV moves further to
If any of the above conditions are not satisfied, the allow oil to return to the suction port.
TCM switches solenoids S1 and S2 to ON.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-15

KAA5A200 KAA5A220

Converter Clutch Regulator Valve B1R Exhaust Valve

The converter clutch regulator valve regulates the pres- The B1R exhaust valve is a two position spring loaded
sure of the oil which applies the converter clutch. Input valve located in the transmission case directly adjacent
oil from the line 500 circuit is regulated within the valve, to the front servo. It permits the servo release oil to be
with the output pressure being variable according to rapidly exhausted into the transmission case during
the signal pressure from the S5 circuit. Converter clutch application of the front band (B1). This prevents the
apply and release application is smoothed by need to force the oil back from the front servo through
electronically varying the S5 circuit pressure. 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 KAA5A240
valve which applies or releases the converter clutch.
The switching of this valve is governed by the signal POWER TRAIN SYSTEM
pressure from S7. The Power Train System consists of;
When the valve is in the OFF or released position, con- • A torque converter with single face lock-up clutch
verter feed oil from the PRV is directed to the release
side of the converter clutch. After flowing through the
• Four multi-plate clutch assemblies
converter, oil returns to the converter clutch control • Two brake bands
valve and is then directed to the oil cooler. • Two one-way clutches
When the valve is in the ON or applied position, regu- • Planetary gear set
lated oil from the converter clutch regulator valve is • Parking mechanism
directed to the apply side of the converter clutch. This
A conventional six pinion Ravigneaux compound plane-
oil remains within the converter because the converter
tary gear set is used with overdrive (fourth gear) being
clutch piston is sealed against the flat friction surface
obtained by driving the carrier.
of the converter cover. To provide oil flow to the cooler
the converter clutch control valve directs converter feed The cross-sectional arrangement is very modular in
oil from the PRV directly to the cooler circuit. nature.
Four main sub-assemblies are installed within the case
to complete the build. These subassemblies are;

SSANGYONG Y200
5A-16 AUTOMATIC TRANSMISSION

• Gear set-sprag-centre support the B1 band. The 3-4 shift is accomplished by re-
• C1 -C2 -C3 -C4 clutch sub-assembly applying the B1 band and overrunning the 3-4 OWC.
Reverse gear is engaged by applying the C3 clutch
• Pump assembly
and the B2 band.
• Valve body assembly
The C4 clutch is applied in the Manual 1, 2 and 3 ranges
One, or a combination of selective washers are used to provide engine braking. In addition, the C4 clutch
between the input shaft flange and the number 4 is also applied in the Drive range for second and third
bearing to control the transmission end float. This gears to eliminate objectionable freewheel coasting.
arrangement allows for extensive subassembly testing
The B2 band is also applied in the Manual 1 range to
and simplistic final assembly during production.
accomplish the low-overrun shift.
A general description of the operation of the Power
Both the front and rear servos are dual area designs
Train System is detailed below.
to allow accurate friction element matching without the
First gear is engaged by applying the C2 clutch and need for secondary regulator valves. All the friction
locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 elements have been designed to provide low shift
shift is accomplished by applying the B1 band and energies and high static capacities when used with
overrunning the 1-2 OWC. The 2-3 shift is the new low static co-efficient transmission fluids. Non-
accomplished by applying the C1 clutch and releasing asbestos friction materials are used throughout.

ELEMENTS ENGAGED
Gear Gear C1 C2 C3 C4 B1 B2 1-2 3-4 LU
Ratio OWC OWC CLUTCH
First 2.741 X X X
Second 1.508 X X X
Third 1.000 X X X X X X*
Fourth 0.708 X X X X X
Reverse 2.428 X X
Manual 1 2.741 X X X X
* For Certain Vehicle Applications, Refer to the Owner's Manual.

KAA5A250

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-17

Torque Converter Clutch Packs

The torque converter consists of a turbine, stator pump, There are four clutch packs. All clutch packs are com-
impeller and a lock-up damper and piston assembly. posed of multiple steel and friction plates.
As in conventional torque converters, the impeller is C1 CLUTCH: When applied, this clutch pack allows
attached to the converter cover, the turbine is splined the input shaft to drive the planet carrier. This occurs
to the input shaft and the stator is mounted on the in third and fourth gears.
pump housing via a one way clutch (sprag).
C2 CLUTCH: When applied this clutch pack allows
The addition of the damper and piston assembly en- the input shaft to drive the forward sun gear via the 3-
ables the torque converter to lock-up under favorable 4 OWC. This occurs in all forward gears.
conditions. Lock-up is only permitted to occur in third
C3 CLUTCH: When applied this clutch pack allows
and fourth gears under specified throttle and vehicle
the input shaft to drive the reverse sun gear. This only
speed conditions.
occurs in reverse gear.
Lock-up is achieved by applying hydraulic pressure
C4 CLUTCH: When applied this clutch provides engine
to the damper and piston assembly which couples the
braking on overrun. This occurs in Manual 1, 2 and 3
turbine to the converter cover, locking-up the converter
and also Drive 2 and Drive 3 to prevent objectionable
and eliminating unwanted slippage. Whenever lock-
free wheel coasting.
up 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.

KAA5A270

KAA5A260

SSANGYONG Y200
5A-18 AUTOMATIC TRANSMISSION

Bands area of the apply piston is utilized. In fourth gear both

areas are utilized for greater clamping force.
The transmission utilizes two bands, the B1 band
(sometimes known as the 2-4 band), and the B2 band The B2 band is a solid band which is engaged by the
(sometimes known as the low-reverse band). rear servo piston. B2 is activated in Park, Reverse,
Neutral and Manual 1. When activated B2 prevents
The B1 band is a flexible band which is engaged by
the planet carrier assembly from rotating. In Manual 1
the front servo piston. B1 is activated in second and
only the inner area of the apply piston is utilized. In
fourth gear. When activated B1 prevents the reverse
Park, Reverse and Neutral, both areas are utilized for
sun gear from rotating by holding the C3 clutch
greater clamping force.
assembly stationary. In second gear only the outer

KAA5A290
KAA5A280

Planetary Gear Set

One Way Clutches
The planetary gear set used in the transmission is a
The transmission uses two OWCs, the 1-2 OWC and
conventional six pinion Ravigneaux compound gear
the 3-4 OWC. (Note that a third OWC is located in the
set.
torque converter, also known as a sprag.)
The 1-2 OWC is located between the planetary carrier Parking Mechanism
assembly and the center support. This allows the carrier When Park is selected the manual lever extends the
to rotate around the center support in one direction park rod rearwards to engage the parking pawl. The
only. The one way clutch is engaged only in Drive 1. pawl will engage the external teeth on the ring gear
This 3-4 OWC is located between the C4 and the C2 thus locking the output shaft to the transmission case.
clutch assemblies. This allows the C2 clutch to drive When Park is not selected a return spring holds the
the forward sun gear in first, second and third gears parking pawl clear of the output shaft, preventing
but unlocks in fourth gear and during overrun. accidental engagement of Park.

KAA5A300

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-19

POWER FLOWS • Power Flow - Drive 3

The power flows for the various transmission selections • Power Flow - Drive 3 Lock Up
are listed below; • Power Flow - Drive 4 (Overdrive)
• Power Flow - Neutral and Park • Power Flow - Drive 4 Lock Up
• Power Flow - Reverse The following table details the engaged elements
versus the gear selected for all transmission selections.
• Power Flow - Manual 1
• Power Flow - Drive 1
• Power Flow - Drive 2

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Park and Neutral - - - - - X - - -
Reverse - - X - - X - - -
Manual 1 - X - X - X - X -
Drive 1 - X - - - - X X -
Drive 2 and Manual 2 - X - X X - - X -
Drive 3 and Manual 3 X X - X - - - X -
Drive 3 Lock Up and X X - X - - - X X
Manual 3 Lock Up
Drive 4 Overdrive X X - - X - - X -
Drive 4 Lock Up X X - - X - - X X

SSANGYONG Y200
5A-20 AUTOMATIC TRANSMISSION
PARK AND NEUTRAL

KAA5A31A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-21

Power Flow - Park and Neutral • Line (pump) pressure is applied to the Primary Regu-
lator Valve (PRV) and to the solenoid supply
In Park and Neutral, there is no drive to the planetary
pressure regulator valve.
gear set. The rear band is applied to eliminate ‘clunk’
on engagement of the reverse gear, and to improve • The converter, oil cooler, and lubrication circuits are
the low range engagement for 4WD applications. No charged from the primary regulator valve.
other clutches or bands are applied. • The line 500 circuit is charged by the solenoid
In Park the transmission is mechanically locked by supply pressure regulator valve.
engaging a case mounted pawl with teeth on the output • The S5 circuit is charged by the variable pressure
shaft ring gear. solenoid (S5).
Control • Line pressure is prevented from entering the drive
circuit by the manual valve.
To maintain this arrangement in the steady state sole-
noids and valves are activated as follows: • The B1 circuit and all clutch circuits are open to ex-
haust.
• Solenoids S1 and S2 are switched OFF.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Park and Neutral - - - - - X - - -

KAA5A320

SSANGYONG Y200
5A-22 AUTOMATIC TRANSMISSION
REVERSE

KAA5A33A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-23

Power Flow - Reverse Control

In Reverse, transmission drive is via the input shaft To maintain this arrangement in the steady state sole-
and the forward clutch cylinder to the hub of the C3 noids and valves are activated as follows;
clutch. The elements of the transmission function as • Solenoids S1 and S2 are switched OFF.
follows; • Line pressure is directed through the reverse lockout
• The C3 clutch is engaged and drives the reverse valve to both the inner and outer apply areas of the
sun gear in a clock-wise direction. rear servo piston for B2 band application.
• The B2 band is engaged and holds the planetary • Line pressure feeds the reverse oil circuit via the
gear carrier stationary causing the long pinion to manual valve.
rotate anti-clockwise about its axis on the pinion • Reverse oil is routed from the manual valve to the
shaft. C3 clutch.
• The long pinion drives the internal ring gear in the • Reverse oil is also applied to the spring end of the
same direction. primary regulator valve to assist the spring and to
• The internal ring being splined to the output shaft boost the line pressure value.
drives it in an anti-clockwise or reverse direction. • All other clutch and band apply circuits are open to
exhaust.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Reverse - - X - - X - - -

KAA5A340

SSANGYONG Y200
5A-24 AUTOMATIC TRANSMISSION
MANUAL 1

KAA5A35A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-25

Power Flow - Manual 1 Control

In Manual 1, transmission drive is via the input shaft To maintain this arrangement in the steady state sole-
to the forward clutch cylinder. The elements of the noids and valves are activated as follows;
trans-mission function as follows; • Solenoids S1 and S2 are switched ON.
• The C2 clutch is engaged to drive the forward sun • The 1-2, 2-3, and 3-4 shift valves are held in their
gear, via the 3-4 OWC. first gear positions by line 500 pressure.
• The B2 band is engaged to hold the planetary gear • Drive (line pressure) oil from the manual valve en-
carrier stationary. gages the C2 clutch.
• The forward sun gear drives the short pinion anti- • Lo-1st (line pressure) oil is routed through the 1-2
clockwise. shift valve to the C4 clutch, and to the inner apply
• The short pinion drives the long pinion clockwise. area of the rear servo piston for B2 band application.
• 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.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Manual 1 - X - X - X - X -

KAA5A360

SSANGYONG Y200
5A-26 AUTOMATIC TRANSMISSION
DRIVE 1

KAA5A37A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-27

Power Flow - Drive 1 Control

In Drive 1, transmission drive is via the input shaft to To maintain this arrangement in the steady state sole-
the forward clutch cylinder. The elements of the noids and valves are activated as follows:
transmission function as follows : • Solenoids S1 and S2 are switched ON.
• The C2 clutch is engaged to drive the forward sun • The 1-2, 2-3, and 3-4 shift valves are held in their
gear via the 3-4 OWC. first gear positions by line 500 pressure.
• The forward sun gear drives the short pinion anti- • Drive (line pressure) oil from the manual valve en-
clockwise. gages the C2 clutch.
• 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.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Drive 1 - X - - - - X X -

KAA5A380

SSANGYONG Y200
5A-28 AUTOMATIC TRANSMISSION
DRIVE 2 AND MANUAL 2

KAA5A39A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-29

Power Flow - Drive 2 and Manual 2 • Drive (line pressure) oil from the manual valve en-
gages the C2 clutch.
In Drive 2 and Manual 2, transmission drive is via the
input shaft and forward clutch cylinder. The elements • When S1 switches OFF, S1 oil pressure, which is
of the transmission function as follows; derived from line 500 pressure, moves the 3-4 shift
valve to the left. At the same time S1 oil is directed
• The C2 clutch is applied to drive the forward sun to the 1-2 shift valve which moves the valve to the
gear.
second gear position.
• The forward sun gear drives the short pinion anti-
clockwise. • 2nd oil (line pressure) from the 1-2 shift valve is di-
rected to the band apply regulator valve, and to
• The short pinion drives the long pinion clockwise. the 2-3 shift valve.
• The B1 band is applied holding the reverse sun • The band apply feed regulator valve supplies 2nd
gear stationary therefore the long pinion walks oil (regulated to line pressure multiplied by the valve
around the reverse sun gear taking the internal ring ratio) to the Band Apply Feed (BAF) circuit.
gear and output shaft with it in a clockwise or
forward direction. • Band apply feed oil is directed to;
- The outer apply area of the front servo
• The C4 clutch is applied to bypass the 3-4 OWC
and provide engine braking on overrun. - The 1-2 shift valve to provide an exhaust port
when the transmission is shifted to first gear
Control
- The 3-4 shift valve for use when the transmission
To maintain this arrangement in the steady state sole- is shifted into fourth gear
noids and valves are activated as follows;
• Drive (line pressure) is routed through the 3-4 shift
• Solenoid S1 is switched OFF. S2 is switched ON. valve to apply the C4 clutch.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Drive 2 and Manual 2 - X - X X - - X -

KAA5A400

SSANGYONG Y200
5A-30 AUTOMATIC TRANSMISSION
DRIVE 3 AND MANUAL 3

KAA5A41A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-31

Power Flow - Drive 3 and Manual 3 • The band apply feed regulator valve supplies 2nd
oil (regulated to line pressure multiplied by the valve
In Drive 2 and Manual 2, transmission drive is via the
ra-tio) to the Band Apply Feed (BAF) circuit.
input shaft and forward clutch cylinder. The elements
of the transmission function as follows; • Band apply feed oil is directed to;
• The C2 clutch is engaged to drive the forward sun - The outer apply area of the front servo
gear. - The 1-2 shift valve to provide an exhaust port
• The C1 clutch is engaged to drive the planet carrier. when the transmission is shifted to first gear
• The short pinion drives the long pinion clockwise. - The 3-4 shift valve for use when the transmission
is shifted into fourth gear
• The forward sun gear and the planet carrier are driv-
en clockwise at the same speed therefore there is • 2nd oil at the 2-3 shift valve is directed to the 3rd
no relative motion between the sun gear and the oil circuit.
pinions. • 3rd oil from the 2-3 shift valve is directed to the
• The ring gear and output shaft are driven in a clock- clutch apply regulator valve, and to the 4-3
wise or forward direction at input shaft speed. sequence valve.
• The C4 clutch is applied to bypass the 3-4 OWC • The clutch apply regulator valve supplies oil (regu-
and provide engine braking on overrun. lated to line 500 pressure multiplied by the valve
ratio) to the Clutch Apply Feed (CAF) circuit.
Control
The CAF oil is directed to;
To maintain this arrangement in the steady state sole-
- The C1clutch
noids and valves are activated as follows:
- The 4-3 sequence valve
• Solenoid S1 is switched OFF. S2 is switched OFF.
• With S1 and S2 switched OFF, the 2-3 and 3-4 shift • At the 4-3 sequence valve the CAF oil becomes
Band 1 Release Feed (B1R-F) oil, and is directed
valves are held in the third gear position by line
through the 3-4 shift valve to the spring end of the
500 pressure.
4-3 sequence valve, and to the release side of the
• The 1-2 shift valve is held in the third gear position front servo piston to hold band 1 OFF.
by S1-S2 oil pressure.
• Drive (line pressure) is routed through the 3-4 shift
• 2nd oil (line pressure) from the 1-2 shift valve is di- valve to apply the C4 clutch.
rected to the band apply feed regulator valve and
to the 2-3 shift valve.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Drive 3 and Manual 3 X X - X - - - X -

KAA5A420

SSANGYONG Y200
5A-32 AUTOMATIC TRANSMISSION
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 • When S7 is switched ON, S7 feed oil to the converter
Lock Up clutch control valve is switched OFF and allowed
to exhaust through the S7 solenoid. This allows the
In Drive 3 Lock Up and Manual 3 Lock Up, transmission valve to move to the clutch engage position.
drive is the same as for Drive 3 but with the application
of the converter lock up clutch to provide positive no- • Regulated apply feed oil, drive oil at the converter
clutch regulator valve, is directed by the converter
slip converter drive.
clutch control valve to the engage side of the
Control converter clutch.
Control for Drive 3 Lock Up and Manual 3 Lock Up is • Converter clutch release oil is exhausted at the con-
the same as for Drive 3 with the addition of the verter clutch control valve.
converter clutch circuit activated by solenoid S7.
• Converter feed oil is re-routed by the converter clutch
control valve directly to the oil cooler and lubrication
circuit.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Drive 3 Lock Up and Manual 3 X X - X - - - X X
Lock Up

KAA5A440

SSANGYONG Y200
5A-34 AUTOMATIC TRANSMISSION
DRIVE 4 (OVERDRIVE)

KAA5A45A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-35

Power Flow - Drive 4 (Overdrive) • The 1-2 shift valve is held in the fourth gear position
by S2 oil pressure.
In Drive 4 (Overdrive), transmission drive is via the
input shaft to the forward clutch cylinder. • 2nd oil (line pressure) from the 1-2 shift valve is di-
rected to the band apply feed regulator valve, and
The elements of the transmission function as follows;
to the 2-3 shift valve.
• The C1 clutch is applied to drive the planet carrier
clockwise. • The band apply feed regulator valve supplies 2nd
oil (regulated to line pressure multiplied by the valve
• The B1 band is applied to hold the reverse sun gear ra-tio) to the Band Apply Feed (BAF) circuit.
stationary.
• Band apply feed oil is directed to;
• As the planet carrier tuns, the long pinion walks - the outer apply area of the front servo
around the stationary reverse sun gear and rotates
around its axis driving the internal ring gear and - the inner apply area of the front servo piston via
output shaft in a clockwise or forward direction at a the 3-4 shift valve
speed faster than the input shaft i.e. in overdrive - the 1-2 shift valve to provide an exhaust port
ratio. when the transmission is shifted to first gear
• The forward sun gear is also driven faster than the • 2nd oil at the 2-3 shift valve is directed to the 3rd
input shaft and overruns the 3-4 OWC. oil circuit.
• The C2 clutch is engaged to reduce the speed differ- • 3rd oil from the 2-3 shift valve is directed to the
ential across the 3-4 OWC. clutch apply regulator valve, and to the 4-3
sequence valve.
Control
To maintain this arrangement in the steady state sole- • The clutch apply regulator valve supplies oil (regu-
noids and valves are activated as follows; lated to line 500 pressure multiplied by the valve
ratio) to the Clutch Apply Feed (CAF) circuit.
• Solenoid S1 is switched ON. S2 is switched OFF.
• The CAF oil is directed to;
• With S1 switched ON, the 3-4 shift valve is held in
- the C1 clutch
the fourth gear position by line 500 pressure on the
small end of the valve. - the 4-3 sequence valve
• With S2 switched OFF, the 2-3 shift valve is held in • Drive oil (line pressure) from the manual valve en-
the fourth gear position by line 500 pressure on the gages the C2 clutch.
large end of the valve.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Drive 4 Overdrive X X - - X - - - -

KAA5A460

SSANGYONG Y200
5A-36 AUTOMATIC TRANSMISSION
DRIVE 4 LOCK UP

KAA5A47A

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-37

Power Flow - Drive 4 Lock Up • Regulated apply feed oil, drived from drive oil at
the converter clutch regulator valve, is directed by
In Drive 4 Lock Up, transmission drive is the same as
the converter clutch control valve to the engage side
for Drive 4 but with the application of the converter
of the converter clutch.
lock up clutch to provide positive no-slip converter
drive. • Converter clutch release oil is exhausted at the con-
verter clutch control valve.
Control
• Converter feed oil is re-routed by the converter clutch
To maintain this arrangement in the steady state sole- control valve directly to the oil cooler and lubrication
noids and valves are activated as follows; circuit.
• 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.

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Drive 4 Lock Up X X - - X - - - -

KAA5A480

SSANGYONG Y200
5A-38 AUTOMATIC TRANSMISSION

DIAGNOSTIC INFORMATION AND PROCEDURES

Refer to the appropriate “Diagnostic Trouble Code
DIAGNOSIS (DTC)” information and repair the vehicle as
directed. After repairing the vehicle, perform the
BASIC KNOWLEDGE REQUIRED road test and verify that the code has not set again.
You must be familliar with some basic electronics to • Perform the Electrical/Garage Shift Tests.
use this section of the Service Manual. They will help
you to follow diagnostic procedures. • Perform the Road Test Procedure in this section.

Notice: Lack of the basic knowledge of this transmis-

• Inspect the oil and check for metal or other contami-
nants in the oil pan.
sion when performing diagnostic procedures could re-
sult in incorrect diagnostic performance or damage to TRANSMISSION FLUID LEVEL
transmission components. Do not, under any circum-
stances, attempt to diagnose a transmission problem
SERVICE PROCEDURE
without this basic knowledge. This procedure is to be used when checking a concern
Notice: If a wire is probed with a sharp instrument with the fluid level in a vehicle. A low fluid level will
and not properly sealed afterward, the wire will corrode result in slipping and loss of drive/ reverse or delay
and an open circuit will result. on engagement of drive/ reverse when the vehicle is
cold.
Diagnostic test probes are now available that allow
The vehicle is first checked for transmission diagnostic
you to probe individual wires without leaving the wire
open to the environment. These probe devices are messages on the scan tool. If the oil level is low, it is
inexpensive and easy to install, and they permanently possible to register a vehicle speed signal fault.
seal the wire from corrosion. The vehicle is to be test driven to determine if there is
an abnormal delay when selecting drive or reverse, or
Special Tools loss of drive. One symptom of low fluid level is a
You should be able to use a Digital Volt Meter (DVM), momentary loss of drive when driving the vehicle around
a circuit tester, jumper wires or leads and a line a corner. Also when the transmission fluid level is low,
pressure gauge set. The functional check procedure a loss of drive may occur when the transmission fluid
is designed to verify the correct operation of electronic temperature is low.
components in the transmission. This will eliminate the If there is no loss of drive when the vehicle is driven
unnecessary removal of transmission components. warm and a vehicle speed signal fault is registered,
then fluid should be added to the transmission.
FUNCTIONAL CHECK
When adding or changing transmission fluid use only
PROCEDURE Castrol TQ 95 automatic transmission fluid. The use of
Begin with the Functional Check Procedure which pro- incorrect fluid will cause the performance and durability
vides a general outline of how to diagnose automatic of the transmission to be severely degraded.
transmission. The following functional check procedure Fluid Level Diagnosis procedure
will indicate the proper path of diagnosing the transmis-
sion by describing the basic checks and then referenc- 1. If the vehicle is at operating temperature allow the
ing the locations of the specific checks. vehicle to cool down for two hours, but no greater
than four hours. Or if the vehicle is at cool status,
• Check the fluid level according to the Fluid Level start the engine and allow the engine to idle for
Service Procedure.
approximately 5 minutes or, if possible, drive the
• Check the transmission fluid leak. vehicle for a few kilometers. This will allow the
• Check if the transmission fluid is not burnt by smell. transmission to be within the correct temperature
Notice: The specific fluid used in this transmission range. Transmission fluid level should be checked
turns brown during normal operation. Brown fluid at temperature 50 - 60 °C (82 - 140 ° F).
does not indicate a transmission fault.
Caution: Removal of the fluid filler plug when the
• Ensure that the transmission is not in Limp Home transmission fluid is hot may cause injury if fluid
Mode (LHM). drains from the filler hole.
• Check the battery terminals and the earth connec-
tions for corrosion or looseness. 2. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
• Check that the cooler flow is not restricted. few seconds in each range. Return the gear shift
• Check all electrical plug connections for tightness. control lever to P (Park). Turn the engine OFF.
• Use on-board diagnostic tool or a scan tool to see
if any transmission trouble codes have been set.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-39

3. Park the vehicle on a hoist, inspection pit or similar ranges, pausing a few seconds in each range and
raised level surface. The vehicle must be control adding the fluid until gear application is felt.
level to obtain a correct fluid level measurement. Then add an additional 0.5 litres of fluid. Return
4. Place a fluid container below the fluid filler plug. the gear shift lever to P (Park). Turn the engine OFF
5. Clean all dirt from around the fluid filler plug. and raise the vehicle. Install the fluid filler plug and
Remove the fluid filler plug. Clean the filler plug tighten it to 33 N•m (24 lb-ft).
and check that there is no damage to the ‘O’ ring. 5. Drive the vehicle at 3.5 to 4.5 kilometers with light
• If fluid drains through the filler hole the transmis- throttle so that the engine does not exceed 2500
sion may have been overfilled. When the fluid rpm.
stops draining the fluid level is correct. Install This should result in the transmission temperature
the fluid filler plug and tighten it to 33 N•m (24 being in the range 50 - 60 °C (82 - 140 °F). With the
lb-ft). brake applied, move the shift lever through the gear
• If fluid does not drain through the filler hole, the ranges, pausing a few seconds in each range at
transmission fluid level may be low. Install the the engine idling.
filler pump into the filler hole. Lower the vehicle 6. Return the gear shift lever to P (Park).
with the filler pump still connected and partially Turn the en-gine OFF and raise the vehicle on the
fill the fluid through the filler hole. hoist, if applicable, ensuring the vehicle is level.
Start the vehicle in P (Park) with the parking When the three minutes passed after the engine
brake and the brake applied. With the engine stopped, remove the filler plug.
idling, move the gear shift. control lever through Check if the fluid level is aligned with the bottom of
the gear ranges, pausing a few seconds in each the filler hole. If not, add a small quantity of fluid to
range and adding the fluid until gear application the correct level. Install the fluid filler plug and
is felt. tighten it to 33 N•m (24 lb-ft).
Return the gear shift lever to P (Park). 7. Wipe any fluid around the filler plug with a rag or
Turn the engine OFF and raise the vehicle. When shop towel.
the three minutes passed after the engine
stopped, remove the filler pump. FLUID LEAK DIAGNOSIS AND
Check if the fluid level is aligned with the bottom REPAIR
of the filler hole. If not, add a small quantity of
The cause of most external leaks can generally be lo-
fluid to the correct level. Install the fluid filler
cated and repaired with the transmission in the vehicle.
plug and tighten it to 33 N•m (24 lb-ft).
•If fluid does not drain through the filler hole al- Methods for Locating Leaks
though adding a total of 1.5 liters, the General Method
transmission should be inspected for fluid leaks 1. Verify that the leak is transmission fluid.
and any leaks should be fixed before setting
the transmission fluid level. 2. Thoroughly clean the suspected leak area.
6. When the fluid level checking procedure is com- 3. Drive the vehicle for approximately 25 km (15 miles)
pleted, wipe any fluid around the filler plug with a or until the transmission reaches normal operating
rag or shop towel. temperature (88 °C, 190 °F).
4. Park the vehicle over clean paper or cardboard.
Fluid Level Set After Service
5. Turn the engine OFF and look for fluid spots on the
1. Depending on the service procedure performed, paper.
add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level: 6. Make the necessary repairs to correct the leak.
Converter empty 8.0 liters (8.5 quarts) Powder Method
Converter full 3.8 liters (4.0 quarts) 1. Thoroughly clean the suspected leak area.
2. Follow steps 1 through 4 of the Fluid Level 2. Apply an aerosol type powder (foot powder) to the
Diagnosis Procedure. suspected leak area.
3. Clean all dirt from around the fluid filler plug. 3. Drive the vehicle for approximately 25 km (15 miles)
Remove the fluid filler plug. Clean the filler plug or until the transmission reaches normal operating
and check that there is no damage to the ‘O’ ring. temperature (88 °C, 190 °F).
4. Lower the vehicle with the filler pump still connected 4. Turn the engine OFF.
and start the vehicle in P (Park) with the parking 5. Inspect the suspected leak area and trace the leak
brake and the brake applied. With the engine idling, path through the powder to find the source of the
move the gear shift control lever through the gear leak.

SSANGYONG Y200
5A-40 AUTOMATIC TRANSMISSION

6. Make the necessary repairs. • THROTTLE POSITION

Dye and Black Light Method • ACCEL. PEDAL POSITION
1. Add dye to the transmission through the • TRANSMISSION GEAR STATE
transmission fluid filler plug. Follow the • GEAR SHIFT LEVER POSITION
manufacturer’s recommen-dation for the amount of • TRANSMISSION FLUID TEMPERATURE
dye to be used.
• CLOSED THROTTLE POSITION LEARN
2. Use the black light to find the fluid leak.
• OPEN THROTTLE POSITION LEARNT
3. Make the necessary repairs.
• CLOSED ACCEL. PEDAL POSITION LEARNT
Repairing the Fluid Leak • OPEN ACCEL. PEDAL POSITION LEARNT
Once the leak point is found the source of the leak • A/C COMPRESSOR STATUS
must be determined. The following list describes the
potential causes for the leak:
• KICKDOWN SWITCH STATUS
• 4WD STATUS
• Fasteners are not torqued to specification.
• MODE SWITCH
• Fastener threads and fastener holes are dirty or
corroded. • THROTTLE POSITION VOLTAGE

• Gaskets, seals or sleeves are misaligned, damaged • GEAR SHIFT LEVER POSITION VOLTAGE
or worn. • TRANS. FLUID TEMPERATURE VOLTAGE
• Damaged, warped or scratched seal bore or gasket • A/C SWITCH
surface. • KICKDOWN SWITCH VOLTAGE
• Loose or worn bearing causing excess seal or sleeve • 4WD LAMP LOW VOLTAGE
wear.
• 4WD LAMP HIGH VOLTAGE
• Case or component porosity.
• MODE SWITCH VOLTAGE
• Fluid level is too high.
• BATTERY VOLTAGE
• Plugged vent or damaged vent tube. 6. Monitor the A/C COMPRESSOR STATUS signal
• Water or coolant in fluid. while pushing the A/C switch.
• Fluid drain back holes plugged. • The A/C COMPRESSOR STATUS should come
ON when the A/C switch is pressed, and turn
ELECTRICAL / GARAGE SHIFT OFF when the A/C switch is repushed.
TEST 7. Monitor the GEAR SHIFT LEVER POSITION signal
This preliminary test should be performed before a hoist and move the gear shift control lever through all
or road test to make sure electronic control inputs are the ranges.
connected and operating. If the inputs are not checked • Verify that the GEAR SHIFT LEVER POSITION
before operating the transmission, a simple electrical value matches the gear range indicated on the
condition could be misdiagnosed as a major instrument panel or console.
transmission condition. • Gear selections should be immediate and not
A scan tool provides valuable information and must harsh.
be used on the automatic transmission for accurate 8. Move gear shift control lever to neutral and monitor
diagnosis. the THROTTLE POSITION signal while increasing
1. Move gear shift control lever to P (Park) and set and decreasing engine speed with the accelerator
the parking brake. pedal.
2. Connect scan tool to Data Link Connector (DLC) • THROTTLE POSITION should increase with en-
terminal. gine speed.
3. Start engine.
ROAD TEST PROCEDURE
4. Turn the scan tool ON.
5. Verify that the appropriate signals are present. • Perform the road test using a scan tool.
These signals may include: • This test should be performed when traffic and road
conditions permit.
• ENGINE SPEED
• Observe all traffic regulations.
• VEHICLE SPEED

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-41

ELECTRONIC ADJUSTMENTS Throttle Position Calibration

Should the throttle position data stored in the TCU be
Idle Speed Adjustments
lost or be out of specification, as indicated by a
Carry out the adjustments to the idle speed as detailed diagnostic trouble message, it may be re-established
in the workshop manual. by the following procedure.
Vehicle Coding • Check that the hot engine idle speed is within
The vehicle coding is integrated as part of the specfication.
diagnostic software. A scan tool has the function to • Allow the engine to idle in 'Drive' for 60 seconds
code the ve-hicle through the K-line. with the air conditioner (if fitted) turned off. The
closed throttle reference point in the TCU has now
Throttle Clearing been set.
The leant throttle clearing routine uses the mode switch
and gear lever. Carry out the following steps to
• Switch the engine off but leave the ignition on. Hold
the accelerator pedal on the floor for 60 seconds.
complete the automated throttle clearing procedure: The wide open throttle reference point in the TCU
1. Switch ignition 'ON' with handbrake applied and has now been set.
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
5A-42 AUTOMATIC TRANSMISSION

SYMPTOM DIAGNOSIS
DRIVE FAULTS

Condition Possible Causes Action

No Drive in D • Insufficient auto transmission • Check the fluid level. Top up as
fluid. necessary.
• Blocked feed in C1/C2 cylinder. • Inspect and clean C1/C2 feed.
• ‘Z’ link displaced. • Reinstall/renew the ‘z’ link.
• Primary Regulator Valve (PRV) • Remove, clean and re-install the
jammed open. PRV.
• Overdrive shaft or input shaft • Inspect and replace as necessary.
seal rings failed.
• 3-4 or 1-2 One Way Clutch • Inspect and replace as necessary.
(OWC) installed backwards or
failed.
• C2 piston broken or cracked. • Inspect and replace as necessary.
No Drive in Reverse • Rear band or servo faulty. • Check servo adjustment or
No engine braking in Manual 1 replace rear band as necessary.
Engine braking in Manual 1 is OK • Failure in C3, C3 hub or C1/C2 • Check for failure in C3, C3 hub
cylinder. or C1/C2 cylinder. Repair as
necessary.
• Damaged input shaft sealing rings. • Inspect and replace as necessary.
No drive in Drive and Reverse • Jammed Primary Regulator • Inspect and clean PRV.
Valve (PRV).
• Damaged/broken pump gears. • Inspect and replace pump
gears as necessary.
• Dislodged output shaft snap ring. • Inspect and repair as necessary.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-43

FAULTY SHIFT PATTERN

Condition Possible Causes Action

2-3 shift only (no 4th or 1st) • S1 always OFF. • Inspect S1. Repair or replace as
necessary.
• Check for 12 Volts applied to S1
at all times or for wiring fault.
1-4 shift only1-3-4 • S1 always ON. • Inspect S1. Repair or replace as
(Delayed 1-2 shift) necessary.
• Check for 12 Volts applied to S1
at all times or for wiring fault.
4-3 shift only • S2 always OFF. • Inspect S2. Repair or replace as
necessary.
• Check for open circuit or wiring
fault.
1-2-Neutral (1st over run) • S2 always ON. • Inspect S2. Repair or replace as
necessary.
• Check for open circuit or wiring
fault.
1-3 shift only • B1 failed. • Inspect and repair as necessary.
• Loose band adjustment. • Inspect and adjust as necessary.
• Front servo piston or seal failed. • Inspect and repair as necessary.
• S1/S2 ball misplaced, • Inspect and replace or refit as
necessary
1-3-4 only • Smaller ‘O’ ring on front servo • Inspect ‘O’ ring. Refit or replace
piston failed or missing. as necessary.
• 2-3 shift valve jammed. • Inspect the 2-3 shift valve.
Repair or replace as necessary.
1-2-1 only • C1 clutch failed or slipping in 3rd • Inspect C1 clutch. Repair or
and 4th. (Gives 1st in 3rd and replace as necessary.
2nd in 4th.)
No manual 4-3, 3-2 or 2-1 • Over-run Clutch (OC) /low ball • Inspect ball. Refit or replace as
misplaced. necessary.
No manual 1st • Rear band slipping when hot. • Inspect rear band adjustment.
Adjust as necessary.
• Reverse/Low-1st ball misplaced. • Inspect ball. Refit or replace as
necessary.
• Rear servo inner ‘O’ ring • Inspect ‘O’ ring. Refit or replace
missing. as necessary.
1st gear only or 2nd,3rd, and 4th • 1-2 shift valve jammed. • Inspect the 1-2 shift valve.
only Repair or replace as necessary.
1st and 2nd only or 1st, 3rd and • 2-3 shift valve jammed. • Inspect the 2-3 shift valve.
4th only Repair or replace as necessary.
1st, 2nd and 4th only or 1st, 2nd, • Inhibitor switch fault, 1-2-3 only. • Inspect inhibitor switch. Repair
and 3rd (tied up in 3rd) or replace as necessary.
• 3-4 shift valve jammed. • Inspect the 3-4 shift valve.
Repair or replace as necessary.

SSANGYONG Y200
5A-44 AUTOMATIC TRANSMISSION

Condition Possible Causes Action

Harsh 2-3 shift • Jammed band 1 release valve. • Inspect the release valve.
Repair or replace as necessary.
• Faulty S3 or S2 solenoid. • Inspect S3 or S2. Repair or
replace as necessary.
• Faulty clutch apply regulator • Inspect the regulator valve.
valve. Repair or replace as necessary.
• Missing or damaged clutch • Inspect the ball. Refit or replace
apply feed ball. as necessary.
• Damaged input shaft sealing • Inspect the sealing rings. Refit
rings. or replace as necessary.
• Damaged C1 piston ‘O’ rings. • Inspect the ‘O’ rings. Refit or
replace as necessary.
• Damaged or dislodged C1 • Inspect the bleed ball. Refit or
piston bleedball. replace as necessary.
Harsh 3-4 shift • Faulty S1 or S4 solenoid. • Inspect S1 or S4. Repair or
replace as necessary.
• Jammed band 1 release valve. • Inspect the release valve.
Repair or replace as necessary.
• Incorrect front band adjustment. • Inspect the band. Adjust as
necessary.
• Damaged front servo piston ‘O’ • Inspect the ‘O’ rings. Refit or
rings. replace as necessary.
• Faulty or damaged variable • Inspect S5. Repair or replace as
pressure solenoid (S5). necessary.
• Faulty band apply regulator • Inspect the regulator valve.
valve. Repair or replace as necessary.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-45

SHIFT QUALITY FAULTS

Condition Possible Causes Action

All Shifts Firm • Incorrect auto transmission fluid • Drain and fill with specified ATF.
(ATF).
• S5 faulty won, or incorrectly • Check that S5 is fitted correctly,
fitted. or replace S5.
• Band apply and clutch apply • Inspect band apply and clutch
regulator springs misplaced. apply regulator springs. Refit or
replace as necessary
Manual 4-3-2-1 is soft delayed or • Over-run Clutch (OC) /Low-1st • Inspect the ball. Refit or replace
missing ball misplaced. as necessary.
• C4 clutch worn or burnt. • Inspect C4 clutch. Replace or
repair as necessary.
• C4 wave plate not lined up with • Check the alignment. Realign as
the holes in the piston. necessary.
Firm 1-2 Hot • S5 worn. • Inspect S5 and replace as
necessary.
4th Tied up • Incorrect C4 pack clearance. • Check the clearance and adjust
as necessary.
• Damaged C4 clutch. • Inspect C4. Repair or replace as
necessary.
• Cracked C2 piston (leaking into • Inspect piston. Repair or
C4). replace as necessary.
Tied up on 2-3 • Incorrect band adjustment • Inspect and adjust band as
necessary.
• Front servo plastic plug missing • Replace the plug.
• B1R spring broken. • Replace the spring.
Flare on 2-3 • B1R spring/plug left out. • Replace the spring/plug.
• C1/B1R ball misplaced. • Refit the ball.
• C1 clutch damaged. • Inspect the clutch. Repair the
clutch as necessary.
• Restriction in C1 feed. • Inspect and clean C1 feed.
• C1 piston check ball jammed. • Replace the piston.
• Overdrive or input shaft sealing • Inspect and replace the sealing
rings damaged. rings and/or shaft as necessary.
Slips in 4th • C1/B1R ball misplaced. • Inspect and replace the ball.
• Overdrive or input shaft sealing • Inspect and replace the sealing
rings damaged. rings and/or shaft as necessary.
• C1 clutch damaged. • Inspect and repair the C1 clutch
as necessary.
Slips in reverse, no manual 1st • Rear band incorrectly adjusted • Inspect and adjust or replace
or damage rear band.
• Low-1st check ball misplaced. • Inspect and re-fit the ball.
Flare on 4-3, Flare on 3-2 • 4-3 sequence valve in backwards. • Refit the valve.
Firm Manual low shift-high line • Low-1st check ball misplaced. • Replace the ball.
press.

SSANGYONG Y200
5A-46 AUTOMATIC TRANSMISSION

Condition Possible Causes Action

Harsh 1-2 shift • Faulty inhibitor switch. • Check the resistance. Replace
the inhibitor switch as necessary.
• Faulty throttle position sensor. • Inspect and replace the sensor
as necessary.
• Incorrect front band adjustment. • Inspect and adjust the band as
necessary.
• Damaged front servo piston ‘O’ • Inspect and replace the ‘O’
rings. rings as necessary.
• Faulty or damaged variable • Inspect, repair or replace S5 as
pressure solenoid (S5). necessary.
• Faulty S1 or S4 solenoid. • Inspect, repair or replace S1 or
S4 as necessary.
• Faulty Band Apply Regulator • Inspect, repair or replace the
(BAR) valve. BAR as necessary.
• Misassembled front servo return • Inspect and repair as necessary.
spring.
Stalls when Drive Or Reverse • Jammed Converter Clutch • Inspect and clean CCCV.
Control Valve (CCCV).
Selected Shudder on Rolldown • Faulty solenoid 7. • Inspect, repair or replace as
necessary.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-47

AFTER TEARDOWN FAULTS

Condition Possible Causes Action

C2 burnt • Gear shift lever linkage out of • Inspect, repair C2 and adjust
adjustment. the linkage as necessary.
• S6 foiled - stuck low. • Repair C2. Inspect, repair or
replace S6 as necessary.
• Overdrive/output shaft sealing • Repair C2. Inspect, replace the
rings damaged. sealing rings and/or shaft as
necessary.
• C2 piston cracked. • Repair C2. Inspect, repair or
replace the C2 piston as
necessary.
C4 burnt • Incorrect C4 pack clearance. • Inspect C4 and repair as
necessary.
• Inspect and adjust the C4 pack
clearance as necessary.
• C4 wave plate not lined up • Repair C4. Inspect and realign
properly. the wave plate as necessary.
• Overdrive or output shaft sealing • Repair C4. Inspect and realign
rings damaged. the sealing rings and/or shaft as
necessary.
• C2 piston cracked. • Repair C4. Inspect and replace
the C2 piston as necessary.
• Over-run Clutch (OC) /low-1st • Repair C4. Inspect and refit the
ball misplaced. ball as necessary.
B1 burnt • B1R spring broken. • Inspect and repair B1 and
replace the spring as necessary.
• Input shaft sealing ring cut. • Replace sealing ring.
• C1/B1R ball misplaced. • Repair B1. Refit the ball as
necessary.
C1 burnt • B1R spring left out. • Inspect and repair C1 and
replace the spring.
• Overdrive or input shaft sealing • Repair C1. Inspect and replace
rings damaged. the sealing tongs and/or shaft
as necessary.
• C1 piston cracked. • Repair C1. Inspect and replace
the C1 piston as necessary.
• Ball capsule jammed. • Repair C1. Inspect and refit the
capsule as necessary.
• 4-3 sequence valve in backwards. • Repair C1. Inspect and refit the
valve as necessary.
• Clutch Apply Feed (CAF) /B1R • Repair C1. Inspect and replace
ball left out. the ball as necessary.
B2 burnt • Rear band incorrectly adjusted • Inspect and adjust the band as
(Slips in reverse - no manual 1st ) or damaged. necessary.
• Reverse-low/first ball misplaced. • Inspect and refit the ball as
necessary.

SSANGYONG Y200
5A-48 AUTOMATIC TRANSMISSION

Condition Possible Causes Action

Firm converter lock or unlock • Input shaft 'O' ring missing or • Inspect and replace the 'O' ring
damaged. as necessary.
• Converter clutch regulator valve • Inspect and refit the valve as
in backwards. necessary.
No lock up at light throttle • Input shaft 'O' ring missing or • Inspect and replace the 'O' ring
damaged. as necessary.
• C1 bias valve in backwards. • Inspect and refit the valve as
necessary.

SSANGYONG Y200
5A-50 AUTOMATIC TRANSMISSION

TROUBLE CODE DIAGNOSIS - GASOLINE VEHICLE

TCM DIAGNOSTIC SYSTEM to the EOBD scan tool to pass on any EOBD relevant
codes from the TCM. The table below contains a list of
OVERVIEW all supported DTCs and the classification of each for
Notice: To prevent Transmission Control Module (TCM) EOBD purposes. Where a type B DTC has been set in
damage. The ignition key must be OFF when an EOBD vehicle, the response to the fault may include
disconnection or reconnection the power to the TCM action by the ECM, including the illumination of the
(for example bttery cable, TCM pigtail connector, TCM Malfunction lndicator Lamp (MIL). Refer to Section 1F,
fuse, jumper cables, etc.). Engine Control, for details on EOBD system function,
When the TCM detects a system fault, a Diagnostic checks and fault clearing.
Trouble Code (DTC) is set in the TCM. This code is
present while the fault conditions are met and is stored CLEARING TROUBLE CODES
as a 'History DTC' until cleared. Condition for setting TCM DTCs should be cleared after repairs have been
and clearing each TCM DTC are provided in the relevant completed. Some diagnostic tables will tell you to clear
sections. the codes before using the chart, which will help to
In the case where the vehicle type is certified for Eure find the cause of the problem more quickly. Always
On-Board Diagnostic (EOBD) compliance, the Engine note the DTCs present before clearing - this information
Control Module (ECM) provides the communication link may be helpful in the diagnostic process."

DIAGNOSTIC TROUBLE CODES

DTC Description Type

P0706 Transmission Range Sensor Circuit Range/Performance B

P0707 Transmission Range Sensor Circuit Low input B
P0708 Transmission Range Sensor Circuit High input B
P0710 Transmission Fluid Temperature Sensor Circuit Malfunction D
P0790 Normal/Performance Switch Circuit Malfunction D
P1703 Engine Speed Signal Error D
P1704 Shaft Speed Signal Error D
P1708 TCM Supply Voltage Low D
P1709 TCM Supply Voltage High D
P1712 Kickdown Switch Circuit Malfunction D
P1713 Pedal Signal Error D
P1714 EEPROM Vehicle Code Error D
P1715 VPS Offset Error D
P1717 RAM Error D
P1718 ROM Error D
P1719 CAN Bus Error D
P1720 EEPROM Error D
P1721 Throttle Signal Error D
P1722 Vehicle Type Determination Error D
P1733 Solenoid 1 Circuit Open D
P1734 Solenoid 2 Circuit Open D
P1735 Solenoid 3 Circuit Open D
P1736 Solenoid 4 Circuit Open D
P1737 Solenoid 5 Circuit Open D

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-51

DIAGNOSTIC TROUBLE CODES (Cont'd)

DTC Description Type

P1738 Solenoid 6 Circuit Open D

P1739 Solenoid 7 Circuit Open D
P1741 Solenoid 1 Circuit Short D
P1742 Solenoid 2 Circuit Short D
P1743 Solenoid 3 Circuit Short D
P1744 Solenoid 4 Circuit Short D
P1745 Solenoid 5 Circuit Short D
P1746 Solenoid 6 Circuit Short D
P1747 Solenoid 7 Circuit Short D

DTC Types • TCM stores a history DTC on the first driving cycle
with a fail.
Each DTC is directly related to a diagnostic test. The
Diagnostic management system sets DTCs based on • EOBD system stores a history DTC on the second
the failure of the tests during a driving cycle or cycles. consecutive driving cycle with a fail, (the DTC will
The following are the two types of DTCs and the charac- be armed after the first fail).
teristics of those codes; • EOBD system stores a freeze frame on the second
Type B consecutive driving cycle with a fail, (if empty).

• Emissions related. Type D

• EOBD system "Armed" after one driving cycle with • Non-Emissions related.
a fail. • Does not request illumination of any lamp.
• EOBD system "Disarmed" after one driving cycle • Stores a history DTC on the first driving cycle with
with a pass. a fail.
• Illuminates the MIL on the second con-secutive • EOBD system does not store a freeze frame.
driving cycle with a fail.

SSANGYONG Y200
5A-52 AUTOMATIC TRANSMISSION

TROUBLE CODE DIAGNOSIS - DIESEL VEHICLE

TCM DIAGNOSTIC SYSTEM as a 'History DTC' until cleared. Condition for setting
and clearing each TCM DTC are provided in the relevant
OVERVIEW sections.
Notice: To prevent Transmission Control Module (TCM)
damage. The ignition key must be OFF when CLEARING TROUBLE CODES
disconnection or reconnection the power to the TCM TCM DTCs should be cleared after repairs have been
(for example bttery cable, TCM pigtail connector, TCM completed. Some diagnostic tables will tell you to clear
fuse, jumper cables, etc.). the codes before using the chart, which will help to
When the TCM detects a system fault, a Diagnostic find the cause of the problem more quickly. Always
Trouble Code (DTC) is set in the TCM. This code is note the DTCs present before clearing - this information
present while the fault conditions are met and is stored may be helpful in the diagnostic process."

DIAGNOSTIC TROUBLE CODES

DTC Description

P0707 Transmission Range Sensor Circuit Low Input

P0708 Transmission Range Sensor Circuit High Input
P0710 Transmission Fluid Temperature Sensor Circuit Malfunction
P0790 Normal/Performance Switch Circuit Malfunction
P1703 Engine Speed Signal Error
P1704 Shaft Speed Signal Error
P1708 TCM Supply Voltage Low
P1709 TCM Supply Voltage High
P1710 Air Conditioning Switch Circuit Malfunction
P1712 Kickdown Switch Circuit Malfunction
P1714 EEPROM Vehicle Code Error
P1715 VPS Offset Error
P1716 Throttle Not Learnt Error
P1717 RAM Error
P1718 ROM Error
P1720 EEPROM Error
P1721 Throttle Signal Error
P1722 Vehicle Type Determination Error
P1733 Solenoid 1 Circuit Open
P1734 Solenoid 2 Circuit Open
P1735 Solenoid 3 Circuit Open
P1736 Solenoid 4 Circuit Open
P1737 Solenoid 5 Circuit Open
P1738 Solenoid 6 Circuit Open
P1739 Solenoid 7 Circuit Open
P1741 Solenoid 1 Circuit Short
P1742 Solenoid 2 Circuit Short
P1743 Solenoid 3 Circuit Short
P1744 Solenoid 4 Circuit Short

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-53

DIAGNOSTIC TROUBLE CODES (Cont'd)

DTC Description

P1745 Solenoid 5 Circuit Short

P1746 Solenoid 6 Circuit Short
P1747 Solenoid 7 Circuit Short

SSANGYONG Y200
5A-54 AUTOMATIC TRANSMISSION

YAD5A010

TCM DIAGNOSTIC SYSTEM CHECK

Circuit Description Diagnostic Aids
The Transmission Control Module (TCM) Diagnistic An intermittent fault may be caused by a poor connec-
System Check is the starting point for any driveability tion, rubbed-through wire insulation or a wire broken
complaint diagnosis. Before using this procedure, inside the insulation. Check for poor connections or a
perform a careful visual/ physical check of the damaged harness. Inspect the TCM harness and con-
Transmission Control Module (TCM) and the nections for improper mating, broken locks, improperly
transmission grounds for cleanliness and tightness. formed or damaged terminals, poor terminal-to-wire
The TCM Diagnostic System Check is an organized connection, and damaged harness.
approach to identifying a problem created by an
electronic transmission control system malfunction.

TCM Diagnostic System Check

Step Action Value(s) Yes No

1 Turn the ignition OFF.
2. Install the scan tool.
3. Turn the ignition ON, with the engine OFF.
1
4. Attempt to display the Transmission Control
Module (TCM) Data List with the scan tool.
Does the scan tool display the TCM data? - Go to Step 2 Go to Step 3
Select the Trouble Code with the scan tool.
Are any Diagnostic Trouble Codes (DTCs) stored? Go to System OK,
2 applicable Check
- DTC table Complete

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-55

TCM Diagnostic System Check (Cont'd)

Step Action Value(s) Yes No

1. Turn the ignition OFF.
2. Disconnect the TCM connector B.
3. Turn the ignition ON.
4. Check the serial data line from TCM connector
terminal A22 to Data Link Connector (DLC)
3 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? - Go to Step 4 Go to Step 5
Repair the open, short to ground or short to voltage in
the serial data circuit or the DLC ignition feed circuit
4 or the DLC ground circuit.
Is a repair complete? - Go to Step 1 -
Check the TCM ignition feed circuit for an open or
5 short to ground and the TCM ground circuit for an
open. - Go to Step 6 Go to Step 7
Is a problem found?
6 Repair the open or short to ground in the TCM ignition
feed circuit or the TCM ground circuit. - Go to Step 1 -
Is a repair complete?
7 1. Turn the ignition OFF.
2. Disconnect the TCM connector. - Go to Step 1 -

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-159

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
TRANSMISSION
Removal and Installation Procedure
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 N•m (52-59 lb-ft)

YAD5A090

6. Remove the cross member bolts and nuts.

Installation Notice
Tightening Torque 70-80 N•m (52-59 lb-ft)

YAD5A100

SSANGYONG Y200
5A-160 AUTOMATIC TRANSMISSION

7. Remove the front propeller shaft bolts from transfer

case.
Installation Notice
Tightening Torque 70-80 N•m (52-59 lb-ft)

YAD5A110

8. Remove the transfer case-to-transmission housing

bolts and remove the transfer case.
Installation Notice

Tightening Torque 44 N•m (33 lb-ft)

9. Disconnect the 10-Pins Plug connector from trans-

mission.

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 N•m (18-26 lb-ft)

YAD5A140

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-161

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 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.
14. Remover the starter. Refer to Section 1E, Engine
KAA5A2N0
Electrical.

15. Remove the extension housing to case bolts and

remove the transmission assembly.
Installation Notice

Tightening Torque 55-65 N•m (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

SSANGYONG Y200
5A-162 AUTOMATIC TRANSMISSION

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

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-163

DISASSEMBLY PROCEDURE
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
5A-164 AUTOMATIC TRANSMISSION

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
AUTOMATIC TRANSMISSION 5A-165

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
KAA5A580 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.

KAA5A590

SSANGYONG Y200
5A-166 AUTOMATIC TRANSMISSION

5. Using cross shaft pin remover/installer (detent le-

ver) 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. Remove the rear servo cover and piston assembly.

13. Remove the B1R circlip, valve and spring.
14. Remove both band adjustment shims.
15. 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
AUTOMATIC TRANSMISSION 5A-167

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 adjust-

ment shims (1) from the input shaft.
3. Remove the circlip from the front of the clutch cylin-
der 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
5A-168 AUTOMATIC TRANSMISSION

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 re-
move the clutch plates.
KAA5A720

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-169

4. Mount the clutch assembly on clutch spring com-

pressor 0555-336259 and compress the piston re-
turn 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
AUTOMATIC TRANSMISSION 5A-171

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 retain-
er 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
KAA5A820
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.

KAA5A830

SSANGYONG Y200
5A-172 AUTOMATIC TRANSMISSION

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 re-
verse 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 1-
2, 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
AUTOMATIC TRANSMISSION 5A-173

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 ’E’clip 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
5A-174 AUTOMATIC TRANSMISSION

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
AUTOMATIC TRANSMISSION 5A-175

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 N•m (35-53 lb-in)

18. Thoroughly check the terminal wiring loom for

condition and continuity.

KAA5A580

SSANGYONG Y200
5A-176 AUTOMATIC TRANSMISSION

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 N•m (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 assem-

bly 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 N•m (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 down-
wards. 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 auto-
matic 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 20-27 N•m (15-20 lb-ft)
KAA5A560

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 N•m (22-26 lb-ft)

Front Servo Assembly

1. Lubricate the cover ‘O’ ring with automatic
transmission fluid and fit to the cover.
2. Lubricatethepiston‘O’ rings with automatic trans-
mission 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
AUTOMATIC TRANSMISSION 5A-181

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
KAA5A0G0
on the outside of the cylinder, until the outer
diameter of the C2 piston enters the inner diameter
of the cylinder.

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.
KAA5A690 14. Lubricate the ‘O’ rings with ATF and fit them to
their respective grooves.
Notice: ‘O’ rings must not be twisted in the
grooves.

SSANGYONG Y200
5A-182 AUTOMATIC TRANSMISSION

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.

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
KAA5A0I0
• Steel plate
• Wave washer

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-183

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 0555-
336260 clutch pack clearance kit.

KAA5A0J0

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.
KAA5A0K0 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)
KAA5A0L0 • Steel plate (selective)
• Friction disc
• Steel plate (selective)
• Friction disc

SSANGYONG Y200
5A-184 AUTOMATIC TRANSMISSION

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.
KAA5A0M0 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.

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 anti-
clockwise 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 cylin-
der.
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 ob-
structions.
2. Check the C3 cylinder bush outside diameter and
the centre support inside diameter are in good con-
dition 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, en-
suring 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 trans-

mission 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
5A-186 AUTOMATIC TRANSMISSION

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
KAA5A0R0
12. Align and fit the pressure plate with the
counterbore facing away from the clutch plates.

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.
KAA5A0S0
e. Record this figure.
f. Subtract the second reading from the first read-
ing to obtain the clutch pack clearance.

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-187

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 auto-
matic transmission fluid for a minimum of five min-
utes 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 for-
ward 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 for-

ward 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 doesn’t
drop out of the bearing retainer.

1. Check the overdrive shaft grooves for any defect.

2. Coat the sealing rings, large and small, with petro-
leum jelly and fit them to the overdrive shaft. The
sealing rings may be held in place with a small
amount of petroleum jelly.

KAA5A0X0

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)
KAA5A0Y0
• Friction disc

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-189

4. Check the clutch pack clearance using 0555-

336260 clutch pack clearance kit.
5. Use selective plates to achieve the correct specifi-
cation.
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 auto-
matic 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.

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
KAA5A660 the groove.

12. Coat the sealing rings with petroleum jelly and fit
onto the input shaft.

KAA5A1A0

SSANGYONG Y200
5A-190 AUTOMATIC TRANSMISSION

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
AUTOMATIC TRANSMISSION 5A-191

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
5A-192 AUTOMATIC TRANSMISSION

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 N•m (10-12 lb-ft)

19. Tighten the solenoid 7 screw.

Installation Notice
KAA5A1K0
Tightening Torque 13-16 N•m (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
AUTOMATIC TRANSMISSION 5A-193

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 N•m (18-20 lb-ft)

Torque Screw (F) : 13-16 N•m (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.
KAA5A1L0

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 N•m (18-25 lb-ft)

KAA5A1M0

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 trans-
mission case with the stylus resting on the end
of the input shaft.
KAA5A1N0 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 be-
tween the No.4 bearing and the converter sup-
port 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
AUTOMATIC TRANSMISSION 5A-195

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
5A-196 AUTOMATIC TRANSMISSION

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
AUTOMATIC TRANSMISSION 5A-197

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 separa-
tor 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 N•m (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 N•m (71-106 lb-in)

• The wiring loom ground wire eyelet terminal is

secured beneath the solenoid 1 retainer.

SSANGYONG Y200
5A-198 AUTOMATIC TRANSMISSION

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 N•m (71-106 lb-in)

KAA5A1W0

22. Install the detent spring assembly (spring, support

plate and screw), ensuring that the screw is tight-
ened to specification. Check the spring for wear
or damage.
Installation Notice
Tightening Torque 20-22 N•m (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 N•m (71-115 lb-in)

KAA5A1Z0

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-199

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
5A-200 AUTOMATIC TRANSMISSION

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 trans-
mission 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 N•m (40-50 lb-ft)

• All the hardware must be correctly installed and

torqued to specification.
KAA5A2D0 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 35 N•m (26 lb-ft)

KAC5A040
KAC5A040

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-201

FRONT AND REAR BAND ADJUSTMENT

Front Band Setting Procedure

KAA5A2E0

1. Measure the projection of the front servo push rod 2. Fit the selected shim(s) to the shank of the anchor
from the transmission case dimension ’A’. strut as follows:
a. Apply air at 650/700 kPa to the front servo apply a. Inspect the shim(s) for damage, wear or corro-
area (B1 outer) sion. Replace as necessary.
b. Measure the travel of the push rod and subtract b. The shim(s) are to be installed between the case
3 mm to find the shim size required. abutment face and the anchor strut flange.
c. Release the air. c. The shim(s) are to be fitted by hand and under
no circumstances to be hammered or forced.
Notice: A minimum of one shim is required at all times
- minimum shim size is 1 mm. The thickness of d. Shim(s) are to be pressed on by hand until an
available shims are listed in the table below. audible click is heard. The click indicates that
the shim is clipped home correctly.
Thickness(mm) Part Number 3. Re-check that the push rod travel. (3mm ±0.25mm)
0.95/1.05 0574-037017
1.15/1.25 0574-037018
1.44/1.56 0574-037019
1.73/1.87 0574-037020
1.93/2.07 0574-037021
2.12/2.28 0574-037022
2.42/2.58 0574-037023
2.61/2.79 0574-037024

SSANGYONG Y200
5A-202 AUTOMATIC TRANSMISSION

Rear Band Setting Procedure

KAA5A2F0

1. Measure distance‘A’ from the rear servo piston to 2. Fit the selected shim(s) to the shank of the anchor
the inner face of the transmission case using vernier strut as follows.
calipers. a. Inspect the shim(s) for damage, wear or
a. Apply air at 650/700 kPa to the rear servo apply corrosion and replace as necessary. The shim(s)
area (B2 outer) are to be installed between the case abutment
b. Measure the travel of the piston, subtract 3.75 face and the anchor strut flange.
mm and divide the remainder by 2.5 to find shim b. The shim(s) are to be fitted by hand and under
size. no circumstances to be hammered or forced
c. Release the air. c. The shim(s) are to be pressed on by hand until
an audible click is heard. The click indicates
Notice: A minimum of one shim is required at all times
that the shim is clipped home correctly.
- minimum shim size is 1 mm. The thickness of
available shims are listed in the table below. 3. Re-check that the piston travel.
(3.75 mm ± 0.625 mm)
Thickness(mm) Part Number
0.0.95/1.05 0574-037017
1.15/1.25 0574-037018
1.44/1.56 0574-037019
1.73/1.87 0574-037020
1.93/2.07 0574-037021
2.12/2.28 0574-037022
2.42/2.58 0574-037023
2.61/2.79 0574-037024

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-203

KAA5A2G0

SSANGYONG Y200
5A-204 AUTOMATIC TRANSMISSION

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
AUTOMATIC TRANSMISSION 5A-205

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
Removal and Installation Procedure
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

4. Installation should follow the removal procedure in

the reverse order.

YAD5A180

SSANGYONG Y200
5A-206 AUTOMATIC TRANSMISSION

SPECIFICATIONS
GENERAL SPECIFICATION

Model Part Numbers And Applications

SYMC P/NO Transmission Engine Version Torque Converter

36100-05442 0574-000013 E23 179K
36100-05432 0574-000012 E32 150K
36100-05412 0574-000014 662LA 150K

Model Specifications

Application Descriprtion
Torque Converter
Mean Diameter of Fluid Circuit Description 260 mm (10.2 in.)
Maximum Torque Multiplication 2.0 : 1
Gear Ratios
First 2.741 : 1
Second 1.508 : 1
Third 1.000 : 1
Fourth 0.708 : 1
Reverse 2.429 : 1
Lubricant
Type Castrol TQ95
Capacity
Dry System 9.0 Liters (approx.)
Service Refill 4.5 Liters (approx.)
Gear Train End Float 0.50 - 0.65 mm (0.020 - 0.026 in.)
Gear Set Pinion End Float 0.10 - 0.50 mm (0.004 - 0.020 in.)

Clutch Pack Details

0574-000012 0574-000013 (14)

C1
Composition 5 4
Steel 5 6
C2
Composition 5 4
Steel 4 5
C3
Composition 4 3
Steel 4 5
C4
Composition 3 3
Steel 4 4

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-207

Model Part Numbers and Applications

E23 Gasoline Engine
THROTTLE SHIFT (km/h)
MODE
OPENING 1/2 2/3 3/4 4/3 3/2 2/1 UNL3 LCK3 UNL4 LCK4
0% 10.1 19.3 36.4 20.8 8.9 9.2 50.7 79.1 71.7 79.1
16 % 10.1 19.3 36.4 20.8 8.9 9.2 50.7 79.1 71.7 79.1
31 % 13.9 30.9 47.0 28.4 12.4 9.2 50.7 79.1 71.7 79.1
49 % 22.3 46.1 70.5 41.8 18.9 9.3 50.7 90.3 74.2 90.3
NORMAL
50 % 22.8 46.4 71.7 42 19.2 9.3 50.7 58.1 75.4 91.5
MODE
58 % 27.2 53.2 89.0 52.7 24.7 10.9 59.4 66.8 81.6 100.2
64 % 30.9 59.4 94.0 60 28.4 12.1 66.8 74.2 86.6 106.4
71 % 34.1 66.5 103.3 69.3 32.6 18.6 71.7 76.7 95.8 115.0
100 % (WOT) 47.4 91.9 147.2 98.9 45.5 34.6 81.6 95.1 134.3 147.2
Kidkdowm 47.9 94.0 149.6 139.7 86.9 45.4 90.7 95.5 147.2 149.6
0% 11.9 22.8 42.0 20.8 8.9 9.2 73.0 75.4 73.0 75.4
16 % 11.9 22.8 42.0 20.8 8.9 9.2 73.0 75.4 73.0 75.4
31 % 22.5 42.0 70.0 33.4 17.3 9.2 73.0 79.1 73.0 79.1
POWER 49 % 27.2 56.9 87.2 42.0 24.7 9.2 73.6 94.0 73.6 94.0
MODE 50 % 30.7 64.3 96.5 49.5 29.7 10.4 76.2 103.9 76.2 103.9
58 % 35.1 73.2 110.8 60.6 37.8 15.1 81.6 110.8 81.6 110.8
64 % 37.6 77.4 116.3 68 42.5 18.1 86.6 116.3 87.8 116.3
71 % 40.1 81.1 121.2 77.7 47.7 20.8 86.6 121.2 97.7 121.2
100 % (WOT) 47.4 91.9 147.2 115.0 66.7 33.0 86.6 136.0 142.2 147.2
Kickdown 47.9 94.0 149.6 139.7 86.9 45.4 90.7 95.5 147.2 149.6

SSANGYONG Y200
5A-208 AUTOMATIC TRANSMISSION

E32 Gasoline Engine

THROTTLE SHIFT (km/h)

MODE
OPENING 1/2 2/3 3/4 4/3 3/2 2/1 UNL3 LCK3 UNL4 LCK4
0% 11.7 20.2 39.5 24.6 10.2 10.5 37.4 81.9 73.1 81.9
15 % 11.7 22.8 39.5 24.6 10.2 10.5 37.4 81.9 73.1 81.9
25 % 13.3 30.4 67.3 32.2 14.6 10.5 37.4 81.9 73.1 81.9
32% 16.8 36.6 76.0 38.0 19.7 11.0 39.5 83.4 73.1 83.4
NORMAL
35 % 18.6 40.1 80.4 40.9 21.9 11.7 40.9 62.9 74.6 86.3
MODE
45 % 24.0 49.7 93.6 52.6 27.8 13.9 46.8 70.2 81.9 93.6
55 % 31.9 66.1 114.1 70.2 32.2 17.3 54.1 79.0 102.4 114.1
70 % 42.1 85.4 146.2 90.7 39.5 21.9 64.3 93.6 128.7 146.2
100 % (WOT) 56.7 110.0 170.4 119.9 46.8 26 93.6 114.1 152.1 170.4
Kidkdowm 57.0 110.6 175.5 163.8 104.7 50.3 116.4 119.3 166.7 175.5
0% 12.3 24.6 40.9 24.6 10.2 10.5 76.0 81.9 76.0 81.9
15 % 14.0 27.8 43.9 29.2 10.2 10.5 76.0 81.9 76.0 81.9
25 % 23.4 43.9 65.8 39.5 17.5 11.0 76.0 81.9 76.0 81.9
32 % 24.6 49.1 76.6 46.1 24.9 11.6 81.9 90.7 81.9 90.7
POWER
35 % 26.3 52.6 81.9 51.2 27.8 12.0 84.8 96.5 84.8 96.5
MODE
45 % 32.2 65.8 105.3 67.3 37.3 15.4 102.4 117.0 102.4 117.0
55 % 38.6 76.9 125.8 87.7 51.2 21.4 111.1 125.8 114.1 125.8
70 % 46.7 90.8 146.2 113.3 66.5 28.7 111.1 146.2 128.7 146.2
100 % (WOT) 56.7 110.0 170.4 148.4 89.9 42.4 111.1 170.4 152.1 170.4
Kickdown 57.0 110.6 175.5 163.8 104.7 50.3 116.4 119.3 166.7 175.5

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-209

662LA Diesel Engine

THROTTLE SHIFT (km/h)

MODE
OPENING 1/2 2/3 3/4 4/3 3/2 2/1 UNL3 LCK3 UNL4 LCK4
0% 11.4 20.4 35.4 26.7 9.3 9.5 47.6 76.2 72.1 76.2
25 % 11.4 20.4 35.4 27.2 9.3 9.5 47.6 76.2 72.1 76.2
40 % 12.2 25.4 40.8 29.9 13.6 9.5 47.6 76.2 72.1 76.2
60 % 14.7 36.5 61.8 38.1 21.8 9.5 47.6 76.2 72.1 76.2
NORMAL
61 % 14.7 36.7 62.0 38.4 22.0 9.5 47.6 50.3 72.1 76.2
MODE
70 % 16.6 40.0 70.7 43.5 25.9 12.2 47.6 51.7 72.1 77.0
75 % 18.2 43.3 76.2 49.0 28.6 13.6 47.6 54.4 72.1 81.6
80 % 21.8 51.7 84.4 54.4 31.3 15.0 49.0 57.7 75.1 89.0
100 % (WOT) 28.6 62.6 104.5 69.4 38.1 19.6 57.1 62.6 92.5 104.5
Kidkdowm 34.8 68.0 110.2 100.7 63.9 31.3 61.2 68.0 100.7 110.2
0% 11.7 21.8 38.1 26.7 9.3 9.5 61.2 76.2 72.1 76.2
25 % 11.7 21.8 38.1 31.3 9.3 9.5 61.2 76.2 72.1 76.2
40 % 14.1 27.5 43.5 32.7 16.3 10.2 61.2 76.2 72.1 76.2
60 % 21.8 44.6 69.4 47.6 27.2 12.8 61.2 76.2 72.1 76.2
POWER
61 % 28.0 57.1 88.7 54.4 35.4 14.4 61.2 88.7 72.1 88.7
MODE
70 % 29.9 59.9 93.9 61.2 40.8 15.8 61.2 93.9 72.1 93.9
75 % 31.3 61.8 96.6 65.3 46.3 17.4 61.2 96.6 75.1 96.6
80 % 32.7 64.8 100.4 70.7 50.3 20.4 61.2 100.4 81.6 100.4
100 % (WOT) 34.0 67.8 105.3 83.0 54.4 23.1 61.2 105.3 92.5 105.3
Kickdown 34.8 68.0 110.2 100.7 63.9 31.3 61.2 68.0 100.7 110.2

SSANGYONG Y200
5A-210 AUTOMATIC TRANSMISSION

FASTENER TIGHTENING SPECIFICATIONS

Application N•m Lb-Ft Lb-Ft ı-
-ı-ı-ı-
Adaptor Housing to Case Bolts 30 - 35 22 - 26
Cam Plate to Case (Parking Pawl) Screws 16 - 22 12 - 16
Centre Support to Case Bolts 20 - 27 15 - 20
Detent Spring Screw 20 - 22 15 - 16
Extension Housing to Case Bolts 54 - 68 40 - 50
Front Propeller Shaft Bolts 70 - 80 52 - 59
Inhibitor Switch to Case Bolts 4-6 -
Oil Cooler Pipes 40 - 45 29 - 33
Oil Pan to Case Bolts 4-6 -
On/Off Solenoid Retainer Screws 8 - 12 -
Output Flange Nuts 35 26
Pump Cover Plate to Crescent Screw 13 - 16 10 - 12
Pump Cover Plate to Pump Cover Screws 13 - 16 10 - 12
Pump Cover to Case Bolts 24 - 34 18 - 25
Pump to Pump Cover Bolts 24 - 27 18 - 20
Rear Propeller Shaft Bolts 70 - 80 52 - 59
Rear Servo Cover to Case Bolts 30 - 35 22 - 26
TCM Mounting Bolt 10 -
Torque Converter Housing to Case Bolts 54 - 68 40 - 50
Torque Converter Mounting Bolts 42 31
Transfer Case to Transmission Housing Bolts 35 - 60 26 - 44
Transmission Filler Plug 30 - 35 22 - 26
Upper Valve Body to Lower Valve Body Screws 11 - 16 8 - 12
Valve Body To Case Bolts 8 - 13 -
Variable Pressure Solenoid (S5) Retainer Screw 8 - 12 -

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-211

TCM WIRING DIAGRAM (GASOLINE ENGINE-1 OF 2)

SCHEMATIC AND ROUTING DIAGRAMS

YAD5A210

SSANGYONG Y200
5A-212 AUTOMATIC TRANSMISSION
TCM WIRING DIAGRAM (GASOLINE ENGINE-2 OF 2) YAD5A220
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-213
TCM WIRING DIAGRAM (DIESEL ENGINE-1 OF 2)
YAD5A230
SSANGYONG Y200
5A-214 AUTOMATIC TRANSMISSION
TCM WIRING DIAGRAM (DIESEL ENGINE-2 OF 2) YAD5A240
SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-215

CONNECTOR END VIEW

KAA5A5O0

SSANGYONG Y200
5A-216 AUTOMATIC TRANSMISSION

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

0555 - 336256
0555 - 336257
Transmission Bench
Pump Puller
Cradle

KAA5A2P0 KAA5A2Q0

0555 - 336259
Clutch Spring
Compressor

KAA5A2R0 KAA5A2S0

0555 - 336260 0555 - 336261

Clutch Pack Clearance Cross Shaft Seal
Kit Remover

KAA5A2T0 KAA5A2U0

0555 - 336262
0555 - 336263
Cross Shaft Seal
Cross Shaft Bullet
Installer

KAA5A2V0 KAA5A2W0

SSANGYONG Y200
AUTOMATIC TRANSMISSION 5A-217

SPECIAL TOOLS TABLE (Cont'd)

0555 - 336265
0555 - 336266
Cross Shaft Pin
Adaptor Housing Seal
Remover / Installer
Installer
(Inhibitor Switch)

KAA5A2X0 KAA5A2Y0

0555 - 336267 0555 - 336268

Pump Alignment Tool Pump Seal Installer

KAA5A2Z0 KAA5A3A0

0555 - 336269 0555 - 336270

End Float Measuring End Float Measuring
Adaptor Shaft

KAA5A3B0 KAA5A3C0

0555 - 336302 0555 - 336045

Output Shaft Bullet Solenoid Bench Tester

KAA5A3D0 KAC5A050

SSANGYONG Y200
5A-218 AUTOMATIC TRANSMISSION

SPECIAL TOOLS TABLE (Cont'd)

0555 - 332083
Solenoid /Thermistor
Electronic Tester

KAC5A060

SSANGYONG Y200
SECTION 5B

MANUAL TRANSMISSION

TABLE OF CONTENTS
General Description and Operation ..................... 5B-2 Maintenance and Repair ................................... 5B-14
Shift Lever ........................................................... 5B-2 On-Vehicle Service ............................................... 5B-14
Transmission Assembly ....................................... 5B-2 Semi-Remote Kit ................................................ 5B-14
Specifications ...................................................... 5B-3 Transmission ..................................................... 5B-19
Diagnostic Information and Procedures .............. 5B-4 Unit Repair .......................................................... 5B-24
Diagnosis Table ................................................... 5B-6 Major Unit .......................................................... 5B-24
Component Locator ............................................ 5B-7 Main Shaft ......................................................... 5B-34
Cross-Sectional View ........................................... 5B-7 Input Shaft ........................................................ 5B-38
Power Flow .......................................................... 5B-8 Counter Shaft .................................................... 5B-40
Seni-Remote Kit Disassembly and Assembly ....... 5B-9 Extension Housing ............................................. 5B-40
Transmission Assembly ..................................... 5B-10 Shift Cover ........................................................ 5B-41
Transmission Assembly Disassembled View ...... 5B-11 Inspection of Components ................................. 5B-45
5B-2 MANUAL TRANSMISSION

GENERAL DESCRIPTION AND OPERATION

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 Description
Model T5WC
Type Floor Change
Gear Ratio 1st 3.969 : 1
2nd 2.341 : 1
3rd 1.457 : 1
4th 1.000 : 1
5th 0.851 :1
Reverse 3.710 : 1
Oil Specification ATF DEXRON II / III
Capacity(litre) 3.4 L
Change Interval Check : Every 15,000 km,
Replace : Every 50,000 km
Weight (Dry) 33kg
Notice: Add LUBRIZOL (280cc) in oil after overhauling.

SSANGYONG Y200
5B-4 MANUAL TRANSMISSION

DIAGNOSTIC INFORMATION AND PROCEDURES

Applicatio Check Action
Will not shift Control lever assembly broken or dam- Replace control lever and housing assem-
(control lever moves) aged. bly.
Damaged offset lever, shift fork, selector Remove extension, adapter or case
place or selector arm. cover. Check or replace damaged parts.
Hard shift or control Clutch not releasing. Adjust or replace clutch.
lever will not move into Improper or low transmission oil. Add or replace with specified oil.
gear Shift or shift rail binding. Remove extension, adapter or case
cover. Check or replace damaged parts.
Binding of sliding synchronizers or gears. Remove extension, adapter or case
cover. Check synchronizers and gears
and replace damaged parts.
If reverse only, faulty backup switch. Check or replace backup switch.
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Gears crash when Engine idle speed too high. Adjust idle speed to specified speed.
shifting Damaged or faulty clutch. Adjust or replace clutch.
Pilot bearing between input shaft and Replace or check roller bearings.
output shaft binding.
Damaged synchronizer. Check or replace synchronizer parts.
Bell housing misaligned. Align bell housing and bore.
Damaged gear(s). Check or replace gear(s).
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Transmission jumps Loosened transmission or flywheel Tighten bolts to specified value. Realign
out housing bolts, improper alignment. if necessary.
Synchronizer damaged or excessively Check or replace synchronizer parts.
worn.
Blocking ring damaged, worn index slots Check or replace blocking ring.
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 Check for wear or damaged. Replace
shaft, rail or shifting fork. worn or damaged parts.
Transmission locked in Fork or offset lever loose on shaft or rail. Replace extension, adapter or case
one gear cover. Check or replace loose parts on
shaft or rail. Replace roll pin(s).
Worn or damaged forks, offset lever, Remove extension, adapter or case
shaft or rail. cover. Check for wear or damaged.
Replace damaged parts.

SSANGYONG Y200
MANUAL TRANSMISSION 5B-5

Applicatio Check Action

Transmission locked in Worn or damaged synchronizer. Check worn or damaged synchronizer
one gear parts and replace if necessary.
Worn or damaged gears. Check worn or damaged gears and
replace if necessary.
Transmission noise Improper or low transmission oil. Add or drain and replace with proper oil.
Loose bolts or other attaching parts. Tighten as specified.
Improper flywheel housing to engine Realign correctly.
crankshaft alignment.
Noisy transmission bearing. Check bearings, bearing rollers and parts
for wear or damage. Replace if neces-
sary.
Noisy gears. Check for worn or damaged
gears(including speedometer gear).
Replace if necessary.
Transmission leakage Leakage from transmission. Clean all exposed surfaces, then check
for leaks.
Vent or breather clogged. Clean or replace vent or breather.
Too much oil. Check oil level.
Loose bolts at sealing faces. Tighten as specified.
Improperly applied sealant. Clean leaking surfaces. Reapply sealant.
Worn or damaged oil seal. Replace oil seal.

SSANGYONG Y200
5B-6 MANUAL TRANSMISSION

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

SSANGYONG Y200
MANUAL TRANSMISSION 5B-7

COMPONENT LOCATOR
CROSS-SECTIONAL VIEW

YAD5B040

1 4th Gear 7 1st Gear

2 3rd-4th Synchronizer 8 5th Gear
3 3rd Gear 9 5th Synchronizer
4 2nd Gear 10 Counter Shaft
5 1st-2nd Synchronizer 11 Reverse Idler
6 Reverse Gear

SSANGYONG Y200
5B-8 MANUAL TRANSMISSION

POWER FLOW

1st 2nd

YAD5B050 YAD5B060

3rd 4th

YAD5B070 YAD5B080

5th Reverse

YAD5B090 YAD5B100

SSANGYONG Y200
MANUAL TRANSMISSION 5B-9

SEMI-REMOTE KIT DISASSEMBLY AND ASSEMBLY

YAD5B110

1 Remote Shift 14 Bolt

2 Shift Lever 15 Breather Hose Bar
3 Shift Inner Boot 16 Control Shift Spring
4 Lining Shift Socket 17 Offset Control Lever
5 Control Housing Arm Insulator 18 Retainer Ring
6 Control Housing Arm 19 Pin
7 Bushing 20 Shift Rail
8 Shift Rod Link 21 Grove Pin
9 Washer 22 Pin & Clip
10 Clip 23 Joint Assembly
11 Shift Rod Pin 24 Joint Housing
12 Cover Assembly 25 Bushing
13 Shift Tower Cover

SSANGYONG Y200
5B-10 MANUAL TRANSMISSION

TRANSMISSION ASSEMBLY

YAD5B270

1 Clutch Housing 12 Speedometer Cable

2 Oil Filler Plug .......................................... 25 N•m 13 Rear Propeller Shaft
3 Transmission Assembly 14 Washer
4 Back-up Switch 15 Bolt ..................................................... 70-80 N•m
5 Washer 16 Cross Member
6 Bolt..................................................... 77-87 N•m 17 Washer
7 Oil Drain Plug .......................................... 25 N•m 18 Bolt ..................................................... 21-35 N•m
8 Bolt..................................................... 81-89 N•m 19 Washer
9 Washer 20 Bolt ..................................................... 62-93 N•m
10 Front Propeller Shaft 21 Breather Hose
11 Transfer Case Assembly

SSANGYONG Y200
MANUAL TRANSMISSION 5B-11

TRANSMISSION ASSEMBLY DISASSEMBLED VIEW

YAD5B460

SSANGYONG Y200
5B-12 MANUAL TRANSMISSION

1 Remote Shift 58 Bearing Corn

2 Shift Lever 59 Bearing Cup
3 Shift Inner Boot 60 Thrust Bearing
4 Lining Shift Socket 61 Thrust Race
5 Control Housing Arm Insulator 62 Blocking-Ring
6 Control Housing Arm 63 Spring
7 Bushing 64 Insert
8 Shift Rod Link 65 Synchronizer Sleeve
9 Washer 66 Spring
10 Clip 67 Blocking-Ring
11 Shift Rod Pin 68 Synchronizer
12 Cover Assembly 69 3rd Speed Gear
13 Shift Tower Cover 70 Needle Bearing
14 Bolt 71 Spacer
15 Bleeder Hose Barb 72 Snap Ring
16 Control Shift Spring 73 Washer
17 Offset Control Lever 74 2nd Speed Gear
18 Retainer Ring 75 Needle Bearing
19 Pin 76 Spacer
20 Shift Rail 77 Synchronizer Sleeve
21 Groove Pin 78 Bearing
22 Pin and Clip 79 O-Ring
23 Joint Assembly 80 Bearing
24 Joint Housing 81 Corn Bearing
25 Bushing 82 Shaft Gear
26 Bolt 83 Counter Shaft Gear
27 Bolt 84 Corn Bearing
28 O-ring 85 Roll Pin
29 Shaft Rail 86 Shift 5th Fork
30 Case Cover 87 Insert
31 Cap Plug 88 Shift Rail
32 Insert 89 Reverse Fork
33 Selecter Plate 90 Spring
34 Selecter Arm 91 Retainer Ring
35 Inlockter Plate 92 Shift Lever
36 Selecter Arm Pin 93 5th Speed Driven Gear
37 Selecter Plate 94 Snap Ring
38 Insert 95 Bearing Cap
39 Shift Fork 96 Shim
40 Output Shaft 97 Rear Retainer
41 Retainer Ring 98 Bolt
42 Washer 99 5th Speed Driven Gear
43 Inner Corn 100 Blocking 5th-Ring
44 Outer-Race 101 Hub Bearing
45 1-2nd Blocking-Ring 102 Insert
46 Output Shaft Assembly 103 Sleeve
47 Insert 104 Spring
48 Ball 105 Spring
49 Spring 106 Synchronizer
50 Reverse Sliding Gear 107 5th Synchronizer Retainer
51 1-2nd Blocking-Ring 108 Snap Ring
52 Outer Corn Race 109 Oil Ring Funnel
53 Inner Corn 110 Roll Pin
54 Sleeve Bearing 111 Reverse Idler Shaft
55 Sleeve 112 Reverse Idler Gear
56 Needle Bearing 113 O-Ring
57 1st Speed Driven Gear 114 Cross member Mounting Hole

SSANGYONG Y200
MANUAL TRANSMISSION 5B-13

115 Bolt 123 Input Bearing Retainer

116 Spacer Seal and O-ring 124 Oil Seal
117 Pivot Pin 125 Shim
118 Back-up Switch 126 Bearing Cap
119 Transmission Case 127 Bearing Corn
120 Filler/Drain Plug 128 Input Drive Shaft
121 Plug 129 Roller Bearing
122 Bolt

SSANGYONG Y200
5B-14 MANUAL TRANSMISSION

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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
MANUAL TRANSMISSION 5B-15

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 lining’s 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
5B-16 MANUAL TRANSMISSION

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

Installation Procedure
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
MANUAL TRANSMISSION 5B-17

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
5B-18 MANUAL TRANSMISSION

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 semi-

remote kit.

YAD5B260

SSANGYONG Y200
MANUAL TRANSMISSION 5B-19

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
5B-20 MANUAL TRANSMISSION

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
MANUAL TRANSMISSION 5B-21

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
5B-22 MANUAL TRANSMISSION

• 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

Installation Procedure
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 77 - 87 N•m

(57 - 64 lb-ft)

YAD5B410

3. Install the cross member and tighten as the

specified torque by supporting the suitable jack.
Installation Notice
62 - 93 N•m
Left/Right
Tightening (45 - 69 lb-ft)
Torque 21 - 35 N•m
Center
(15 - 26 lb-ft)

YAD5B420

SSANGYONG Y200
MANUAL TRANSMISSION 5B-23

4. Install the front and rear propeller shafts to the

transmission.
Installation Notice

81 - 89 N•m
Front
Tightening (60 - 66 lb-ft)
Torque 70 - 90 N•m
Rear
(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 Filler Plug 25 N•m (18 lb-ft)
Torque Drain Plug 25 N•m (18 lb-ft)

• Oil

Spec. ATF Dexron II

Capacity 4WD 3.4L
YAD5B450
2WD 2.0L

SSANGYONG Y200
5B-24 MANUAL TRANSMISSION

UNIT REPAIR
MAJOR UNIT
Disassembly Procedure
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
MANUAL TRANSMISSION 5B-25

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
5B-26 MANUAL TRANSMISSION

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
MANUAL TRANSMISSION 5B-27

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
5B-28 MANUAL TRANSMISSION

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
MANUAL TRANSMISSION 5B-29

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
MANUAL TRANSMISSION 5B-31

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.
• 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.
YAD5B760 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
5B-32 MANUAL TRANSMISSION

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 alignment-
type 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 3-
4 position.

YAD5B810

SSANGYONG Y200
MANUAL TRANSMISSION 5B-33

20. Place the detent spring and offset lever in the

extension housing and push the extension against
the case and shift cover.

YAD5B820

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
YAD5B830 thickness as the measurement ( 0.001 inch). After
shim installation, the end play should be “0”.

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.
YAD5B840

SSANGYONG Y200
5B-34 MANUAL TRANSMISSION

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
Disassembly Procedure
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
MANUAL TRANSMISSION 5B-35

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
5B-36 MANUAL TRANSMISSION

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
MANUAL TRANSMISSION 5B-37

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
5B-38 MANUAL TRANSMISSION

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
Disassembly Procedure
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
MANUAL TRANSMISSION 5B-39

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
5B-40 MANUAL TRANSMISSION

COUNTER SHAFT
Disassembly Procedure
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
Disassembly Procedure
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
MANUAL TRANSMISSION 5B-41

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
Disassembly Procedure
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
5B-42 MANUAL TRANSMISSION

• 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

• Push the shift shaft through the 3-4 shift fork.

YAD5B0U0

SSANGYONG Y200
MANUAL TRANSMISSION 5B-43

• Install the 3-4 shift fork and its selector plate.

YAD5B0V0

• Push the shift shaft through the 3-4 shift fork.

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
5B-44 MANUAL TRANSMISSION

• 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
MANUAL TRANSMISSION 5B-45

INSPECTION OF COMPONENTS
Inspection Procedure
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
YAD5B1B0 2. Check the parts which support bearings and shafts
for excessive wear and replace them if necessary.

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
5B-46 MANUAL TRANSMISSION

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
MANUAL TRANSMISSION 5B-47

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
5B-48 MANUAL TRANSMISSION

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 block-
out gear clash.

YAD5B1R0

SSANGYONG Y200
MANUAL TRANSMISSION 5B-49

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 Maintenance and Repair ................................... 5C-10
General Description ............................................. 5C-2 On-Vehicle Service ............................................... 5C-10
Bleeding of Clutch System ................................... 5C-3 Clutch Disc ........................................................ 5C-10
Specifications ...................................................... 5C-4 Master Cylinder ................................................. 5C-12
Diagnostic Information and Procedures .............. 5C-5 Clutch Pedal ...................................................... 5C-13
Component Locator ............................................. 5C-6 Clutch Pedal Box ............................................... 5C-14
Cross Sectional View ........................................... 5C-6 Inspecton Procedure .......................................... 5C-15
Clutch Hydraulic Lines ......................................... 5C-7 Clutch Disc ........................................................ 5C-15
Clutch Disc Assembly ......................................... 5C-8 Clutch Pedal ...................................................... 5C-16
Clutch Pedal Assembly ....................................... 5C-9 Special Tools and Equipment ............................ 5C-17
Special Tools Table ............................................ 5C-17
5C-2 CLUTCH

GENERAL DESCRIPTION AND OPERATION

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
YAD5C030 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.

YAD5C040

SSANGYONG Y200
5C-4 CLUTCH

SPECIFICATIONS
Type Hydraulic
Clutch Pedal Type Suspended
Max. Pedal Stroke DSL 148 mm
GSL 150 mm
Pedal Free Play 5 - 10 mm
Clutch Disc Type Single Dry Diaphragm
Facing O.D. × I.D. × Thickness 240 × 155 mm
Facing and Quantity 22 cm2 × 1
Thickness of Disc Free 9.85 - 10.2 mm
With Load 9.2 mm
Clutch Cover Assembly Setting Weight 610 kg
Clutch Master Cylinder Stroke 28.4 mm
Inner Diameter Ø15.87 mm
Clutch Fluid DOT3 or DOT4

SSANGYONG Y200
CLUTCH 5C-5

DIAGNOSTIC INFORMATION AND PROCEDURES

Check Possible Cause Action
Clutch slips Excessive Wear of Facing Replace
Hard or Oily Facing Repair or Replace
Damaged Pressure Plate or Flywheel Replace
Damaged or Burnt Diaphragm Spring Replace
Clutch Pedal Free play Insufficient Adjust
Faulty Operation of Clutch Pedal Repair or Replace
Worn or Damaged Clutch Disc Replace
Poor disengagement Vibration or Excessive Run-out of Disc Replace
Rust or Wear of Disc Spline Repair or Replace
Oily Facing Repair or Replace
Damaged Diaphragm Spring Replace
Excessive Clutch Pedal Free play Adjust
Hard to shift or will not shift Excessive Clutch Pedal Free play Adjust Pedal Freeplay
Faulty Clutch Release Cylinder Repair Release Cylinder
Worn Disc, Excessive Run-out, Damaged Repair or Replace
Lining
Dirty or Burred Splines on Input Shaft or Repair as Necessary
Clutch Disc
Damaged Clutch Pressure Plate Replace
Clutch chatters when starting Oily Facing Repair or Replace
Hard or Faulty Facing Replace
Burnt Torsion Spring Replace
Faulty Pressure Plate Replace
Bent Clutch Diaphragm Spring Replace
Hard or Bent Flywheel Repair or Replace
Engine Mounts Loose or Burnt Lever Tighten or Replace
Difficult pedal operation Poor Lubrication on Clutch Cable Lubricate or Replace
Poor Lubrication on Pedal Shaft Lubricate or Replace
Poor Lubrication on Clutch Pedal Repair
Not Using the Clutch Insufficient Clutch Pedal Free play Adjust
Excessive Wear of Facing Replace
After Disengagement Worn or Damaged Release Bearing Replace
Poor Lubrication Contact Surface of Replace
Clutch Bearing
Noisy When Disengaging Faulty Installation of Clutch Assembly or Repair
Bearing
Clutch Pedal is Damaged Pilot Bushing Replace
Partially Depressed and
Vehicle Speed is Reduced

SSANGYONG Y200
5C-6 CLUTCH

COMPONENT LOCATOR
CROSS SECTIONAL VIEW

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1 Clutch Disc 7 Bolt

2 Clutch Cover 8 Hose
3 Clutch Housing 9 Spring Lock Washer
4 Concentric Slave Cylinder 10 Transmission Input Spline
5 Adapter 11 Bolt
6 Bolt 12 Gasket

SSANGYONG Y200
CLUTCH 5C-7

CLUTCH HYDRAULIC LINES

YAD5C020

1 Clutch Pedal 4 Clutch Oil Chamber

2 Clutch Master Cylinder 5 Clutch Hydraulic Hose
3 Clutch Hydraulic Line

SSANGYONG Y200
5C-8 CLUTCH

CLUTCH DISC ASSEMBLY

YAD5C060

1 Clutch Disc 5 Bolt and Washer ...................... 35 N•m (26 lb-ft)

2 Clutch Cover 6 Bolt and Washer ...................... 47 N•m (35 lb-ft)
3 Concentric Slave Cylinder 7 Bolt and Washer ...................... 47 N•m (35 lb-ft)
4 Clutch Housing 8 Adapter

SSANGYONG Y200
CLUTCH 5C-9

CLUTCH PEDAL ASSEMBLY

YAD5C180

1 Snap Pin................................................. Replace 9 Turn Over Spring .......................... Apply Grease

2 Clevis Pin ...................................... Apply Grease 10 Bushing ......................... Replace, Apply Grease
3 Master Cylinder Push Rod 11 Full Stroke Stopper Contact Pad
4 Gasket 12 Interlock Switch Stopper Pad
5 Nut ................................. 16-22 N•m (12-16 lb-ft) 13 Clutch Pedal
6 Spring washer 14 Pedal Pad
7 Nut ....................................................... 8-18 N•m 15 Pedal Mounting Bracket
8 Fulcrum Pin 16 Stopper Bolt ................... 16-22 N•m (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

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
CLUTCH DISC
Removal & Installation Procedure
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
30 - 40 N•m
Tightening Torque
(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
21 - 27 N•m
Tightening Torque
(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 A: 1.5 ~ 1.8 kgf.m
Pipe Nut B: 1.5 ~ 1.8 kgf.m
Cylinder mounting bolt C: 1.5 ~ 1.8 kgf.m
Adapter Nut D: 1.5 ~ 1.8 kgf.m

YAD5C150

MASTER CYLINDER
Removal & Installation Procedure
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 15 - 18 N•m

(11 - 13 lb-ft)

YAD5C160 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
Removal & Installation Procedure
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

Removal & Installation Procedure
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

• Check the pressure plate surface for wear, crack

and discoloration.
• Check the strap plate rivet for looseness and
replace the clutch cover if loosened.

YAD5C270

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).
GSL 158 mm
Max. Stroke
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
182 ± 5 mm
Carpet)
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).

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Free Play 5 - 10 N•m
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.
YAD5C310

SSANGYONG Y200
CLUTCH 5C-17

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

602 589 00 40 00 661 589 00 15 00

Engine Lock Centering Pin

YAD5C320 YAD5C330

SSANGYONG Y200
SECTION 5D1

PART TIME - T/C

TABLE OF CONTENTS
General Infromation and Operation .................. 5D1-2 Transfer Case Assembly .................................. 5D1-17
4WD Operation Overview ................................... 5D1-2 Disassembly and Assembly ............................ 5D1-18
System Structure ............................................... 5D1-3 Maintenance and Repair ................................. 5D1-20
2H Mode (Rear Wheel Drive) .............................. 5D1-5 On-Vehicle Service ............................................. 5D1-20
4H Mode (4WD Drive - High Speed) ................... 5D1-6 Maintenance of Transfer Case Lubricant ........... 5D1-20
4H Mode (4WD Drive - Low Speed) .................... 5D1-7 4H and 4L Indicator ......................................... 5D1-21
System Description ........................................... 5D1-8 TCCU Inspection ............................................. 5D1-21
Specifications .................................................... 5D1-9 Transfer Case Assembly .................................. 5D1-22
Diagnostic Infromation and Procedures .......... 5D1-10 TCCU .............................................................. 5D1-24
General Diagnosis ........................................... 5D1-10 Unit Repair ........................................................ 5D1-25
Self-Diagnosis Test .......................................... 5D1-11 Disassembly Procedure ................................... 5D1-25
Diagnostic Diagram ......................................... 5D1-15 Assembly Procedure ....................................... 5D1-35
Component Locator ......................................... 5D1-16
Cross Sectional View ....................................... 5D1-16
5D1-2 PART TIME - T/C

GENERAL INFORMATION AND OPERATION

4WD OPERATION OVERVIEW
Application Mode Position Operation Condition
Driving Type 2H 2WD Drive(Rear • Normal Driving on the normal road or highway, or
Wheel Drive) high speed driving
4H 4WD Drive(High • Slipped road such as snow, rainy, sand, mud etc.
Speed)
4L 4WD Drive(Low • Max driving force requiring condition such as
Speed) 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 2WD Drive ↔ 4WD • 2WD ↔ 4WD transfer is possible below 70 km
Drive(High Speed) without operating the clutch.
2H, 4H ↔ 4L 2WD Drive, 4WD • Manual Transmission
Drive(High Speed) Transfer starts after the vehicle stops and the clutch
↔ 4WD Drive(Low is applied
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, 4H↔4L

TCCU

Locking Hub Solenoid

Vacuum System Operation

Locking Hub Transfer

Operation

Front Propeller Shaft

Rear Propeller Shaft

Front Axle Rear Axle

Front Wheel Rear Wheel

SSANGYONG Y200
PART TIME - T/C 5D1-5

2H MODE(REAR WHEEL DRIVE)

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Power Flow

Transmission Output
Shaft

T/C Input Shaft Rear Wheel

Output Shaft Rear Propeller Shaft Rear Axle

Rear Wheel

SSANGYONG Y200
5D1-6 PART TIME - T/C

4H MODE(4WD DRIVE - HIGH SPEED)

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Power Flow

Transmission
TCCU Motor
Input Shaft

Shift Cam, Rail,

Fork

Magnetic
Clutch

Hub Output Shaft

Chain

Front Propeller Rear Propeller

Shaft Shaft

SSANGYONG Y200
PART TIME - T/C 5D1-7

4L MODE(4WD DRIVE - LOW SPEED)

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Power Flow

Transmission
TCCU Motor
Input Shaft

Shift Cam, Rail,

Fork

Hub

Planetary Gear
(2.483)

Chain Output Shaft

Front Propeller Rear Propeller

Shaft Shaft

SSANGYONG Y200
5D1-8 PART TIME - T/C

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

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.
YAD5D070
Notice: If there are malfunctions during shifting,
‘4H’ or ‘4L’ indicator light will blink.

SSANGYONG Y200
PART TIME - T/C 5D1-9

SPECIFICATIONS

Model Part-Time 4408 (E)

Type E.S.O.F. Type
Gear Ratio High 1:1
Low 2.48 : 1
Oil Specification ATF S-3, S-4 or DEXRON II, III
Capacity 1.2 L
Lubrication Check : Every 15,000 km
Replace : Every 50,000 km
Manufacturer Borg Warner
Weight 30 kg

SSANGYONG Y200
5D1-10 PART TIME - T/C

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS
Symptoms Check Action
Electric shift problems • Faulty or damaged TCCU, speed • Overhaul and check, replace if neces-
sensor, motor, clutch or internal wirings sary.
• Damaged or worn shift cam, hub, fork • Overhaul and check for wear and
and rail shift damage.
• Binding shift fork, hub collar or gear • Replace if necessary.
Cannot front wheel • Broken drive chain • Check sliding parts, replace if neces-
drive when shifted sary.
4H,4L
Noise in 4WD opera- • Improper or low oil • Drain and replace with specified oil.
tion • Loosened bolts or mounted parts • Retighten as specified.
• Noisy T/C bearing • 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 neces-
sary.
Noise in 4H or 4L • Worn or damaged sprockets or drive • Disassemble and check for wear and
chain damage, replace if necessary.
• Incorrect tire pressure • Adjust tire pressure.
Transfer case oil • Cracked transfer case • Replace the case.
leakage • Leakage from other parts • Clean case and parts and check for
leakage.
• Breather clogging • Remove breather hose and clean,
replace if necessary.
• Improper or too much oil • Use specified oil and adjust oil level.
• Loosened sealing bolts • Retighten
• Improperly applied sealant • Use specified sealant and retighten.
• Worn or damaged oil seal • Replace

SSANGYONG Y200
PART TIME - T/C 5D1-11

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
YAD5D080 flashing indicator light.
• TCCU
• Shift motor
• Magnetic synchronizer clutch
• Speed sensor
• 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
YAD5D110
for proper condition.

SSANGYONG Y200
5D1-12 PART TIME - T/C

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 TCCU
ON
OFF

YAD5D140

4WD CHECK
2 Light Shift Motor
ON
OFF

YAD5D150

4WD CHECK
3 Light Synchronizer Clutch
ON
OFF

YAD5D160

4WD CHECK
4 Light Speed Sensor
ON
OFF

YAD5D170

4WD CHECK

5 Light Locking Hub Solenoid

ON
OFF

YAD5D180

SSANGYONG Y200
5D1-14 PART TIME - T/C

No. Defective Code Malfunctioning Part

4WD CHECK
6 Light Selector Switch
ON
OFF

YAD5D190

4WD CHECK
7 Light Motor Position Sensor
ON
OFF

YAD5D200

SSANGYONG Y200
PART TIME - T/C 5D1-15

DIAGNOSTIC DIAGRAM

YAD5D210

SSANGYONG Y200
5D1-16 PART TIME - T/C

COMTONENT LOCATOR
CROSS SECTIONAL VIEW

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YAD5D250

SSANGYONG Y200
PART TIME - T/C 5D1-17

TRANSFER CASE ASSEMBLY

YAD5D260

1 Rear Companion Flange 8 Transmission Extension Housing

2 Case Cover 9 Bolt
3 Front Companion Flange 10 Washer
4 Breather Plug 11 Front Propeller Shaft
5 Transfer Case 12 Bolt
6 Input Shaft 13 Washer
7 Mounting Bolt 14 Rear Propeller Shaft

SSANGYONG Y200
5D1-18 PART TIME - T/C

DISASSEMBLY AND ASSEMBLY

YAD5D370

SSANGYONG Y200
PART TIME - T/C 5D1-19

1 Transfer Case 41 Rail Shaft

2 Spring Washer 42 Lock-up Fork
3 Oil Seal 43 Snap ring
4 Companion Flange 44 Spacer
5 Shift shaft 45 Driven Sprocket
6 Oil Seal 46 Driving Sprocket
7 Pipe Plug 47 Drive Chain
8 Screw 48 Nut
9 Bolt 49 Gasket
10 Speed Sensor and Harness Bracket 53 Spring Pin
11 Speed Sensor Assembly 54 Hose Clamp
12 Speed Sensor 55 Hose Coupling
13 O-Ring 56 Oil Strainer
14 Locking Clip 58 Reduction Hub
15 Connector 59 Shift Fork Assembly
16 Motor Assembly 60 Shift Fork Facing
17 Oil Seal 61 Roller and Retainer
18 Bearing 66 Nut
19 Bolt 67 Plane Washer
20 Pump Assembly 68 Oil Seal
21 Output Shaft Assembly 71 Spacer
22 Bearing 72 Front Output Assembly
23 Ring Gear 73 Breather
24 Cover Assembly 74 Bolt
25 Nut 75 Front Adapter Assembly
26 Snap Ring 76 Snap Ring
27 Bearing 80 Snap Ring
28 Needle Bearing 81 Bearing
30 Clutch Coil Assembly 82 Input Shaft Assembly
31 Speed Gear 83 Sleeve Assembly
32 Oil Seal 84 Needle Bearing
33 Return Spring 86 Thrust Washer
34 Magnet 87 Retaining Ring
35 Clutch Housing 88 Thrust Plate
36 Snap Ring 89 Sun Gear
37 Snap Ring 90 Gear Carrier Assembly
38 Lock-up Hub 97 Electric Shift Cam
39 Sleeve Return Spring 99 Spacer
40 Lock-up Collar

SSANGYONG Y200
5D1-20 PART TIME - T/C

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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.
• Tighten the oil level plug.
Installation Notice
YAD5D220
20 - 30 N•m
Tightening Torque
(15 - 22 lb-ft)

2. Oil Change
• 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

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begins to drip out.
• Tighten the oil level plug.

YAD5D230

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
PART TIME - T/C 5D1-21

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. Operation Condition Voltage(V)

4H or 4L 4.75 - 5.35
J1 - 7
2H 0 - 0.50
4H indicator light ON < 1.00
J1 - 8
4H indicator light OFF > 11.00
2H or 4H 4.75 - 5.35
J1 - 13
4L 0 - 0.50
Clutch pedal applied < 0.50
J1 - 14
Clutch pedal released > 11.00
4L indicator light ON < 1.00
J1 - 15
4L indicator light OFF > 11.00
Motor OFF < 1.00
J1 - 16
Motor ON > 11.00
Motor OFF < 1.00
J1 - 17
Motor ON > 11.00
Auto locking hub ON > 11.00
J1 - 23
Auto locking hub OFF < 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
5D1-22 PART TIME - T/C

TRANSFER CASE ASSEMBLY

1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the damper mounting bolt.
4. 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 N•m
Front
Tightening (60 - 66 lb-ft)
Torque 70 - 90 N•m
Rear
(52 - 66 lb-ft)

YAD5D300

SSANGYONG Y200
PART TIME - T/C 5D1-23

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 N•m
Tightening Torque(1)
(9 - 17 lb-ft)
6 - 8 N•m
Tightening Torque(2)
(53 - 71 lb-in)

YAD5D310

9. Remove the transfer case by removing the bolts

attaching the transfer case to the transmission.
Installation Notice
35 - 60 N•m
Tightening Torque
(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
5D1-24 PART TIME - T/C

TCCU
1. Disconnect the negative terminal from the battery.

YAD5D330

2. Remove the TCCU connector.

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yyyy YAD5D340

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3. Remove the TCCU mounting bolt and remove the
TCCU.
• TCCU installation position : Under the driver’s
seat

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yyyy YAD5D350

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4. Installation should follow the removal procedure
in the reverse order.
Notice: Be careful not to give any impact to the
TCCU body.

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Installation Notice
Tightening Torque 10 N•m (89 lb-ft)

YAD5D360

SSANGYONG Y200
PART TIME - T/C 5D1-25

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
5D1-26 PART TIME - T/C

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
5D1-28 PART TIME - T/C

• 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
PART TIME - T/C 5D1-29

• 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.

Inspection Procedure
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
5D1-32 PART TIME - T/C

• 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
PART TIME - T/C 5D1-33

4. Inspection of contact patterns

Description Normal Abnormal

Normal Wear

YAD5D600

End Face Wear

YAD5D610 YAD5D620

Traveling Face Wear

YAD5D630 YAD5D640

Upper Face Wear

YAD5D650 YAD5D660

Lower Face Wear

YAD5D670 YAD5D680

SSANGYONG Y200
5D1-34 PART TIME - T/C

5. Chip pattern of the gear face

Description Patterns Action

Corner chip at drive face 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 Replace

tooth

YAD5D730

Side edge chip at drive face Replace

YAD5D740

SSANGYONG Y200
PART TIME - T/C 5D1-35

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
5D1-36 PART TIME - T/C

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.

11. Position the input shaft assembly over front cover

YAD5D810 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 Tightening Torque
6 Bolts 28 - 48 N•m
(21 - 35 lb-ft)
Breather 8 - 15 N•m

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.
YAD5D850
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.

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
YAD5D870
the snap ring into the shaft groove over spacer.

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

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
YAD5D890 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
YAD5D900
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)

• 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.
YAD5D910 • Align the cover bearings with output shafts.
• Align the cover blind hole with rail shaft and
make sure that return spring is not cocked.

SSANGYONG Y200
5D1-42 PART TIME - T/C

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 Diagnostic Trouble Code (DTC) 1714 ................ 5D2-34
TOD System Function ........................................ 5D2-2 Diagnostic Trouble Code (DTC) 1715 ................ 5D2-36
4WD Operation Overview ................................... 5D2-3 Diagnostic Trouble Code (DTC) 1716 ................ 5D2-38
System Structure ............................................... 5D2-4 Diagnostic Trouble Code (DTC) 1721 ................ 5D2-40
4H Mode (4WD Drive - High Speed) ................... 5D2-5 Diagnostic Trouble Code (DTC) 1722 ................ 5D2-42
4L Mode (4WD Drive - Low Speed) ..................... 5D2-7 Diagnostic Trouble Code (DTC) 1731 ................ 5D2-44
Specifications .................................................... 5D2-9 Diagnostic Trouble Code (DTC) 1732 ................ 5D2-46
Tightening Specifications ................................. 5D2-10 Diagnostic Trouble Code (DTC) 1733 ................ 5D2-48
Component Locator ......................................... 5D2-11 Diagnostic Trouble Code (DTC) 1734 ................ 5D2-50
Transfer Case Cross Sectional View ................. 5D2-11 Diagnostic Trouble Code (DTC) 1735 ................ 5D2-52
Transfer Case Assembly .................................. 5D2-13 Diagnostic Trouble Code (DTC) 1736 ................ 5D2-54
Function Description ........................................ 5D2-14 Diagnostic Trouble Code (DTC) 1741 ................ 5D2-56
TOD System Select Mode ................................ 5D2-14 Diagnostic Trouble Code (DTC) 1742 ................ 5D2-58
Component Function ........................................ 5D2-14 Diagnostic Trouble Code (DTC) 1743 ................ 5D2-60
Definition fo Terminology .................................. 5D2-16 Diagnostic Trouble Code (DTC) 1750 ................ 5D2-61
Control Unit ..................................................... 5D2-18 Diagnostic Trouble Code (DTC) 1751 ................ 5D2-63
System Operation ............................................ 5D2-20 Diagnostic Trouble Code (DTC) 1752 ................ 5D2-64
Diagnosis .......................................................... 5D2-30 Diagnostic Trouble Code (DTC) 1753 ................ 5D2-65
Diagnostic Tests .............................................. 5D2-24 Diagnostic Trouble Code (DTC) 1754 ................ 5D2-66
Coding on TOD ................................................ 5D2-25 Maintenance and Repair ................................. 5D2-67
Schmatic Wiring Diagram ................................. 5D2-27 On-Vehicle Service ............................................. 5D2-67
TOD Control Unit Diagnostic System Check ..... 5D2-28 Transfer Case (TOD) Component Locator ......... 5D2-67
Diagnostic Trouble Codes (DTC’s) ................... 5D2-29 Transfer Case Assembly .................................. 5D2-68
4WD Check Indicator Stays on with Ignition TOD Control Unit .............................................. 5D2-70
Switch on ...................................................... 5D2-30 Shift Motor ....................................................... 5D2-70
4WD Low Indicator Stays on with Ignition Speed Sensor in Front and Rear Propeller Shaft 5D2-71
Switch on ...................................................... 5D2-31 Unit Repair ........................................................ 5D2-74
No 4WD Check or 4WD Low Indicator with Transfer Case Assembly .................................. 5D2-76
Ignition Switch on ......................................... 5D2-32
Special Tools and Equipment .......................... 5D2-89
4WD Low Indicator Blink Steadily ..................... 5D2-33
Special Tools Table ......................................... 5D2-89
5D2-2 TRANSFER CASE - TOD

GENERAL INFORMATION AND OPERATION

TOD system means the full time 4WD system and the TOD SYSTEM FUNCTION
registered trade mark of Borg Warner. TOD is an
abbreviation of Torque On Demand. 4H Mode
TOD control unit automatically tailors torque distribution The TOD system transfer case controls the clutch
to road, offering full time four wheel drive. TOD mechanism to comply with rotation in front and rear
distributes electronically-controlled power into front and propeller shaft and if its difference exceeds the
rear wheels whose ratio change from 0 : 100 to 50 : 50 permissible range, corresponding power is distributed
complying with wheel speed differences. into front wheel through electromagnetic clutch (EMC).
Also TOD control unit analyzes data from wheel speed Hall effect speed sensors are located front and rear
sensor and engine output then changes pressure of propeller shafts, send signals to TOD transfer case
electromagnetic clutch. This pressure controls front control unit (TCCU). The EMC coil is activated by
propeller shaft and power to front wheel. Power to front variable current on exceeding difference of speed in
wheel depends on degree of pressure corresponding front and rear propeller shafts.
clutch slip.
TOD is designed to distribute the power to front and 4L Mode
rear axle by operation of 4H/4L switch and shift motor. When select 4L mode, EMC is locked to apply
Shifting 4WD high (4H) to 4WD low (4L) is performed maximum torque into front and rear propeller shafts.
towards reducing high-low collar by means for Shift motor rotates also 4L position by rotation of cam
connection high-low shift fork with output shaft in order thus propeller shaft torque changes from 1:1 to 2.48:1
to join with planetary gear. Torque transmits input shaft by planetary gear set.
then sun gear rotating front planetary gear. Front
planetary gear joins with output shaft and drives at Transfer Case Control Unit (TCCU)
low position. Transfer case control unit (TCCU) receives, front and
The TOD system has 2 selectable mode, 4H and 4L. rear propeller shaft speed, shift motor position and
4H is the normal operating mode when drive of which 4H/4L switch signals and controls electromagnetic
gear ratio is 1:1 and 4L mode distributes power to clutch (EMC), shift motor. TCCU communicates with
front and rear wheels 50 : 50 of which gear ratio is scan tool with K-line for diagnosis. It located under
2.48:1. the front LH seat.

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-3

4WD OPERATION OVERVIEW

Application Mode Position Operation Condition

Driving Type 4H 4WD Drive(High Normal Driving on the normal road or highway, or high
Speed) speed driving
Slipped road such as snow, rainy, sand, mud etc.
4L 4WD Drive(Low Max driving force requiring condition such as towing,
Speed) rough road.
Same function as part time transfer case 4L.
Transferring 4H ↔ 4L 4WD Drive A vehicle should stop for transfer.
High Speed ↔ Manual Transmission
Low Speed • Transfer starts after the vehicle stops and the clutch
is applied
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
5D2-4 TRANSFER CASE - TOD

SYSTEM STRUCTURE

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SSANGYONG Y200
TRANSFER CASE - TOD 5D2-5

4H MODE (4WD DRIVE - HIGH SPEED)

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SSANGYONG Y200
5D2-6 TRANSFER CASE - TOD

Power Flow

Front Speed Sensor

Transmission Input
Rear Speed Sensor TOD Control Unit
Shaft

Throttle Open Rate

(TPS Value)

Magnetic Clutch
MAX DUTY

Force Distribution Unit

BALL RAMP

Multi-Plate Clutch

Driving Sprocket Output Shaft

Chain

Front Propeller Shaft Rear Propeller Shaft

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-7

4L MODE (4WD DRIVE - LOW SPEED)

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SSANGYONG Y200
5D2-8 TRANSFER CASE - TOD

Power Flow

Transmission Input
Front Speed Sensor
Shaft

Rear Speed Sensor TOD Control Unit

Throttle Open Rate

(TPS Value)

Magnetic Clutch Planetary Gear

MAX DUTY (2.483)

Force Distribution Unit

BALL RAMP

Multi-Plate Clutch

Driving Sprocket Output Shaft

Chain

Front Propeller Shaft Rear Propeller Shaft

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-9

SPECIFICATIONS

Check Action
TOD Model TOD (Torque On Demand) Transfer Case (4423E)
Length 343.0 mm
Weight (w/oil) 37.9 kg
Shift Mode 4H and 4L
Gear Ratio High 1:1
Low 2.48 : 1
Oil Specification ATF S-3, S-4 or Dexron II, III
Capacity 1.4 L
Interval Inspect Every 15,000km,
Max. Torque Replace Every 50,000km
550 lb ft (76kg cm)
TOD Control Voltage Normal Range 9-16 V
Unit CAN Comm. 6-16 V
Current(Below Max. Ignition Switch OFF 2 mA
Operation Voltage) Ignition Switch ON 1A
Max. Operation Current Motor OFF 7A
Motor ON 20 A

SSANGYONG Y200
5D2-10 TRANSFER CASE - TOD

TIGHTENING SPECIFICATIONS

Application N•m Kgf.m

Clutch Coil Retaining Bolt 10 1.0
Drain Plug 25 2.5
Filter Plug 25 2.5
Front Case - Rear Case Mounting Bolt 31 3.1
Front Propeller Shaft - Front Output Shaft/Flange Mounting Bolt 85 8.6
Planner Damper - Transfer Case Mounting Bolt 35 3.6
Rear Output Shaft Flange Mounting Nut 167 17.0
Rear Propeller Shaft - Rear Output Shaft/Flange Mounting Bolt 85 8.7
Shift Motor Adjusting Nut 5 0.5
Shift Motor Bracket Bolt 10 1.0
Shift Motor Mounting Bolt 10 1.0
Speed Sensor Retaining Bolt 5 0.5
Transfer Case Control Unit (TCCU) Retaining Bolts 10 1.0
Transfer Case - Transmission Adapter Housing Mounting Bolt 48 4.9

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-11

COMPONENT LOCATOR
TRANSFER CASE CROSS SECTIONAL VIEW

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YAD5D040

SSANGYONG Y200
5D2-12 TRANSFER CASE - TOD

1 Case 37 Chain
2 Bearing 38 Cover
3 Ring Gear 39 Bearing
4 Oil Seal 40 Oil Seal
5 Retaining Ring 41 Dowel Pin
6 Input Shaft 42 Bearing Sleeve
7 Carrier 43 Seal
8 Pinion Gear 44 Snap Ring
9 Pinion Shaft 45 Center Bearing Support
10 Thrust Washer 46 Ball Bearing
11 Needle Roller 47 Dowel Pin
12 Spacer 48 Viscous Coupling
13 Bearing 49 Pinion Gear
14 Bushing 50 Thrust Washer
15 Sun Gear 51 Pinion Shaft
16 Thrust Plate 52 Thrust Washer
17 Hub 53 Thrust Washer
18 Bearing 54 Bushing
19 Snap Ring 55 Output Shaft
20 Snap Ring 56 Ring Gear
21 Snap Ring 57 Retaining Ring
22 Hub Reduction 58 Needle Bearing
23 Shift Fork 59 Ball Bearing
24 Spacer 60 Speed Gear
25 Shaft Shift 61 Flange
26 Spring 62 Oil Seal
27 Cam 63 Washer
28 Breather Hose 64 Nut
29 Breather Plug 65 Flange
30 Shift Rail 66 Dust Deflector
31 Intermediate Shaft 67 Tone Wheel
32 Thrust Washer 68 Bolt
33 Pump 69 Motor
34 Clamp Hose 70 Bolt
35 Upper Sprocket 71 Cap Screw
36 Thrust Washer

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-13

TRANSFER CASE ASSEMBLY

YAD5D050

1 Input Shaft 5 Drain Plug

2 Air Control Cap 6 Filler Plug
3 Front Companion Flange 7 Shift Cam Driving Motor
4 Rear Companion Flange

SSANGYONG Y200
5D2-14 TRANSFER CASE - TOD

FUNCTION DESCRIPTION
TOD SYSTEM SELECT MODE COMPONENT FUNCTION
4H is the mode when drive normally of which gear ratio Shift Motor
is 1 : 1 and 4L mode distributes power to front and
It locates backside transfer case, which drives rotary
rear wheels 50 : 50 of which gear ratio is 2.48 : 1.
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 HI-
LO 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
TOD system controls clutch mechanism to comply with
seat.
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
YAD5D070
thus propeller shaft torque changes from 1 : 1 to 2.48 : 1
by planetary gear set.
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
TRANSFER CASE - TOD 5D2-15

Pin Function Pin Function Shift Motor Connector

1 Motor HI-LO 16 Speed Reference
2 Motor LO-HI 17 Ground
3 EMC 18 Ground
4 Battery (+) 19 Battery (+)
5 Ignition 20 K-LINE
6 Position Return 21 4L Illumination
7 Diagnosis Display 22 CAN-H
8 - 23 CAN-L
9 HI / LO Switch 24 Auto T/M, Neutral
10 Position 2 25 ABS Input
YAD5D100
11 Front Speed 26 Brake Switch
12 TPS Supply (Diesel) 27 Position 1
13 Speed/TPS Return 28 Position 3 Pin Function

14 Motor HI-LO 29 Rear Speed A Motor HI-LO (clockwise)

15 Motor LO-HI 30 Position 4 B Motor HI-LO (counter-clockwise)

C Position Return
Speed Sensor, Clutch Coil, Motor Connector D Position 1
E Position 2
Speed Sensor, Clutch Coil and Motor Connector are F Position 3
located at the upper & rear side of the transfer case
(upper shift motor) as shown. G Position 4
• Shift Motor Connector : Black (upper arrow as
shown)
Speed sensor, clutch coil connector
• Speed Sensor and Clutch Coil Connector : White
(lower arrow as shown)

YAD5D110

YAD5D090

Pin Function
H Clutch Coil
I Front Speed Return
J Front Speed
K Front Speed Sensor Voltage Supply
L Rear Speed Sensor Voltage Supply
M Rear Speed
N Rear Speed Return

SSANGYONG Y200
5D2-16 TRANSFER CASE - TOD

DEFINITION OF TERMINOLOGY
Definitions Description
Rear 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 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 Each rotation of the front propeller shaft will result in 30 speed sensor pulse.
Clutch) An Electromagnetic clutch used to control the amount of torque applied to the front
propeller shaft.
TOD TOD is an abbreviation of Torque On Demand and means that the torque is transferred
according to the operating condition.
TPS (Throttle Position TPS is an abbreviation of Throttle Position Sensor. For MSE engine, the potentiometer
Sensor) in the throttle actuator acts as TPS.
PWM PWM is an abbreviation of Pulse Width Modulation and is a type of output value
control by adjusting pulse width.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being modu-
lated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front Overrun A condition where the front propeller shaft is turning at a rate which is faster than the
rear propeller shaft.
Rear Overrun A condition where the rear propeller shaft is turning at a rate which is faster than the
front propeller shaft.
High Range The highest (numerically lowest = 1 : 1) gear ratio between the input and outputs of
the Transfer Case.
Low Range The lowest (numerically highest = 2.48 : 1) gear ratio between the input and outputs of
the Transfer Case.

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-17

Definitions Description
4H/4L Switch A switch which selects the desired gear ratio.
Electric motor which changes the Transfer Case range.
Shift Motor A set of 4 Gray code switches which provide feedback to the TOD indicating the
position of the Shift Motor.
Position Encoder A switch on vehicles equipped with a manual transmission which indicates that the
clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicates that the
transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speed is
indicated by propeller shaft speed measurement.

SSANGYONG Y200
5D2-18 TRANSFER CASE - TOD

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

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-19

Classification Pin No. Pin Name Description

Power Supply 17,18 Ground TOD control unit ground
4,19 Input TOD control unit battery supply : (Fuse No 13,20A)
Signal Input 5 Ignition Ignition ON / OFF
27 Position 1 Position encoder 1
: check of shift motor position
10 Position 2 Position encoder 2
: check of shift motor position
28 Position 3 Position encoder 3
: check of shift motor position
30 Position 4 Position encoder 4
: check of shift motor position
9 4H/4L Switch Transfer case mode input
24 Auto T/M Neutral Check of neutral gear position in Auto T/M
12, 16 Speed Voltage Supply 5V supply (TPS / speed sensor)
11 Front Speed Front speed sensor signal input
29 Rear Speed Rear speed sensor signal input
25 ABS Operation ABS ON / OFF
26 Brake Switch Brake Switch ON/OFF Signal Input
22 CAN-L CAN bus low line
23 CAN-H CAN bus high line
20 K-LINE (1) Connect to Diagnostic Connector No. 15
Signal Output Motor LO-HI Motor output port
- LO to HI : join with battery
- HI to LO (or motor brake) : join with ground
Motor HI-LO Motor output port
- HI to LO : join with battery
- LO to HI (or motor brake) : join with ground
3 EMC TOD Output
21 4L Illumination When the transfer case is in “4L” mode, illumi-
nates “4L” indicator.
6 Position Return Position encoder ground
7 Self Diagnosis Display Illuminates “4L” indicator “4WD check lamp” turns
ON Upon defect ; Ground circuit
13 Speed Ground for speed sensor / TPS

(1) K-LINE : It means that Communication line for coding and diagnosis with diagnostic scanning tool.

SSANGYONG Y200
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 Motor Position Position Code 1/2/3/4 Motor Position
1110 Left Stop 1001 Neutral
1010 Left of High 0001 Zone 2
0010 High 0101 Low
0000 Right of High 0100 Right Stop
1110 Zone 1 - -

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-21

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 Motor Position System Response (Action)

4H Left Stop No action required. 4L bulb off.
4H Left of High No action required. 4L bulb off.
4H High No action required. 4L bulb off.
4H Right of High 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 Zone 1 Same as above
4H Neutral Same as above
4H Zone 2 Same as above
4H Low Blink 4L bulb. After the shift conditions are met,
attempt a shift to 4L. After successfully shifting into
4L, stop blinking 4L bulb.
4H Right Stop Same as above
4L Left Stop Blink 4L bulb. After the shift conditions are met,
attempt a shift to 4L. After successfully shifting into
4L, stop blinking 4L bulb.
4L Left of High Same as above
4L High Same as above
4L Right of High Same as above
4L Zone 1 Same as above
4L Neutral Same as above
4L Zone 2 Same as above
4L Low No action required. 4L bulb on.
4L Right Stop No action required. 4L bulb on.

SSANGYONG Y200
5D2-22 TRANSFER CASE - TOD

A command to shift will only be acted upon if the TOD Indicator function on shifting
is reading a valid code at the time the command to Once a range change has been initiated the 4L Indicator
shift is made. will begin to blink at a rate of 0.3 seconds on, 0.3
After a shift has started, the TOD will power the shift seconds off until the shift is completed or canceled.
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.

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. YAD5D140

2. Both propeller shaft speeds are below 87 rpm

(2580 pulses/minute). If a successful shift has been completed, the 4L
Indicator will be illuminated if the motor is in Low and
If the transmission is taken out of neutral before 2
it will be turned off if the motor is in High.
seconds has elapsed, or either propeller shaft speed
increases above the limit, the shift will be suspended 4L Indicator illuminates as below figure.
and the 4L Indicator will continue to blink until the
criteria are met again or the 4H/4L Switch is returned Electric shift default mode
to the original position. If the motor fails to reach its destination, the TOD will
attempt the following (in order):
Range change 1. The TOD will wait 3 seconds then attempt the shift
When the shift criteria are met, the motor is rotated in again.
the appropriate direction (as determined by the selector 2. If the second attempt to reach the destination fails
switch) until one of the following occurs: the TOD will wait 3 seconds then attempt to rotate
1. The motor reaches its destination. the motor back to the original position. If
2. The motor is on for 5 seconds without reaching its successful, all future shifts will be inhibited until
destination. The shift has failed and the TOD will the Ignition is cycled.
respond as default mode. 3. If the attempt to return to the original position fails,
3. A fault occurs with either the motor or position the TOD will wait 3 seconds then attempt to rotate
encoder. Refer to the diagnosis requirement. the motor to the original position again. If the
second attempt to return to the original position is
When the motor is energized, the Ignition, 4H/4L
successful, the 4WD CHECK lamp will be
Switch, propeller shaft speeds, and transmission
illuminated, and all future shifts will be inhibited
neutral inputs are ignored.
until the Ignition is cycled.

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-23

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.

SSANGYONG Y200
5D2-24 TRANSFER CASE - TOD

DIAGNOSIS
While the TOD is active it periodically monitors its inputs 5. If a shift command has been received, but not
and outputs. If a fault is detected the “4WD CHECK” acted upon when a failure occurs the TOD will
lamp is illuminated and a fault code is stored in the cancel the command and not respond to any
TOD memory. subsequent shift commands.
When requested, fault codes are downloaded to a 6. If a shift command is in progress when an invalid
diagnostic connector (K-line) serial communications position code is confirmed it will be halted and
using SCAN-100. the TOD will turn the motor toward the high
position. Afterwards the TOD will not respond to
DIAGNOSTIC TESTS any shift commands.
7. If the shift motor/position encoder assembly
TOD Internal Function failure (other than a motor failure which occurs
When the Ignition is turned on the TOD tests its ROM when the motor is energized) recovers
and RAM. If there is a fault, the TOD immediately resets continuously for one second the TOD will function
itself and re-tests the ROM and RAM. If the fault normally. The “4WD CHECK” lamp is turned off
persists the TOD continues to reset and re-test until but the fault code will remain in memory.
the fault is corrected or the ignition is turned off. All 8. A motor failure (i.e. open or short circuit) which
TOD functions are inhibited until the fault is corrected. occurs when the motor is energized can only be
The 4WD CHECK lamp is not illuminated if there is a cleared by cycling the ignition off-on.
ROM or RAM fault.
If the ROM/RAM passes the EEPROM memory is Front Speed Sensor Test
tested. If there is a fault the 4WD CHECK lamp is If a Front Speed Sensor fault is detected continuously
illuminated and the TOD continues to operate using for 0.5 second the 4WD CHECK lamp is illuminated.
the default calibration data stored in ROM. Fault codes The TOD then responds as follows:
are not stored when there is an EEPROM fault.
1. If the system is in High Range the TOD uses the
An EEPROM fault can only be cleared by cycling Rear Speed Sensor to determine the EMC Touch
ignition off-on. Off level and wheel slip control is suspended.
2. If the system is in Low Range, the EMC Duty Cycle
Shift Motor Assembly Test
is set to maximum (independent of vehicle speed)
If the TOD detects a shift motor or position encoder until the system is shifted out of 4L.
fault continuously for one second the “4WD CHECK”
3. All Electric Shift activity is halted until the Ignition
lamp is turned on and the appropriate fault code is
is cycled. If a shift is in progress it will be
stored in memory.
completed.
1. A shift motor fault when the motor is off is defined
If the Front Speed Sensor recovers continuously for
as follows:
O.5 second the TOD will function normally. The 4WD
• Motor H-L shorted to Ground CHECK lamp is turned off but the fault code will remain
• Motor L-H shorted to Ground in memory.
• Motor open circuit
Rear Speed Sensor Test
2. A shift motor fault when the motor is energized is
defined as follows: If a Rear Speed Sensor fault is detected continuously
for 0.5 second the 4WD CHECK lamp is illuminated.
• Motor H-L shorted to Ground The TOD then responds as follows:
• Motor L-H shorted to Ground 1. If the system is in High Range the TOD uses the
• Motor H-L shorted to Motor L-H Front Speed Sensor to determine the EMC Touch
• Motor open circuit Off level and wheel slip control is suspended.
3. A position encoder fault is defined as follows: 2. If the system is in Low Range, the EMC Duty Cycle
• Any position code which does not correspond is set to maximum (independent of vehicle speed)
to the valid 9 codes. until the system is shifted out of 4L.
• A short to ground on any of the encoder lines. 3. All Electric Shift activity is halted until the Ignition
is cycled. If a shift is in progress it will be
4. If no shifts are in progress when a failure occurs
completed.
the TOD will not respond to any shift commands.
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.
SSANGYONG Y200
TRANSFER CASE - TOD 5D2-25

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.
YAD5D150 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.

SSANGYONG Y200
5D2-26 TRANSFER CASE - TOD

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

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-27

SCHEMATIC WIRING DIAGRAM

YAD5D190

SSANGYONG Y200
5D2-28 TRANSFER CASE - TOD

TOD CONTROL UNIT DIAGNOSTIC SYSTEM CHECK

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)
6 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? - Go to Step 7 System OK
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
7 manual.
4. Turn the ignition switch to ON.
5. Delete DTC with scan tool.
Is the repair complete? - System OK -

SSANGYONG Y200
5D2-36 TRANSFER CASE - TOD

DIAGNOSTIC TROUBLE CODE (DTC) 1715

TP Sensor Loss of Signal Action Taken When the DTC Sets
The TOD will illuminates 4WD CHECK indicator and
Circuit Description
DTC is stored in TOD.
The transfer case control unit (TOD) receives throttle
position (TP) sensor signals from engine control module Diagnostic Aids
(ECM) through CAN bus line.
• Check for poor connections of CAN bus line.
Conditions for Setting the DTC • Check for ECM and TP sensor.
The transfer case control unit (TOD) can not receive
Test Description
throttle position (TP) sensor signal from engine control
module (ECM). There is a bad communication between The number(s) below refer to step(s) on the diagnostic
TOD and ECM. table.
2. This step decides the causal parts of the problem.
• TOD is malfunction.
4. This step checks the ground condition.
• ECM is malfunction.
6. This step checks the connection status.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
1. Turn the ignition switch to OFF.
2. Connect the scan tool to data link connector (DLC) Go to “TOD
and follow the directions given in the scan tool Diagnostic
2
manual. System
3. Turn the ignition switch to ON and request engine Check”
DTC. Refer to
Are there any engine DTC related throttle position (TP) Section
sensor? - Engine Go to Step 3
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
3 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? 0Ω Go to Step 5 Go to Step 4
Repair or replace any open wires, faulty connector, or
4 terminal.
Is the repair complete? - System OK -

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-37

Step Action Value Yes No

1. Replace the TOD.
2. Connect all connectors.
5
3. Request DTC with scan tool.
Is the repair complete? - System OK Go to Step 6
6 Replace the ECU.
Is the repair complete? - System OK -

SSANGYONG Y200
5D2-38 TRANSFER CASE - TOD

DIAGNOSTIC TROUBLE CODE (DTC) 1716

TP Sensor Out of Range Action taken When the DTC Sets
The TOD will illuminates 4WD CHECK indicator and
Circuit Description
DTC is stored in TOD.
The transfer case control unit (TOD) receives throttle
position (TP) sensor signals from engine control module Diagnostic Aids
(ECM) through CAN bus line.
Check for poor connections of CAN bus line.
Conditions for Setting the DTC Check for ECU and TP sensor.
D The transfer case control unit (TOD) receives throttle
Test Description
position (TP) sensor signal from engine control module
(ECM), but the signal is out of the range. The number(s) below refer to step(s) on the diagnostic
table.
There is a bad communication between TOD and ECU.
2. This step decides the causal parts of the problem.
• TOD is malfunction.
4. This step checks the ground condition.
• ECU is malfunction.
6. This step checks the connection status.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Check”
1. Turn the ignition switch to OFF. Go to Step 2
2. Connect the scan tool to data link connector (DLC) Go to “TOD
and follow the directions given in the scan tool Diagnostic
2 manual. System
3. Turn the ignition switch to ON and request engine Check”
DTC. Go to specific
Are there any engine DTC related throttle position (TP) engine DTC
sensor? - diagnosis. Go to Step 2
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.
3 • 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? 0Ω Go to Step 4 Go to Step 5
Repair or replace any short wires, faulty connector, or
4 terminal.
Is the repair complete? - System OK -

DIAGNOSTIC TROUBLE CODE (DTC) 1722

Electromagnetic Clutch Short to Ground Diagnostic Aids

Circuit Description • Check for poor connections of the circuit.

To control the distribution of the torque to front propeller • Check for EMC.
shaft, the transfer case control unit (TOD) sends a
Test Description
signal to the electromagnetic clutch (EMC). Then the
clutch disc is compressed or released by the EMC. The number(s) below refer to step(s) on the diagnostic
table.
Conditions for Setting the DTC 2. This step checks poor connection or damage on
Even the TOD send signal for controlling the EMC, it the pin.
receives uncontrolled propeller shaft speed signal. 3. This step, along with step 4, checks the voltage
• The wiring circuit to EMC is shorted to ground. supply condition.
5. This step checks the ground condition.
Action Taken When the DTC Sets 7. This step checks the continuity of the wire and
The TOD will illuminates 4WD CHECK indicator and short to battery condition.
DTC is stored in TOD.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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.
2 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 3 System OK
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.
3 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? 11 ~ 14 V Go to Step 5 Go to Step 4
1. Check the fuse EF9, F10 and voltage supply circuit.
2. Repair or replace any open or damaged circuit or
4
fuse.
Is the repair complete? - Go to Step 5 -

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-43

Step Action Value Yes No

Connect a digital ohmmeter between each of the
following TOD connector terminal and ground.
5 • A9 (Ground)
• A10 (Ground)
Does the resistance of the all circuits measure within the
value specified? 0Ω Go to Step 7 Go to Step 6
Repair or replace any open or damaged circuit.
6 - Go to Step 7 -
Is the repair complete?
1. Disconnect the 7-pin connector under the body.
7 2. Measure the voltage between terminal 4 and ground.
Is the resistance within the value specified? 0Ω Go to Step 9 Go to Step 8

8 Repair open or short to battery circuit.

SSANGYONG Y200
5D2-44 TRANSFER CASE - TOD

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-49

Step Action Value Yes No

1. Repair any damaged pins, terminals, open or short to
ground circuit.
2. Reconnect the connectors and make sure it is seated
properly.
4 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? - Go to Step 5 System OK
Measure the resistance between terminals of the male
white 7-pin connector.
Is the measurement within specified range?
5 • Terminal 7 and terminal 5 5 ~ 6 MΩ
• Terminal 7 and terminal 1 5 ~ 6 MΩ
• Terminal 5 and terminal 1 9 ~ 10 kΩ Go to Step 7 Go to Step 6
Replace rear propeller shaft speed sensor.
6
Is the repair complete? - System OK -
1. Replace the TOD.
2. Turn the ignition switch to OFF.
3. Connect the scan tool to data link connector (DLC)
7 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? - System OK -

SSANGYONG Y200
5D2-50 TRANSFER CASE - TOD

DIAGNOSTIC TROUBLE CODE (DTC) 1734

Rear Speed Sensor Voltage High Diagnostic Aids

Circuit Description • Check for short to ground or open circuit.

The transfer case control unit (TOD) supplies 5 volts • Check for front propeller speed sensor.
reference voltage to the front speed sensor and
Test Description
receives speed signals generated by Hall effect speed
sensor. The number(s) below refer to step(s) on the diagnostic
table.
Conditions for Setting the DTC 3. This step checks the continuity.
• The wiring circuit for speed sensor shorted to 5. This step checks the speed sensor.
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.

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-55

Step Action Value Yes No

DIAGNOSTIC TROUBLE CODE (DTC) 1743

Shift System Timeout Diagnostic Aids

Circuit Description • Check for short to ground circuit.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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
2
manual.
3. Turn the ignition switch to ON. Go to
4. Request DTC with scan tool. Applicable
Is the DTC 1741 or 1742 also shown? - DTC Table Go to Step 3
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
3 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 4 System OK
1. Remove the shift motor.
2. Connect the black 7-pin connector to shift motor.
4
3. Check the motor operation by turning the 4H/4L Replace shift
switch. motor and Go
Is the motor run? - Go to Step 5 to Step 3
5 Replace the TOD.
Is the repair complete? - System OK Go to Step 6
Repair any problems in transfer case assembly.
6 -
Is the repair complete? System OK -

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-61

DIAGNOSTIC TROUBLE CODE (DTC) 1750

General Position Encoder Fault (Invalid Diagnostic Aids
Code) • Check for short to ground circuit.
Circuit Description Test Description
The transfer case control unit (TOD) receives position The number(s) below refer to step(s) on the diagnostic
encoder signals from position encoder. table.
Conditions for Setting the DTC 3. This step checks the continuity of the position
encoder line.
If the TOD detects a shift motor fault continuously for
one second, the 4WD CHECK indicator will illuminated 5. This step checks the connector and connection
and the diagnostic trouble code (DTC) will stored to status.
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 Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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
2
manual.
3. Turn the ignition switch to ON.
4. Request DTC with scan tool.
Is the DTC 1751, 1752, 1753, or 1754 also shown? - Go to Step 3 Go to Step 5
1. Disconnect 18-pin connector from the transfer case
control unit (TOD).
2. Measure the resistance between following terminals:
• B15 (TOD) and ground
3
• B5 (TOD) and ground
• B16 (TOD) and ground
• B18 (TOD) and ground
Is any of the resistance equal to specified value? 0Ω Go to Step 4 Go to Step 5
Repair all of the short to ground circuit.
4
Is the repair complete? - System OK -
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
5 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 6 System OK

SSANGYONG Y200
5D2-62 TRANSFER CASE - TOD

Step Action Value Yes No

Replace the shift motor with position encoder.
6
Is the repair complete? - System OK Go to Step 7
Replace the TOD.
7 Is the repair complete? - System OK -

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-63

DIAGNOSTIC TROUBLE CODE (DTC) 1751

Position 1 Shorted to Ground Diagnostic Aids

Circuit Description • Check for short to ground circuit.

The transfer case control unit (TOD) receives position Test Description
encoder signals from position encoder.
The number(s) below refer to step(s) on the diagnostic
table.
Conditions for Setting the DTC
3. This step checks the continuity of the position
• Position 2 code does not correspond to the specific encoder line.
codes.
5. This step checks the connector and connection
• A short to ground on any of the encoder lines. status.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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 Go to “DTC
2 1750 General
manual.
Position
3. Turn the ignition switch to ON.
Encoder Fault
4. Request DTC with scan tool. (Invalid
Is the DTC 1751 only current trouble code? - Go to Step 3 Code)”
1. Turn the ignition switch to OFF.
2. Disconnect 18-pin connector from the transfer case
control unit (TOD).
3
3. Measure the resistance between terminal A15 of TOD
connector and ground.
Is the resistance equal to specified value? 0Ω Go to Step 4 Go to Step 5
Repair short to ground circuit.
4
Is the repair complete? - System OK -
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
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 6 System OK
6 Replace the shift motor.
Is the repair complete? - System OK Go to Step 7
Replace the TOD.
7
Is the repair complete? - System OK -

SSANGYONG Y200
5D2-64 TRANSFER CASE - TOD

DIAGNOSTIC TROUBLE CODE (DTC) 1752

Position 2 Shorted to Ground Diagnostic Aids

Circuit Description • Check for short to ground circuit.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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 Go to “DTC
2 1750 General
manual.
Position
3. Turn the ignition switch to ON.
Encoder Fault
4. Request DTC with scan tool. (Invalid
Is the DTC 1752 only current trouble code? - Go to Step 3 Code)”
1. Turn the ignition switch to OFF.
2. Disconnect 18-pin connector from the transfer case
control unit (TOD).
3
3. Measure the resistance between terminal A10 of TOD
connector and ground.
Is the resistance equal to specified value? 0Ω Go to Step 4 Go to Step 5
Repair short to ground circuit.
4
Is the repair complete? - System OK -
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 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 6 System OK
Replace the shift motor.
6
Is the repair complete? - System OK Go to Step 7
Replace the TOD.
7 - System OK -
Is the repair complete?

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-65

DIAGNOSTIC TROUBLE CODE (DTC) 1753

Position 3 Shorted to Ground Diagnostic Aids

Circuit Description • Check for short to ground circuit.

The transfer case control unit (TOD) receives position Test Description
encoder signals from position encoder.
The number(s) below refer to step(s) on the diagnostic
table.
Conditions for Setting the DTC
3. This step checks the continuity of the position
• Position 3 code does not correspond to the specific encoder line.
codes.
5. This step checks the connector and connection
• A short to ground on any of the encoder lines. status.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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 Go to “DTC
2 1750 General
manual.
3. Turn the ignition switch to ON. Position
Encoder
4. Request DTC with scan tool. Fault(Invalid
Is the DTC 1753 only current trouble code? - Go to Step 3 Code)”
1. Turn the ignition switch to OFF.
2. Disconnect 18-pin connector from the transfer case
control unit (TOD).
3
3. Measure the resistance between terminal A28 of TOD
connector and ground.
Is the resistance equal to specified value? 0Ω Go to Step 4 Go to Step 5
Repair short to ground circuit.
4
Is the repair complete? - System OK -
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 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 6 System OK
Replace the shift motor.
6
Is the repair complete? - System OK Go to Step 7
Replace the TOD.
7
Is the repair complete? - System OK -

SSANGYONG Y200
5D2-66 TRANSFER CASE - TOD

DIAGNOSTIC TROUBLE CODE (DTC) 1754

Position 4 Shorted to Ground Diagnostic Aids

Circuit Description • Check for short to ground circuit.

The transfer case control unit (TOD) receives position Test Description
encoder signals from position encoder.
The number(s) below refer to step(s) on the diagnostic
table.
Conditions for Setting the DTC
3. This step checks the continuity of the position
• Position 4 code does not correspond to the specific encoder line.
codes.
5. This step checks the connector and connection
• A short to ground on any of the encoder lines. status.

Step Action Value Yes No

Was the TOD Diagnostic System Check performed? Go to “TOD
Diagnostic
1
System
- Go to Step 2 Check”
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 Go to “DTC
2 1750 General
manual.
3. Turn the ignition switch to ON. Position
Encoder
4. Request DTC with scan tool. Fault(Invalid
Is the DTC 1754 only current trouble code? - Go to Step 3 Code)”
1. Turn the ignition switch to OFF.
2. Disconnect 18-pin connector from the transfer case
control unit (TOD).
3
3. Measure the resistance between terminal A30 of TOD
connector and ground.
Is the resistance equal to specified value? 0Ω Go to Step 4 Go to Step 5
Repair short to ground circuit.
4
Is the repair complete? - System OK -
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 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 6 System OK
6 Replace the shift motor.
Is the repair complete? - System OK Go to Step 7
7 Replace the TOD.
Is the repair complete? - System OK -

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-67

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
TRANSFER CASE (TOD) COMPONENT LOCATOR

YAD5D200

1 Transmission (A/T) 5 Front Propeller Shaft

2 TOD Transfer Case 6 Bolt (M14, 4) .................................... 81 - 89 N•m
3 Extension Housing 7 Rear Propeller Shaft
4 Bolt................................................... 35 - 60 N•m 8 Bolt (M14, 4) .................................... 81 - 89 N•m

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

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-69

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
81 - 89 N•m
Tightening Torque
(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
81 - 89 N•m
Tightening Torque
(60 - 66 lb-ft)

YAD5D260

13. Unscrew 5 units of mounting bolt (M12) from

extension housing in transmission.
Installation Notice

Tightening Torque 35 - 60 N•m

(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

SSANGYONG Y200
5D2-70 TRANSFER CASE - TOD

TOD CONTROL UNIT

yyyy
;;;;
Removal & Installation Procedure
1. Disconnect (-) cable from battery.
2. Pull toward the driver seat and disconnect the 30
pin connector from TOD control unit.

;;;;
yyyy YAD5D280

;;;;
yyyy
3. Unscrew 2 bolts.

;;;;
yyyy YAD5D290

;;;;
yyyy
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.

;;;;
yyyy
Installation Notice
Tightening Torque 10 N•m (89 lb-in)

YAD5D300

SHIFT MOTOR
Removal & Installation Procedure
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.
YAD5D310

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-71

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
YAD5D320 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.

SPEED SENSOR IN FRONT AND

REAR PROPELLER SHAFT
Replacement Procedure
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
5D2-72 TRANSFER CASE - TOD

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
TRANSFER CASE - TOD 5D2-73

Installation Notice

Tightening Torque 3 - 6 N•m

(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
5D2-74 TRANSFER CASE - TOD

UNIT REPAIR
TRANSFER CASE, DISASSEMBLED VIEW

YAD5D360

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-75

1 Bearing 39 Shift Rail

2 Bushing 40 Shaft, Shift
3 Carrier Assembly 41 Spacer
4 Sun Gear 42 Torsion Spring
5 Thrust Plate 43 Electric Shift Cam
6 Input Shaft 44 Transfer Case Shift Motor
7 Output Shaft Thrust Washer 45 Bolt
8 Bearing 46 J-clip
9 Snap Ring 47 Connector Retainer
10 High-low Collar 48 Bolt
11 Rear Output Shaft 49 Support Stud
12 Oil Strainer 50 Lower Speed Sensor (Front)
13 Coupling Hose 51 Plug
14 Hose Clamp 52 Identification Decal
15 Pump Assembly 53 Cover
16 Thrust Washer 54 Tone Wheel, Lower
17 Sprocket, Drive (24T) 55 Chain, Drive
18 Clutch Pack Assembly 56 Sprocket, Driven (24T)
19 Insulator Washer 57 Magnet, Oil Pan
20 Armature 58 Case
21 Snap Ring 59 Case Flange and Output Shaft
22 Wave Washer 59 Case Assembly
23 Apply Cam 60 Breather Bar
24 Ball 61 Spiral Pin
25 Cam and Coil Assembly 62 Oil Seal
26 Nut (2) 63 Pin, Dowel
27 Output Shaft Yoke Washer 64 Ring Gear
28 Oil Seal 65 Retaining Ring
29 Case Flange 66 Snap Ring
30 Bolt 67 Bearing
31 Upper Speed Sensor (Rear) 68 Snap Ring
32 Nut 69 Bearing
33 Washer 70 Speedometer Drive Gear
34 Bolt (M10 X 105 X 30) 71 Facing, Shift Fork
35 Tag, Identification 72 Upper Tone Wheel
36 Thrust Bearing 73 Oil Seal
37 Clutch Coil Assembly 74 Bearing Sleeve
38 Fork, Reduction Shift 75 Bearing

SSANGYONG Y200
5D2-76 TRANSFER CASE - TOD

DISASSEMBLY PROCEDURE
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.

4. Remove outer tube on speed sensor connector.

YAD5D370
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
TRANSFER CASE - TOD 5D2-77

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
5D2-78 TRANSFER CASE - TOD

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
TRANSFER CASE - TOD 5D2-79

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
5D2-80 TRANSFER CASE - TOD

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.
• 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.

YAD5D500

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
TRANSFER CASE - TOD 5D2-81

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
5D2-82 TRANSFER CASE - TOD

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
TRANSFER CASE - TOD 5D2-83

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
5D2-84 TRANSFER CASE - TOD

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
8 - 11 N•m
Tightening Torque
(71 - 97 lb-in)

YAD5D680

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-85

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
5D2-86 TRANSFER CASE - TOD

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.

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-87

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
5D2-88 TRANSFER CASE - TOD

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
8 - 11 N•m
Tightening Torque
(71 - 97 lb-in)

55. Retighten the two nuts that attach the slotted

support bracket to the end of the motor.
Installation Notice
3 - 6 N•m
Tightening Torque
(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 N•m

61. Install the drain plug and tighten.

19 - 30 N•m
Tightening Torque
(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
19 - 30 N•m
Tightening Torque
(14 - 22 lb-ft)

64. Install the transfer case as outlined in removal and

Installation.

SSANGYONG Y200
TRANSFER CASE - TOD 5D2-89

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

Snap Ring Plier Input Shaft Support

YAD5D780 YAD5D790

Bearing Removal/
Bearing Installer
Installer

YAD5D800 YAD5D810

Seal Installer

YAD5D820

SSANGYONG Y200
SECTION 6A

POWER STEERING

TABLE OF CONTENTS
General Description and Operation ..................... 6A-2 Oil Quantity Check and Air Bleeding .................... 6A-9
Specifications ...................................................... 6A-2 Maintenance and Repair ................................... 6A-12
Diagnostic Information and Procedures .............. 6A-3 On-Vehicle Service ............................................... 6A-12
Component Locator ............................................ 6A-4 Power Steering Pipe/Hose .................................. 6A-12
Power Steering System Locator ............................ 6A-4 Power Steering Box Assembly ........................... 6A-13
Steering Gear Box Cross Section ......................... 6A-5 Steering Gear Pump .......................................... 6A-14
Power Steering Assembly .................................... 6A-6 Assembly Installation ........................................ 6A-14
General Inspection ............................................... 6A-7 Unit Repair .......................................................... 6A-17
Oil Pump Pressure ............................................... 6A-7 Steering Gear Box ............................................. 6A-17
Power Steering Gear Preload Adjustment ............. 6A-8 Special Tools and Equipment ............................ 6A-23
Oil Change .......................................................... 6A-8 Special Tools Table ............................................ 6A-23
6A-2 POWER STEERING

GENERAL DESCRIPTION AND OPERATION

SPECIFICATIONS

Steering Wheel Number of spoke 4-Spoke Type

Outer Diameter 390 mm
Steering Gear Box Type Rack and pinion
Gear Ratio
Steering Angle Inner 36° 17´
Outer 32° 40´
Oil pump Type Vane
MAX. Pressure 82 ~ 92 kgf/cm²
Outlet 10.5L/min
Size 124mm
Tilt column Angle Upper 4°
Lower 4°
Turning Radius 5.7 m
Oil Type ATF DEXRON II
Capacity 1L

SSANGYONG Y200
POWER STEERING 6A-3

DIAGNOSTIC INFORMATION AND PROCEDURES

Phenomena Checks Action
Hard Steering Lack of Lubrication Lubricate
Abnormal Wear or Binding of Steering Ball Joint Replace
Damaged or Faulty Steering Gear Replace gear assembly
Improper Preload of Steering Pinion Adjust
Faulty Steering Shaft Joint Replace
Steering Fluid Leaks Repair or replace
Lack of Fluid or Air-in System Replenish or bleed
Faulty Steering Oil Pump Replace
Steering Pulls to One Damaged or Loosened Pump Drive Belt Adjust or replace
Side Clogging Oil Line Repair or replace
Damaged Wheel or Tire Repair or replace
Faulty Suspension System Repair or replace
Damaged Steering Linkage Repair
Damaged Wheel and Tire Repair or replace
Faulty Brake System Repair or replace
Faulty Suspension System Repair or replace
Excessive Wheel Play Worn Steering Gear Replace gear assembly
Worn or Damaged Steering Ball Joint Replace
Loosened Steering Gearbox Bolts Retighten
Poor Return of Steering Damaged or Binding Steering Ball Joint Replace
Wheel Improper Preload of Steering Pinion Replace gear assembly
Damaged Wheel or Tire Repair or replace
Faulty Suspension System Repair or replace
Steering Wheel Damaged Steering Linkage Replace
Shimmy Loosened Steering Gearbox Mounting Bolt Retighten
Damaged or Binding Steering Ball Joint Replace
Worn or Damaged Front Wheel Bearing Replace
Damaged Wheel or Tire Repair or replace
Faulty Suspension System Repair or replace
Abnormal Noise From Loosened Steering Gearbox Mounting Bolt Retighten
Steering System Faulty Steering Gear Replace gear assembly
Steering Column Linterference Replace
Loosened Steering Linkage Retighten
Damaged or Loosened Oil Pump Drive Belt Adjust or replace
Loosened Oil Pump Bracket Retighten
Loosened Oil Pump Mounting Bolt Retighten
Air-in System Bleed
Faulty Oil Pump 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
6
5
1 3 4
2

8 7
9

YAD6A030

1 Tie Rod End 6 Mounting Bracket

2 Tie Rod 7 Tie Rod End
3 Bellows 8 Tie Rod End
4 Rack Housing 9 Cylinder Tube
5 Feed Tube 10 Valve Assembly

SSANGYONG Y200
6A-6 POWER STEERING

POWER STEERING ASSEMBLY

2
11 10 1
13
14
9
3

9
11
10 4

6
8
7

YAD6A150

1 Power Steering Pump Reservoir Assembly 8 Hexagon Bolt

2 Power Steering Pump Cap Assembly 9 Fan Screw (M5)
3 Clip 10 Welded Nut
4 Return Line 11 Pipe Clamp
5 Pressure Line 12 Hexagon Bolt
6 Power Steering Gear 13 Nut
7 Power Steering Pipe Mounting Bracket Clip. 14 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
YAD6A040
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/cm²

9. Open the gauge valve completely and then

measure the oil pressure.
A 3 - 5 kgf/cm²

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.
MAX 5. Separate the oil return line from the oil tank.
MIN
6. Remove the high pressure cable in the ignition
coil.
7. Operating the ignition motor periodically, turn the
YAD6A070
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.

SSANGYONG Y200
POWER STEERING 6A-9

OIL QUANTITY CHECK AND AIR

BLEEDING
Oil Quantity Check
1. Place the vehicle on flat road and start the engine
MAX and keep it idling.
5mm
MIN
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 36° 17´
Outer 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
6A-12 POWER STEERING

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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 6A-13

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
6A-14 POWER STEERING

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 Torque
Upper 23 N•m (17 lb-ft)
Bolt
Lower 23 N•m (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
70 - 90 N•m
95 mm Bolt/Nut (Upper)
(52 - 66 lb-ft)
70 - 90 N•m
95 mm Bolt/Nut (Lower)
YAD6A260 (52 - 66 lb-in)

SSANGYONG Y200
POWER STEERING 6A-15

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
70 - 90 N•m
Center Bolt/Nut
(52 - 66 lb-ft)
70 - 90 N•m
Left Bolt/Nut
(52 - 66 lb-in)

YAD6A270

4. Install the steering lower shaft to the gearbox. The

joint bolt on the lower shaft should be tightened
B A 1 toward ‘B’ (threaded) from ‘A’ (non-threaded).
Installation Notice
2 25 - 30 N•m
Tightening Torque
(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 7 - 10 N•m
Tightening Torque
(62 - 89 lb-in)

YAD6A300

SSANGYONG Y200
6A-16 POWER STEERING

7. Install the supply/return pipe in gear box housing.

Installation Notice
12 - 18 N•m
Supply Pipe 2
(9 - 13 lb-ft)
1 12 - 18 N•m
Return Pipe 1
(9 - 13 lb-ft)

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
1 picture.
Notice: After inserting the hose into the reservoir
tank completely, install in order that the spring
3 clamp is placed in the center of nipple.

10. After installing completely, do bleeding.

YAD6A330

SSANGYONG Y200
POWER STEERING 6A-17

UNIT REPAIR
a
STEERING GEAR BOX
Disassembly
1. Disassembly the tie rod end boot (a).

YAD6A340

2. Remove the cylinder tube (2) in gear box.

2 3. Remove the valve tube (1) in gear box.
1

YAD6A350

4. Remove the lock nut (1) and separate the plug (2)
1 and spring (3).

YAD6A360

5. Remove the dust cover (1) and pull off the retainer
1 ring (2).

YAD6A370

SSANGYONG Y200
6A-18 POWER STEERING

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.
Notice: Tap the draft using the hammer as lik the
5
picture.

YAD6A390

8. Tapping the pinion bearing softly using the plane

and long draft and rubber hammer, remove the
bearing.
6

YAD6A400

9. Remove the pinion shaft seal (7), needle bearing

7 (8), retainer ring (9).
8 Notice: Do not overhaul the power steering gear
housing and rack gear, if the damage happened,
9
replace them with assembly.

YAD6A410

SSANGYONG Y200
POWER STEERING 6A-19

Rack Gear Shaft Checks

3 1. Check the rack gear damage.
2 • Set up the v-block (1) on the plane table.
4 • 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.
1

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).

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.
1
• Check the rack and pinion boot for the crack or
2 wear.

YAD6A440

4. Check the steering gear housing for the crack,

deformation and wear.
a

YAD6A450

SSANGYONG Y200
6A-20 POWER STEERING

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

10. Check the bearing and oil seal for the damage.
1 • Check the pinion shaft seal for the wear or
leakage.
2
• 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
POWER STEERING 6A-21

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.
7 7
• Install the retaining ring (6).
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
6A-22 POWER STEERING

5. Install the fluid pressure line in power steering gear

and tighten them as specified torque.
2
1 Tighten the fitting to the piston side.
2 Tighten the fitting to the cylinder side.
1

YAD6A530

6. Assemble the tie rod end boot.

Notice: Apply the grease to the tie rod end ball
joint and boot.

YAD6A540

SSANGYONG Y200
POWER STEERING 6A-23

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

Tie Rod End Remover

YAD6A550

SSANGYONG Y200
SECTION 6E

STEERING COLUMN
TABLE OF CONTENTS
General Description and Operation ............... 6E-2 Steering Column & Wheel ................................ 6E-7
Steering Wheel ................................................. 6E-2 Maintenance and Repair .................................. 6E-8
Column & Shaft Assembly ............................... 6E-2 On-Vehicle Service .............................................. 6E-8
Lower Shaft ....................................................... 6E-2 Steering Column ............................................... 6E-8
Tightening Torque ............................................. 6E-3 Steering Wheel & Shaft ................................... 6E-11
Diagnostic Information and Procedures ........ 6E-4 Unit Repair ........................................................ 6E-15
Component Locator ......................................... 6E-5 Steering Gear Box ...........................................6E-15
Steering Column Assembly .............................. 6E-5 Special Tools And Equipment ........................ 6E-16
Steering Assembly Cross Section ................... 6E-6 Special Tools Table ......................................... 6E-16
6E-2 STEERING COLUMN

GENERAL DESCRIPTION AND OPERATION

The steering wheel and column have the function of COLUMN & SHAFT ASSEMBLY
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.

STEERING WHEEL

YAD6E020

LOWER SHAFT

YAD6E010

Type 4 Spoke Type

Outer Diameter 390 mm

The vibration absorbing damper is mounted in steering

wheel in order that the vibration may be minimized. YAD6E030

Type 4 Spoke Type

Angle 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 Torque
Steering Column Shaft Steering Column Mounting Bolt (upper) 20 - 25 N•m (15 - 18 lb-ft)
Steering Column Mounting Bolt (lower) 20 - 25 N•m (15 - 18 lb-ft)
Steering Wheel and Steering Column shaft Lock Nut 40 - 60 N•m (30 - 44 lb-ft)
Steering Column and Airbag Module Connection Bolt 7 - 11 N•m (62 - 97 lb-in)
Steering Column and Lower Shaft Connection Bolt 25 - 30 N•m (18 - 22 lb-ft)
Power Steering Gear Steering Gear Box and Gear Box Cross Member 70 - 90 N•m (52 - 66 lb-ft)
Box Mounting Bolt
Steering Gear Box and Lower Shaft Connection Bolt 25 - 30 N•m (18 - 22 lb-ft)
Tie Rod End and Steering Lock Connection Nut 35 - 45 N•m (26 - 33 lb-ft)
Tie Rod End Lock Nut 65 - 80 N•m (48 - 59 lb-ft)
Steering Gear Box and Pressure Hose Connection Nut 15 - 20 N•m (11 - 15 lb-ft)
Steering Gear Box and Return Line Connection Nut 15 - 20 N•m (11 - 15 lb-ft)
Power Steering Pump Power Pump Bracket and Timing Gear Case Cover 20 - 23 N•m (15 - 17 lb-ft)
Mounting Bolt
Power Pump and Pressure Hose Connection Nut 40 - 50 N•m (30 - 37 lb-ft)
Power Steering Line Return Line and Cilp Connection Bolt 9 - 14 N•m (80 - 124 lb-in)

SSANGYONG Y200
6E-4 STEERING COLUMN

DIAGNOSTIC INFORMATION AND PROCEDURES

Phenomena Checks Action
Noise (When operating Loosened or Poor Tightening Steering Column Nut Retightening
the steering wheel) Worn or Damaged Steering Shaft Bearing Replace steering column
Lossened or Poor Interm shaft Pinch Bolt Retightening
Excessive Steering Worn or Damaged Steering Shaft Bearing Replace steering column
Force
Poor Operating of Inner Defect of Lock Cylinder Replace steering column
Ignition Switch Inner Defect of Ignition Switch Replace ignition switch

SSANGYONG Y200
STEERING COLUMN 6E-5

COMPONENT LOCATOR
STEERING COLUMN ASSEMBLY

YAD6E040

1 Steering Wheel 3 Lower Shaft Assembly

2 Column Shaft Assembly 4 Steering Gear Assembly

SSANGYONG Y200
6E-6 STEERING COLUMN

STEERING ASSEMBLY CROSS SECTION

Side

Rear

YAD6E050

SSANGYONG Y200
STEERING COLUMN 6E-7

STEERING COLUMN & WHEEL

3
4

5
2
6

YAD6E060

1 Steering Column shaft 5 Bolt

2 Lower Shaft 6 Washer
3 Bolt 7 Bolt
4 Nut

SSANGYONG Y200
6E-8 STEERING COLUMN

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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
STEERING COLUMN 6E-9

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
6E-10 STEERING COLUMN

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
STEERING COLUMN 6E-11

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 1. Insert the lower shaft into the gear box (spline part)
and then tighten the blots as specified torque.
Notice:
2 • Install the lower shaft to tighten the bolt in non-
spline part of upper spline part
• Install to align the assembly marking
Installation Notice
30 - 40 N•m
Tightening Torque
(22 - 30 lb-ft)
YAD6E200

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 non-
spline part of upper spline part
• Install to align the assembly marking
Installation Notice
30 - 40 N•m
Tightening Torque
(22 - 30 lb-ft)

YAD6E210

SSANGYONG Y200
6E-12 STEERING COLUMN

3. Tighten the floor bolt of steering column as

specified torque.
Installation Notice
20 - 25 N•m
Tightening Torque
(15 - 18 lb-ft)
4. Tighten the upper bolt of steering column shaft
as specified torque.
Installation Notice
20 - 25 N•m
Tightening Torque
(15 - 18 lb-ft)
YAD6E220

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
STEERING COLUMN 6E-13

8. Connect the fuel cut vacuum hose with the

connector.
Notice: The identification color is marked in fuel
cut vacuum hose.

Classification Color
Fuel Cut Vacuum Hose-Inlet Green
Fuel Cut Vacuum Hose-Outlet 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
6E-14 STEERING COLUMN

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
STEERING COLUMN 6E-15

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
6E-16 STEERING COLUMN

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

SteeringWheel
Remover

YAD6E340

SSANGYONG Y200
SECTION 7A

HEATING AND VENTILATION SYSTEM

TABLE OF CONTENTS
Description and Operation ................................... 7A-2 Heater Controls .................................................. 7A-12
General ............................................................... 7A-2 Blower Noise ..................................................... 7A-13
Specifications ...................................................... 7A-3 Component Locator ........................................... 7A-14
Air Delivery and Function ..................................... 7A-4 Airflow Through Vents With Rear Heating Duct ... 7A-14
Schematic and Routing Diagrams ........................ 7A-6 Repair Instructions .............................................. 7A-15
Diagnostic Information and Procedures .............. 7A-7 On-Vehicle Service ............................................... 7A-15
Insufficient Heating Or Defrosting ........................ 7A-7 Air Duct Assembly ............................................ 7A-15
Blower Electrical .................................................. 7A-9 Rear Cooler Duct ............................................... 7A-16
Improper Air Delivery Or No Mode Shift .............. 7A-10 Heater and Blower Module Assembly................. 7A-17
Too Much Heat .................................................. 7A-11 Heater Suction and Discharge Hose ................... 7A-18
7A-2 HEATING AND VENTILATION SYSTEM

DESCRIPTION AND OPERATION

GENERAL Heater system is consist of heater hose, heater module,
blower motor and adjustment system.
Heater is the system that circulate the suction air
The control switch assembly (adjustment system)
through the heater core to deliver the heat of engine
equipped with the instrument panel can control the
coolant to the suction air and designed for heating
temperature, the amount and the direction of the outlet.
and defrosting in the passenger room.
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

Engine Type GSL GSL

Blower Motor Max. Capacity 7.425 - 9.075 kcal/h ←
Heater Core Fin Pitch 1.52 mm ←
Size (L x H x W) 194.6 x180 x 35 mm ←
Heating Capacity 8,250 (Min. 4,700) kcal/h ←
Blower Motor Resistance 1st Mode 3.25 Ω ←
2nd Mode 1.45 Ω ←
3rd Mode 0.35 Ω ←
4th Mode Ω ←
Front A/C and Heater Unit Type Heater+Evaporator and Blower (2 pieces)
Heating Capacity Min. 4600 kcal/h (5.5 m3/Min)
Cooling Capacity Min. 4700 kcal/h (7.5 m3/Min)
Expansion Valve Block Type
Input Power Max. 250 W
Rear Cooler Type Evaporator and Blower (only Cooler)
Cooling Capacity Min. 2700 kcal/h (5 m3/Min)
Expansion Valve ANGLE Type
Input Power Max. 180 W

SSANGYONG Y200
7A-4 HEATING AND VENTILATION SYSTEM

AIR DELIVERY AND FUNCTION Air Mix Door Motor

Mode Door Motor Installation Location
It’s located at the lower side of heater housing
Installation Location
It’s located at the left side of heater case. Function
It controls the open/close of damper by the control
Function
command of automatic temperature control to adjust
It controls the open/close of the outlet at Vent, Foot or the temperature of outlet air.
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.

Intake Door Motor

Installation Location
It’s 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
HEATING AND VENTILATION SYSTEM 7A-5

Recirculation Switch Tempera-

VENT BI-LEVEL FOOT FOOT/DEF DEF ture
MODE
Control
REC FRE Lever
CENTER VENT (1) A B – – – – – –
SIDE VENT (2) A B B B B – – –
Front FOOT (3) – C B C – – – –
DEFROSTER (4) – – D C B – – –
SIDE DEF (5) – – D D C – – –
VENT* (6) B C – – – – – –
Rear
FOOT (7) – C B D – – – –
INTAKE Door (A) (B) –
AIR MIX Door – – A B C

YAD7A030

SSANGYONG Y200
7A-6 HEATING AND VENTILATION SYSTEM

BLOWER MOTOR DIAGRAM SCHEMATIC & ROUTING DIAGRAM

YAD7A040

SSANGYONG Y200
HEATING AND VENTILATION SYSTEM 7A-7

DIAGNOSTIC INFORMATION AND PROCEDURES

INSUFFICIENT HEATING OR DEFROSTING

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 Action
Check Is the cable connected Yes Check the range of the door travel and the effort required to
connection and retained properly? move it.
and the No Connect and attach the cable properly.
attachment
Check the operation of the temperature control switch.
of the door
cable Does the door operate Yes If required, repair.
properly? No Recheck the system using “Control setting/Correct Results”
test.
Is there a problem with Yes Repair or replace the temperature control switch or the cable.
the temperature control No System OK
switch or wiring?

Is the system OK after Yes Check the airflow from the defroster or the vent outlets.
the repair complete? No System OK
Is the heavy airflow? Yes Switch the mode knob to defrost.
No Remove the heater outlet and then remove any obstructions
in the heater outlet.
Is the airflow proper? Yes Check the blower speed for change in the airflow as the
control is turned 1 to 4.
No Repair or replace any obstructions at heater and air delivery
case.
Does the blower motor Yes Go to “Blower Electrical”
speed increase? No System OK
Is the system OK after Yes Set the blower switch to 4th.
the repair complete? Rotate the temperature control from full cold to full hot.
No Listen to an airflow change.
Does the airflow change? Yes Repair or replace any obstruction between the blower and the
system outlets.
No Check and repair the door adjustments, the cables, the
linkage and the control.

SSANGYONG Y200
HEATING AND VENTILATION SYSTEM 7A-11

TOO MUCH HEAT

Check Action
Mode Is there too much heat Yes Set the temperature control switch to defrost position.
switch to when the mode switch is No Set the mode switch to the vent position.
the floor in the floor position?
position
Is the airflow proper? Yes 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.
No Check the door travel, the cables, the controls and the
linkage for the defrost position and then repair or replace as
needed.
Is the heavy airflow? Yes Check the door travel, the cables, the controls and the
linkage for the full hot, full cold position and then adjust as
needed.
No Check for a change in the airflow at different blower speed.
Check the change.
Does the airflow change? Yes System OK
No Go to “Blower Electrical”
Is the airflow proper? Yes Turn the ignition “OFF”.
Turn the temperature control knob to full hot, then rapidly to
full cold.
No Check the system case for leaks and check the floor outlet
attachment.
Can you hear the sound Yes Adjust the vent door to vent mode.
of the temperature door No Check the door travel, the cables, the controls and the
slam? linkage for the full hot, full cold position and then adjust as
needed.

SSANGYONG Y200
7A-12 HEATING AND VENTILATION SYSTEM

HEATER CONTROLS
Check Action
Turn the Is excessive effort Yes Check the cable for improper routing, kinks, wiring
temperature required to move the interference or other instrument panel interference.
control control? No Set the blower switch to 4th.
switch
Repeat to turn the temperature control knob to full hot, then
rapidly to full cold
Does the control operate Yes Remove the cable from any door that binds on the cable.
properly? Cycle the door manually.
Check the door binding.
No Repair or replace the problem.
Is there any door Yes Check the door seal for proper installation.
binding? No Check the control for binding.
Does the control bind? Yes Reinstall the cable to the door.
Repair the instrument panel interference with the cable.
No Remove the cable from the control.
Check the control for binding.
Does the control bind? Yes Replace the control switch.
No Replace the cable.
Is excessive effort Yes Remove the cable from the control.
required to move the Operate the control switch.
control?
No System OK
Does the control operate Yes System OK
properly without any No Replace the control switch.
interference?
Is the installation good Yes Check a binding door for the shaft alignment, a bent shaft, a
condition? bent door or warped case and then repair as needed.
No Repair the door seal or replace as needed.

SSANGYONG Y200
HEATING AND VENTILATION SYSTEM 7A-13

BLOWER NOISE
Check Action
Cycle Is the blower noise Yes Remove any obstruction or foreign material of the duct.
through the constant at high blower Check floor/defroster door seals.
blower speeds or certain modes,
Repair or replace as needed.
speeds, but absent at lower
the modes speeds or in other No Check for the vibration from the blower motor and fan
and the modes? assembly at each blower speed by feeling the blower motor
temperature housing.
settings in Check for the foreign materials at the opening of the blower
order to inlet.
find the Did you find the Yes Remove all foreign materials and repair or replace the blower
noise. excessive vibration and motor and fan assembly.
-Close all any foreign material? No Set the blower switch to 4th.
of the Check any noise from full hot to full cold temperature
doors and positions in the defroster, floor and vent modes.
windows.
Is the noise constant? Yes Remove any obstruction or foreign material of the duct.
-Turn the
ignition Check the floor/defroster door seals.
“ON”. Repair or replace as needed.
-Set the No Check any noise in the floor mode.
blower Is the noise constant? Yes Remove any obstruction or foreign material of the duct.
switch to Check the floor/defroster door seals.
4th.
Repair or replace as needed.
-Set the
No Check any noise in the vent mode.
control
switch to Is the noise constant? Yes Remove any obstruction or foreign material of the duct.
full hot Check the vent door seals.
position. Repair or replace as needed.
Is the blower noise Yes Check the temperature door seals
constant at any modes No Check the system for obstructions, foreign materials between
but absent at all modes the fan and the temperature door and then repair or replace
of temperature control the fan as required.
lever?

SSANGYONG Y200
7A-14 HEATING AND VENTILATION SYSTEM

COMPONENT LOCATOR
AIRFLOW THROUGH VENTS WITH REAR HEATING DUCT

YAD7A050

1 Blower and Evaporator Assembly 8 A/C Controller

2 Heater Assembly 9 Console Middle Ventilation Duct
3 Side Defroster Duct (LH) 10 Console FOOT Duct
4 Main Defroster Nozzle 11 Console Rear Ventilation Duct
5 Side Defroster Duct (RH) 12 Rear cooler Duct
6 Side Defroster Joint 13 Rear cooler Assembly
7 Console Front Ventilation Duct 14 Rear cooler Controller

SSANGYONG Y200
HEATING AND VENTILATION SYSTEM 7A-15

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
AIR DUCT ASSEMBLY
Removal & Installation Procedure
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
7A-16 HEATING AND VENTILATION SYSTEM

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

Removal & Installation Procedure
1. Remove the rear quarter inner panel.
2. Remove the tapping screw and hex screw at the
duct.
3. Remove the duct.

YAD7A110

4. Installation should follow the removal procedure

in the reverse order.

YAD7A120

SSANGYONG Y200
HEATING AND VENTILATION SYSTEM 7A-17

HEATER AND BLOWER MODULE

ASSEMBLY
Removal & Installation Procedure
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
7A-18 HEATING AND VENTILATION SYSTEM

• 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
Removal & Installation Procedure
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 Compressor Oil Replacement ............................ 7B-17
Specifications ...................................................... 7B-2 Replacement of Refrigerant Connection .............. 7B-18
Repair Instructions ............................................... 7B-3 Repair Instructions .............................................. 7B-19
Basic A/C System Function .................................. 7B-5 On-Vehicle Service ............................................... 7B-19
Component Locator ............................................. 7B-7 Air Filter (Auto A/C) ............................................ 7B-19
A/C System Component ...................................... 7B-7 Receiver-Dryer ................................................... 7B-20
A/C System Pipe Line .......................................... 7B-8 Condenser ......................................................... 7B-21
Compressor Location ........................................... 7B-9 Compressor....................................................... 7B-23
Diagnostic Information and Procedures ............ 7B-10 A/C High/Low Pressure Line ............................... 7B-23
General Diagnosis ............................................. 7B-10 A/C Module Assembly ....................................... 7B-24
Diagnosis Using The Manifold Gauge ................ 7B-11 Unit Repair ........................................................... 7B-25
Maintenance and Repair ................................... 7B-13 Compressor....................................................... 7B-25
Refrigerant Charging .......................................... 7B-13 Special Tools and Equipment ............................ 7B-27
Special Tools Table ............................................ 7B-27
7B-2 GENERAL HVAC SYSTEM

DESCRIPTION AND OPERATION

SPECIFICATIONS

Component Application Specifications

Compressor Model V5 V7
Type Variable Displacement ←
Displacement 9.8 - 151 cc/rev 9.8 - 179 cc/rev
PCD Ø130 ←
Cylinder 5 7
Oil (Synthetic Oil) 265 ml ←
Condenser Type MFC (6-PASS)
Size 620 w x 479 h x 20 t
Receiver-Dryer Capacity 250 cc
Desiccant XH-9 (35 g)
Pressure Switch DSL : Dual Pressure, GSL: Triple Pressure
Refrigerant Type R-134a
Refrigerant Capacity Single: 850 ± 50 g, Dual: 1200 ± 50 g

SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-3

REPAIR INSTRUCTIONS 3. Check the operation of the blower fan.

4. Check all the air ducts for leaks or restrictions. Low
Air Conditioning airflow rate may indicate a restricted evaporator
Vehicle air conditioning is the cooling (refrigerant), core.
heating and ventilation of the air in the passenger 5. Check for slippage of the compressor clutch.
compartment. Refrigerant is accomplished by making
6. Check the drive belt tension.
practical use of the three laws of nature. These laws of
nature and their practical application are as follows:
Handling O-Ring
• Heat transfer 1. Even though O-rings may look identical, it is
• Latent heat of vaporization extremely important that only recommended service
• Effect of pressure on boiling or condensation replacement air conditioning O-rings be used, or
excessive leakage of the refrigerant may occur.
Heat Transfer 2. Always O-ring and installation area should be kept
The principle of heat transfer are that the heat always clean. Any foreign material and dust may result in
flow from hot to cold, the rate of heat transfer will excessive refrigerant leakage.
increase as the difference in temperature between two 3. Before installation, verify that both O-ring and
objects increases, and the mass of an object remains fittings have not been nicked or deformed.
the same regardless of its heat contents. Deformed or nicked parts must be replaced.
Latent Heat of Vaporization 4. Failure to use the proper service replacement parts
and procedures may result in excessive refrigerant
Everything in the world is composed of matter and the leakage.
matter exists in one of following states;
• Solid Handling Refrigerant
• Liquid 1. Always work in a well-ventilated area.
• Vapor 2. If you have difficulty breathing, seek medical
When a liquid boils, it changes to vapor and absorbs attention immediately. If refrigerant comes in
heat without raising the temperature of the resulting contact with any part of your body, flush the
vapor. exposed area with water. If a rush or pain develops
seek medical attention.
When the vapor condenses, it changes back to a liquid
and gives off heat without lowing the temperature of
Handling of Refrigerant Lines and Fittings
the resulting liquid.
1. Using too low or too high a torque when tightening
Effect of Pressure on Boiling or Condensing a fitting can result in loose joints or deformed joint
parts.
When the pressure on the liquid or vapor changes, the
boiling point changes. Increasing the pressure 2. Back up the opposing fitting to prevent the distortion
increases the boiling point, while the boiling point of the connecting lines or the components. Back
decreased by decreasing the pressure on the liquid up both the swaged fitting on the flexible hose
or vapor. connections and the coupling to which it is attached
two wrenches to prevent turning the fitting and
Another effect of the compression is an increase in
damaging the ground seat.
temperature even through heat has not been added.
For example, if you compress the refrigerant R-134a
Maintaining Chemical Stability In the
from 206kPa (30 psi) to 1206kPa (175 psi) the
temperature of vapor will increase from 0 °C (32 °F) to Refrigeration System
54 °C (130 ° F) and boiling point increase. Condensing The efficient operation and life of the air conditioning
point also will increase. system is dependent upon the chemical stability of
the refrigeration system.
Testing the refrigerant system When foreign materials, such as dirt, air or moisture,
1. Check the outer surfaces of the radiator and the contaminate the refrigeration system, they will change
condenser cores to be sure that the airflow is not the stability of the refrigeration and the polyalkalene
blocked by dirt leaves or other foreign material. glycol (PAG) compressor oil. They will also affect the
Check between the condenser and the radiator as pressure-temperature relationship, reduce efficient
well as all outer surfaces. operation and can possibly cause interior corrosion and
2. Check for any restrictions or kinks inthe condenser abnormal wear of moving parts.
core, the hoses and the pipes.

SSANGYONG Y200
7B-4 GENERAL HVAC SYSTEM

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
GENERAL HVAC SYSTEM 7B-5

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
GENERAL HVAC SYSTEM 7B-7

COMPONENT LOCATOR
A/C SYSTEM COMPONENT

YAD7B040

1 Condenser 7 Rear Duct

2 Receiver-Drier 8 Rear Cooler Assembly
3 Compressor 9 Rear Cooler Duct
4 A/C & Heater (Blower) Module 10 Suction Rear Pipe Line
5 Defrost Nozzle/Duct 11 Liquid Rear Pipe Line
6 Front A/C Controller 12 Rear Cooler Controller

SSANGYONG Y200
7B-8 GENERAL HVAC SYSTEM

A/C SYSTEM PIPE LINE

YAD7B330

1 High Pressure Pipe 6 Receiver-Drier

2 Low Pressure Pipe 7 Condenser
3 Heater Hose 8 Liquid Hose
4 High Pressure Hose And Pipe 9 Compressor
5 High Pressure Hose

SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-9

COMPRESSOR LOCATION
Gasoline Engine

YAD7B050

Diesel Engine

YAD7B060

SSANGYONG Y200
7B-10 GENERAL HVAC SYSTEM

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS

Symptom Check Action

Airflow not Magnetic clutch switch don’t Check the fuse Replace
cold. turn ON. Check the A/C switch Replace
Check the triple switch (DSL: Dual switch) Replace
Check the thermo switch (GSL) Replace
Check the compressor relay Replace
Check the magnetic clutch Replace
Check the A/C control unit Replace
Insufficient refrigerant Check the refrigerant capacity Adding refrigerant
Faulty receiver-drier Check the receiver-drier Replace
Abnormal rotating of Check the drive belt’s tension, slip of the Adjusting belt
compressor compressor and clutch
Abnormal compression of Check the compressor Replace
compressor
Faulty expansion valve Check the expansion valve Replace
Airflow is Duct joint leak Check the Duct joint Replace
cold but Evaporator frozen Check the intake air temperature switch Replace
insufficient.
Faulty blower motor Check the blower motor Replace
Blower 1th - 3th inoperative, Check the resistor, connector Replace
4th operative
Airflow is There is air in the refrigerant Measure the pressure Evacuating and
not charging refrigerant
continuous. Faulty expansion valve Check the expansion valve Replace
Insufficient Insufficient refrigerant Check the refrigerant capacity Adding refrigerant
cooling. Faulty receiver-drier Check the receiver-drier Replace
Faulty condenser Check the fin’s surface and crack of the Cleaning surface,
tube, tank Replace
Excessive refrigerant in the Check the refrigerant capacity (Verify the Recharging
system capacity higher than high pressure) refrigerant
Abnormal rotating of com- Check the drive belt’s tension Adjusting belt
pressor
Insufficient compression of Check the compressor Replace
compressor
There is air in the unit. Check the pressure Evacuating and
charging refrigerant
Faulty expansion valve Check the expansion valve Replace

SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-11

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 º C - 35 º C, 2,000 rpm of the
engine rpm , full cold and maximum blower speed.

YAD7B070

Symptom Cause Action

1. High and low pressure are abnormally low. • There is a gas leak in the • Check the oil leak,
2. Air at cooler outlet is not cold. cooling system. repair
• Add the refrigerant

YAD7B080

1. High and low pressure are abnormally high. • Insufficient cooling and • Keep the specified
faulty condenser cooling amount of the
by excessive refrigerant, Clean the
refrigerant. condenser
• Repair the belt

YAD7B090

1. High and low pressure are abnormally high. • Belt is slipped • Clean and repair the
2. Connection at the low pressure is not cold. • There is an air in the receiver-drier
cooling system • Check the oil
contamination etc.

YAD7B100

SSANGYONG Y200
7B-12 GENERAL HVAC SYSTEM

Symptom Cause Action

1. The low-pressure side indicates excessive high • The dust and moisture • Repair the receiver-drier
and high-pressure indicates excessive low. etc. are frozen at the • Replace the expansion
2. There is a moisture in the connection of the re- expansion valve valve for the faulty heat
ceiver-drier and the front/back of the expan- • A gas leak in the heat reducer
sion valve. reducer

YAD7B110

1. The low-side pressure is high or normal inter- • The mixed moisture is • Repair the receiver-drier
mittently. frozen at the expansion and perform the
valve bleeding

YAD7B120

1. The low-pressure and high-pressure are exces- • The faulty expansion • Repair the receiver-drier
sive high. valve, the improper • Check the oil
2. There are a lot of moistures in the connection installation of the heat contamination etc.
of the low-side pressure reducer
• Fail to control the flow
rate

YAD7B130

1. The low-pressure is excessive high and high- • There is an oil leak in • Replace the compressor
pressure is excessive low. the compressor

YAD7B140

SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-13

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
• low pressure hand valve → low pressure
YAD7B150 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.
YAD7B160
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.

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 unit’s
control panel.
2. Open both the gas and the liquid valves on the
YAD7B170 tank.

SSANGYONG Y200
7B-14 GENERAL HVAC SYSTEM

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 manufacturer’s
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.
Single: 850 ± 50 g
Specified amount
Dual: 1200 ± 50 g

Notice:
• If the charging speed is low, it’s more efficient
to place the refrigerant tank in the warm water
YAD7B220
(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
7B-16 GENERAL HVAC SYSTEM

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.

Operation Check

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Notice: Operation Check is recommended before
removing the manifold gauge.

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1. Install the manifold gauge set.

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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.
YAD7B240
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.

SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-17

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, it’s 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
7B-18 GENERAL HVAC SYSTEM

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
GENERAL HVAC SYSTEM 7B-19

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
AIR FILTER (AUTO A/C)
Removal & Installation Procedure
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
7B-20 GENERAL HVAC SYSTEM

RECEIVER-DRIER
Removal & Installation Procedure
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 receiver-

drier and then remove the receiver-drier.

YAD7B370

SSANGYONG Y200
GENERAL HVAC SYSTEM 7B-21

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
Removal & Installation Procedure
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
7B-22 GENERAL HVAC SYSTEM

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
GENERAL HVAC SYSTEM 7B-23

COMPRESSOR
Removal & Installation Procedure
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.
• Disconnect the hoses.
• Remove two sealing washer.
YAD7B460

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
7B-24 GENERAL HVAC SYSTEM

2. Remove the high/low pressure pipe lines.

3. Remove the high/low pressure pipe lines from the
evaporator.

YAD7B490

Installation Procedure
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
YAD7B500 • 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.

Installation Procedure
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
GENERAL HVAC SYSTEM 7B-25

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
YAD7B510
turning to remove the shaft nut.
• Remove the snap ring using the ring plier.
• Remove the clutch drive using the special tool.

YAD7B520

• Remove the clutch shaft key and spring.

YAD7B530

SSANGYONG Y200
7B-26 GENERAL HVAC SYSTEM

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
GENERAL HVAC SYSTEM 7B-27

SPECIAL TOOLS AND EQUIPMENT

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 Abnormal Refrigerant Pressure ............................ 7C-7
System Components-Functional ........................... 7C-2 Repair Instructions ................................................ 7C-8
Specifications ...................................................... 7C-4 On-Vehicle Service ................................................. 7C-8
Diagnostic Information and Procedures .............. 7C-5 Control Switch Assembly ..................................... 7C-8
Insufficient Cooling Diagnosis .............................. 7C-5
7C-2 MANUAL CONTROL HVAC SYSTEM

DESCRIPTION AND OPERATION

SYSTEM COMPONENTS- The operations described are based on bench overhaul
with the compressor removed from the vehicle, except
FUNCTIONAL as noted. They have been prepared in the order of
Compressor accessibility of the components. When a compressor
is removed from the vehicle for servicing, the amount
All compressor are belt-driven from the engine of oil remaining the compressor should be drained,
crankshaft through the compressor clutch pulley. The measured and recorded. This should then be
compressor pulley rotates without driving the discarded and new polyalkaline glycol (PAG) refrigerant
compressor shaft until an electromagnetic clutch coil oil added to the compressor.
is energized. When voltage is applied to energize the
clutch coil, the clutch plate and hub assembly is drawn Important: The oil drain plug must be removed and
rearward toward the pulley. The magnetic force locks the oil drained through the plug opening to insure
the clutch plate and pulley together as one unit to drive complete draining of oil from the compressor.
the compressor shaft.
As the compressor shaft driven, it compresses the low V-5 Compressor-Operation
pressure refrigerant vapor from evaporator into high The V5 is a variable displacement compressor that can
pressure, high temperature vapor. The refrigerant oil match the automotive air conditioning demand under
that is used to lubricate the compressor is carried with all conditions without cycling. The basic compressor
the refrigerant. mechanism is a variable angle wobble-plate with seven
axially oriented cylinders. The center of the control of
Magnetic Clutch the compressor displacement is a billows-actuated
The magnetic clutch is assembled in front of the control valve located in the rear head of the compressor
compressor and controls to stop or operate the that senses compressor suction pressure.
compressor. The wobble-plate angle and the compressor
The center piece is inserted to the compressor displacement are controlled by the crankcase suction
crankshaft and rotate the only the pulley when it pressure differential. When the A/C capacity demand
doesn’t operate the compressor. When the A/C switch is high, the suction pressure will be above the control
is turned ON, the current flows into the wrapped coil of point. The valve will maintain a bleed from crankcase
the stator and the stator is converted to the powerful to suction. With no crankcase suction pressure
electromagnet. Therefore, the compressor can rotate differential, the compressor will have maximum
with the pulley together because the stator can pull displacement.
the center piece tightly. When the A/C capacity demand is lower and the suction
pressure reaches the control point, the valve will bleed
V-5 Compressor-General discharge gas in the crankcase and close off a passage
from the crankcase to suction plenum. The angle of
Description
the wobble-plate is controlled by a force balance of
Vehicle using the V5 compressor may have differences seven pistons. A slight elevation of the crankcase
between installations in the mounting brackets, the suction pressure differential creates total force on the
drive system, the pulleys, the connections and the piston resulting in a movement about the wobble-plate
system capacities. Basic overhaul procedures are pivot pin that reduces the plate angle.
similar between the compressors used on different
The compressor has a unique lubrication system. The
vehicles.
crankcase suction bleed is routed through the rotating
When serving the compressor, keep dirt and foreign wobble-plate for lubrication of wobble-plate bearing.
material from getting on or into the compressor parts
The rotation acts as an oil separator that removes some
and the system. Clean tools and a clean work area are
of the oil from the crankcase where it can lubricate the
important for proper service. The compressor
compressor mechanism.
connections and outside of the compressor should be
cleaned before performance of any on-vehicle repairs Condenser Core
and before removal of the compressor. The parts must
be kept clean at all times and any parts that are to be The condenser assembly in front of the radiator consists
reassembled should be cleaned with trichloroethane, of coils, which carry the refrigerant and cooling fins
naphtha, stoddard solvent, kerosene or equivalent that provide the rapid transfer of heat. The air passing
solvents and dried with dry air. Use only lint-free cloths through the condenser cools the high-pressure
to wipe the parts. refrigerant vapor and causes it to condense it to
condense into a liquid.

SSANGYONG Y200
MANUAL CONTROL HVAC SYSTEM 7C-3

Receiver-Drier Pressure Relief Valve

The sealed receiver-drier assembly is connected The compressor is equipped with a pressure relies
between the condenser and evaporator. It acts as a valve which is placed in the system as a safety factor.
refrigerant storing container, receiving liquid and some Under certain conditions, the refrigerant on the
vapor and refrigerant oil from the condenser. discharge side may exceed the designed operating
At the bottom of the receiver-drier is the desiccant, pressure at approximately at 3,171 to 4,137 kPa
which acts as drying agent for the moisture that may (460 to 600 psi) in an R-134a system. Conditions that
have entered the system. An oil bleed hole is located might cause this valve to open, such as a defective
near the bottom of the receiver-drier outlet pipe to pressure transducer, an inoperative cooling fan, etc.,
provide an oil return path to the compressor. The should be corrected. The refrigerant oil and the
receiver drier is serviceable as an assembly. refrigerant should be replaced as necessary.

Expansion Valve Controller

The expansion valve can fall in three different positions: The operation of the A/C system is controlled by the
open, closed or restricted. switches and knob on the control head. This console-
mounted controller contains following control knobs.
An expansion valve that fails in open position will result
in a noisy A/C compressor or no cooling. The cause Rotary Temperature Control Knob
can be a broken spring, a broken ball or excessive
moisture in the A/C system. If the spring or the ball • Actuates by cable.
are found to be defective, replace the expansion valve. • Raise the temperature of the air entering the vehicle
If excessive moisture is found in the A/C system by sliding to the right or the red portion of the knob.
recycle the refrigerant. • Varies the mix of the fresh air from outside the
A restricted expansion valve will result in low suction vehicle with the heated air from inside the vehicle
pressure and no cooling. This may be caused by debris to suit individual performance.
in the refrigerant system. If debris is believed to be
the cause, recycle the refrigerant, replace the Rotary Mode Control Knob
expansion valve and replace the receiver-drier. • Actuates by cable.

Evaporator • Regulates the air distribution between the

windshield, the instrument panel and the floor vents.
The evaporator is a device which cools and
dehumidifies the air before it enters the vehicle. High Rotary Blower Control Knob
pressure liquid refrigerant flows through the expansion
tube (orifice) and becomes a low pressure gas in the
• Turn on to operate the blower motor at four speeds.
evaporator. The heat in the air passing through the • Turn OFF to stop the blower.
evaporator core is transferred to the cooler surface or • Operates completely independently from both the
the core, which cools the air. mode control knob and temperature control knob.
As the process of heat transfer from the air the • Changes the fan speed in any mode and at any
evaporator core surface is taking place, any moisture speed.
(humidity) in the air condenses on the outside surface
of the evaporator core and is drained off as water.

SSANGYONG Y200
7C-4 MANUAL CONTROL HVAC SYSTEM

SPECIFICATIONS

Component Description
Compressor Type Variable Displacement
Model Single V-5 Compressor
Dual V-7 Compressor
Gasoline 10PAIRC
Displacement Single 9.8 - 151 cc/rev
Dual 179 cc/rev
Gasoline 170.5 cc/rev
Max. RPM 6,000 - 7,500 rpm
Refrigerant Type R-134a
Capacity Single 850 ± 50 g
Dual 1200 ± 50 g
Oil Type Synthetic PAG Oil
Capacity 260 cc
Receiver-Drier Material Aluminum
Capacity 260 cc
A/C Condenser Max. Capacity 11,400 Kcal/h
Evaporator Size 263.0 x 228.6 x 88.9 mm
Capacity 6,500 Kcal/h
A/C Pressure Sensor High Pressure A/C ON/OFF 305/425 psi
Low Pressure A/C ON/OFF 39/30 psi
A/C Cutoff Pressure High Pressure 32 Kgf/cm2
Low Pressure 4 Kgf/cm2

SSANGYONG Y200
MANUAL CONTROL HVAC SYSTEM 7C-5

DIAGNOSTIC INFORMATION AND PROCEDURES

INSUFFICIENT COOLING DIAGNOSIS
Step Action Yes No
1. Check the A/C fuse.
2. Check the operation of the blower motor and cooling fan.
3. Check the accessory belt.
1 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? System OK Go to Step 2
1. Turn the ignition to LOCK.
2 2. Connect the high/low pressure gauges.
Are both pressures within the specified value? Go to Step 4 Go to Step 3
1. If it’s above the specified value, discharge the refrigerant.
2. If it’s below the specified value, add 0.45kg (1 pound) of the
3 refrigerant and repair any leaks as needed.
3. Recover, evacuate and recharge the A/C system.
Is the repair complete? System OK -
1. Start the engine and allow it to run at idle.
2. Turn the A/C switch to ON.
4 3. Set the blower motor switch to 4th.
4. Set the temperature control lever to full cold.
Does the A/C compressor clutch engage? Go to Step 8 Go to Step 5
1. Turn the ignition to LOCK.
5 2. Check the open or short in the compressor wiring.
Is there any open or short in the wiring? Go to Step 6 Go to Step 7
Repair the faulty wiring as needed.
6
Is the repair complete? System OK -
Replace the compressor clutch coil.
7
Is the replacement complete? System OK -
Check for a knocking noise from the A/C compressor. Cycle the A/C
8 compressor ON and OFF in order to verify the source of the noise.
Do you hear a loud knocking noise? Go to Step 9 Go to Step 10
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
9 3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the compressor running normally? System OK -
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.
10 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? Go to Step 11 Go to Step 13

SSANGYONG Y200
7C-6 MANUAL CONTROL HVAC SYSTEM

Insufficient Cooling Diagnosis (Cont’d)

Step Action Yes No

1. Recover the A/C system refrigerant.
2. Replace the expansion valve as needed.
3. Evacuate and recharge the A/C system.
11
4. Check the A/C system for leaks.
5. Operate the A/C system.
Is the discharge temperature normal? Go to Step 13 Go to Step 12
1. Recover the refrigerant of the A/C system.
2. Evacuate and recharge the A/C system.
12
3. Check the A/C system for leaks.
Does the A/C system operate normally? System OK -
Feel the liquid pipe between the condenser and the expansion valve.
13
Is the pipe cold? Go to Step 15 Go to Step 14
1. Repair any restriction in high pressure side.
14 2. Check the A/C system for leaks.
Does the A/C system operate normally? System OK -
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.
15
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? Go to Step 17 Go to Step 16
Add the specified amount of the refrigerant to the A/C system.
16 System OK -
Is the amount within the specified value?
1. Turn the ignition to LOCK.
17 2. Set the A/C switch to OFF position.
Can you turn the compressor clutch freely by hand? Go to Step 18 Go to Step 19
1. Check the A/C system for leaks.
2. Repair any leaks as needed.
18
3. Evacuate and recharge the A/C system.
Does the A/C system operate normally? System OK -
1. Recover the refrigerant of the A/C system.
2. Evacuate and recharge the A/C system.
19 3. Check the A/C system for leaks.
4. Replace the compressor as needed.
Is the repair complete? System OK -

SSANGYONG Y200
MANUAL CONTROL HVAC SYSTEM 7C-7

ABNORMAL REFRIGERANT PRESSURE

Step Action Yes No
1. Verify whether airflow and excessive refrigerant.
2. Check any restriction at the condenser or radiator.
1 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? Go to Step 2 Go to Step 3
1. Recover, evacuate and recharge the A/C system according to the
specified value.
2. Clean the condenser or radiator core.
2 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? System OK -
1. Check the amount of the refrigerant.
2. Check the internal faulty of the compressor.
3 3. Check the faulty of the expansion valve.
4. Check the moisture mix into the system.
Is the high-side refrigerant pressure low abnormally? Go to Step 4 Go to Step 5
1. Replace the compressor and the expansion valve as needed.
2. Recover, evacuate and recharge the A/C system according to the
4 specified value.
3. Repair any leaks as needed.
Is the repair complete? System OK -
1. Check the freezing/clogging of the expansion valve.
2. Check the clogging of the receiver-drier.
5
3. Check the amount of the refrigerant.
Is the low-side refrigerant pressure low abnormally? Go to Step 6 Go to Step 7
1. Clean the expansion valve and replace it as needed.
6 2. Replace the receiver-drier as needed.
Is the repair complete? System OK -
1. Check the expansion valve and the compressor for any faulty.
7 2. Check the excessive amount of the refrigerant.
Is the low-side refrigerant pressure high abnormally? Go to Step 8 Go to Step 9
1. Replace the expansion valve and the compressor as needed.
8 2. Add the specified amount of the refrigerant.
Is the repair complete? System OK -
1. Check the tightening condition of the refrigerant line coupling and
bolts.
9 2. Check the faulty O-ring.
3. Check the faulty gasket or seal of the compressor.
Is there any refrigerant leak? Go to Step 10 System OK
1. Tighten the bolts.
2. Replace the faulty O-ring.
10 3. Replace the faulty compressor.
Is the repair complete? System OK -

SSANGYONG Y200
7C-8 MANUAL CONTROL HVAC SYSTEM

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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
MANUAL CONTROL HVAC SYSTEM 7C-9

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 Compressor Magnetic Clutch Does not Engage.. 7D-24
General ............................................................... 7D-2 Inside Air Temperature Sensor Error ................... 7D-24
FATC Control ....................................................... 7D-3 Ambient Air Temperature Sensor Error ................ 7D-24
FATC Input/Output Routing Diagram .................... 7D-4 Coolant Temperature sensor Error ...................... 7D-25
FATC System Characteristic................................. 7D-5 Air Mix Door Error .............................................. 7D-25
System Basic Function ........................................ 7D-6 Sun Sensor Error ................................................ 7D-27
System Components – Control ............................. 7D-8 Power Transistor Error ........................................ 7D-27
Specifications .................................................... 7D-13 Max-High Relay Error ......................................... 7D-28
Diagnostic Information and Procedures ............ 7D-14 Repair Instructions .............................................. 7D-29
General Diagnosis ............................................. 7D-14 On-vehicle Service ................................................ 7D-29
Insufficient Cooling Diagnosis ............................ 7D-15 Control Switch Assembly ................................... 7D-29
Full Automatic Temperature Control (FATC) Does Blower Motor ..................................................... 7D-30
Not Operate When The Ignition Is On .............. 7D-17 High Blower Relay ............................................. 7D-31
Controller Does Not Illuminate When Light Blower Motor Resistance (Power Transistor) ....... 7D-31
Switch Is On ................................................... 7D-17 Air Mix Door Actuator ......................................... 7D-31
No Hot Air From Blower ...................................... 7D-18 Mode Control Door Actuator ............................... 7D-32
Blower Motor Does Not Run At All ...................... 7D-19 Sun Sensor ........................................................ 7D-32
No Cool Air From Blower .................................... 7D-21 Inside Air Temperature Sensor ........................... 7D-32
Mode Controls Does Not Work ........................... 7D-22 Ambient Air Temperature Sensor ........................ 7D-33
Mode Controls Does Not Work ........................... 7D-22 Coolant Temperature Sensor .............................. 7D-34
Abnormal Refrigerant Pressure .......................... 7D-23
7D-2 AUTOMATIC CONTROL HVAC SYSTEM

DESCRIPTION AND OPERATION

GENERAL Vacuum Fluorescent Display panel provides system
operating information for the driver. With the system
THE V5 FULL AUTOMATIC TEMPERATURE CONTROL in OFF mode, the outside temperature is displayed
(FATC) SYSTEM continuously.
The full automatic temperature control (FATC) uses the The driver may display the current temperature setting
integrated control panel as the driver’s interface to by selecting any mode except OFF or adjusting the
the system. The FATC receives driver’s input signal temperature control.
and various input signal from sensors and controls the
actuators to maintain driver’s desired room Also, it provides the convenience to the driver by
temperature. indicating the ambient air temperature. If it occurs the
faulty in the FATC system, the MICOM informs the driver
Refer to Section 7B, Manual Control Heating, or mechanics of the results of the self-diagnostic check
Ventilation, and Air Conditioning System for general and controls the system by
Information details for the following:
• System Components – Functional.
• The V5 A/C System.
• V5 Compressor – Operation.
• V5 Compressor – General Description.

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-3

FATC CONTROL

YAD7D010

SSANGYONG Y200
7D-4 AUTOMATIC CONTROL HVAC SYSTEM

FATC INPUT/OUTPUT ROUTING DIAGRAM

YAD7D020

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-5

FATC SYSTEM CHARACTERISTIC How to Verify Faulty Code

When the temperature is set to 26 °C and then within 3
Display Performance Enhancement second, push the AMB switch and the OFF switch
It allows VFD (Vacuum Fluorescent Display) to develop simultaneously at three times, the FATC controller
the effect of the visible. temperature display indicates the faulty code after
performing the self-diagnosis by MICOM.
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.

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 YAD7D030
ignition switch is ON.
To enter the diagnostic mode, perform the following Condition For Clearing the Faulty Code
procedure. 1. When the vehicle restarts
1. Turn the ignition switch ON. 2. When push the OFF switch after indicating the faulty
2. Set the temperature control to 26 °C (79 °F). code
3. Within 3 seconds, push the AUTO and the OFF 3. When pass over 32 seconds after indicating the
switches simultaneously, more than three times. faulty code
4. Check the diagnostic trouble code (DTC) in the
temperature indicator screen blinks. If there are no Fault Safety Function
diagnostic trouble code (DTC) set, the screen will FATC air conditioner not only performs self-diagnosis
display 00. but also has safety function against faults. If there is
5. When the FATC controller indicates a DTC, proceed open or short in the sensors or potentiometer of
to the table for the DTC. temperature door some specific value will be
substitute.
6. Push the OFF switch to return the controller to its
normal function. Error Fault Safety Function
Inside air Sensor Error 25 °C will be substituted
DTC Description
as temperature of inside of
0 Normal (No Error) vehicle.
1 Inside Air Temperature Sensor Error Ambient Temperature 25 °C will be substituted
2 Ambient Air Temperature Sensor Sensor Error as ambient temperature.
3 Error Coolant Temperature Sensor ON. 50 °C will be
Sensor Error substituted as coolant
4 Coolant Temperature Sensor Error
temperature.
5 Air Mix Door Error Sun Sensor Error Zero (0) will be substituted
6 Sun Sensor Error as sun load.
7 Power Transistor Error

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
7D-6 AUTOMATIC CONTROL HVAC SYSTEM

SYSTEM BASIC FUNCTION Automatic Control

Td value can be determined by the set temperature
Set Temperature Control value and Td value is set to the target voltage of the
When you set the setting temperature using the blower motor simultaneously. The blower motor can
temperature control switch, the FATC receives the shift without step.
various input signals from sensors including the
Abbreviation: Td (Thermal Demand) : Td value is
information of inside air temperature, ambient
the default for automatic control of the automatic
temperature, coolant temperature and sun loads etc..
temperature control and allows it to control the set
The FATC uses this signals to control automatically
temperature calculating the differences between
the A/C compressor, the mode door, the I/A door, air
inside air temperature and ambient temperature.
mix door and blower motor etc.

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)
YAD7D040
Step Blower Voltage
1 4.5 V Blower Step Blower Motor Voltage
2 6.0 V 1 4.0 - 5.5 V
3 7.5 V 2 5.5 - 7.5 V
4 9.0 V 3 7.5 - 8.5 V
5 11.0 V
4 8.5 - 9.5 V
6 Max Hi 5 9.5 - 10.5 V
6 10.5 - 13.5 V
* 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
it’s 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.

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-7

Defroster Calibration Vent inlet Control

On the blower AUTO step, when the passenger sets
Manual Control
to Defroster (Def), the system increases the blower
voltage by 2 V for some intervals comparing AUTO When you push the I/A control switch, you can control
voltage. But it is excluded the condition when the the I/A door manually and the I/A door changes
blower voltage is above 11.0 V. Also, the voltage between the recirculation air and the fresh air flow
increasing by defroster calibration is limited up to 10.5 V. alternately by the control switch. For changing the fresh
air step (FRE) to the recirculation air step (REC), the
Vehicle Speed Calibration blower voltage decrease 15% and for changing the
recirculation air step (REC) to the fresh air step (FRE),
On the Ambient or the 1/3 Ambient and the blower
the blower voltage return back.
AUTO, the blower decreases the voltage with the
vehicle speed 100 Km/h such as 1.5 V for the Ambient, AUTO Control
1.0 V for the 1/3 Ambient.
But it is the exception for the blower max.

YAD7D060

Control by the Vehicle Speed

YAD7D050 The system controls the vent inlet according to the
vehicle speed in order to prevent the exhaust gas of
Ambient Temperature Display the preceding vehicle from flowing inside with the
vehicle stopping or driving at low speed. The operation
It indicates the ambient temperature as 0.5 ° C
and control condition is following as;
increment in the set temperature digit by ambient
temperature sensor. 1. When the vent inlet mode is AUTO and the A/C
“ON”.
• When you push the AMB key it indicates the ambient
temperature for 5 seconds and return back the set 2. When the vehicle keeps to drive at below 10 km/h
temperature. for 10 seconds and changes the REC mode at stop.
3. If 10 minutes passes after changing the REC mode,
• If you push the AMB key again during indicating in
5 seconds, it returns back. it returns back to the AUTO mode.
• 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.

Delivery Condition
For the initial installation (the initial current draw), the
initial mode follows;

Suction
Actuator Mode A/C Blower Mix
Air
YAD7D070
Condi- FOOT/ Td Basic
FRESH OFF OFF
tion DEF Control

SSANGYONG Y200
7D-8 AUTOMATIC CONTROL HVAC SYSTEM

Vent outlet Control Wiper Calibration Control

Manual Control It is possible to generate the frost on the windshield in
the rainy days. At this time, FATC controller allows the
For pushing the mode switch of AUTO temperature
mode to change the AUTO defroster mode.
control, you can select four type of the vent outlets.
• 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
YAD7D090 fluorescent display (VFD) indicating the status of the
control settings selected.
A/C Control
Sensors and Motors
Manual Control
• Inside air sensor, ambient sensor, coolant
When you pushed the A/C switch “ON” or the Def temperature and sun sensor
switch “ON”, A/C starts to operate.
• Door mode motor, intake air control door motor, air
AUTO Control mix door motor
Basic Control: A/C “ON” has the priority for the initial
operation. Inside Air Sensor
Inside air sensor located in left side of full automatic
Full Cold/Hot Control temperature control (FATC) controller, is a sensor that
When you sets the set temperature to full cold (LO) or detects the interior air temperature and a thermistor
full hot (HI), the system controls the temperature to that decreases its resistance when temperature up and
full cold or full hot regardless of sensor’s detection. increases when temperature down. If there is open or
For LO, it becomes A/C “ON”, front vent mode, short in the sensors, 25 ° C (77 ° F) will be substitute.
recirculation air, max blower speed, air mix door close Inspection
and for HI, A/C “OFF”, floor vent mode, ambient mode,
When the inside air temperature sensor error displays,
air mix door open.
check the followings;

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-9

1. Remove the inside air temperature sensor and Inspection

measure the resistance between the sensor When the coolant temperature sensor error displays,
connectors. check the followings;
(approximately 2.2 KΩ at 25 °C) Replace the inside 1. Measure the resistance between the sensor
air temperature sensor when the resistance value connectors. (approximately 2.2 KΩ at 25 °C)
is excessive low or high.
2. Replace the coolant temperature sensor for outside
2. Replace the inside air temperature sensor for the specified value and check the followings for
outside the specified value and check the within the specified value;
followings for within the specified value;
3. Turn the ignition ON.
3. Turn the ignition ON.
4. Measure the voltage between A13 and B9 terminal
4. Measure the voltage between A13 and A16 terminal of the AUTO temperature control connector.
of the AUTO temperature control connector. (approximately 2.2 V at 25 °C)
(approximately 2.2 V at 25 °C)
5. Verify the open circuit of the wiring harness when
5. Verify the open circuit of the wiring harness when you can not measure the voltage value and replace
you can not measure the voltage value and replace the AUTO temperature control when it’s normal.
the AUTO temperature control when it’s normal.
Sun Sensor
Ambient Sensor
Sun sensor is a photo diode that detects lights.
Ambient sensor is a thermistor (NTC resistance) that Resistance of the diode can be measured as current
decreases its resistance when temperature up and by using voltmeter according to increasing sun loads.
increases when temperature down and it detects If the sun sensor is error, no sun load will be substitute.
ambient air temperature. If there is open or short in
the sensors, 25 ° C (77 °F) will be substitute. The Photo Diode
sensor is located in the left back side of front bumper. It is used to the circuit converting the sun light loads
to the electric signals.
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 KΩ 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. YAD7D110

4. Measure the voltage between A13 and B8 terminal Inspection

of the AUTO temperature control connector. When the sun sensor error displays, check the
(approximately 2.2 V at 25 °C) followings;
5. Verify the open circuit of the wiring harness when 1. Remove the sensor to place it under the sun light
you can not measure the voltage value and replace and measure the current between the connector
the AUTO temperature control when it’s normal. terminals.
2. Place the sun sensor under the shadow place and
Coolant Temperature Sensor measure the current between the connector
Coolant temperature sensor is a thermistor that terminals. If the value is lower than the value under
decreases its resistance when temperature up and the sun light, it’s normal.
increases when temperature down. It detects coolant 3. Turn the ignition ON.
temperature to operate the blower speed at low when
4. Measure the voltage between A13 and B10 terminal
the coolant temperature is less than 50 °C (122 ° F). If
of the AUTO temperature control connector. (Sun
the coolant temperature sensor is open or short, 100
light; 2.5 V, Shadow; 4.8 V)
° C (212 ° F) will be substitute.
5. Verify the open circuit of the wiring harness when
you can not measure the voltage value and replace
the AUTO temperature control when it’s normal.

SSANGYONG Y200
7D-10 AUTOMATIC CONTROL HVAC SYSTEM

Intake Control Door Motor Inspection

The mode motor set the I/A mode by the control signal When the vent inlet mode displayed in the AUTO
of the AUTO temperature control. temperature control is different from the actual mode,
check the followings;
When the mode displayed in the AUTO temperature
control is different from the actual mode, check the 1. Turn the ignition ON.
followings; 2. Measure the voltage between positive terminal and
negative terminal of the Mtr-Act, AI connector.
• Turn the ignition ON.
(Specified value; 12 V)
• Measure the voltage between the (+) terminals at 3. Measure the voltage between P1, P2, P3 and (+)
each mode and verify that changes from 0V before terminal. (If it changes from 0V before the mode
the mode selection to 12V after the mode selection. selection to 12 V after the mode selection, it’s
• If the value is the specified value, check the open normal)
or short circuit. 4. If the value is outside the specified value, check
the open or short circuit.
• If the wiring is normal, replace the AUTO
5. If the wiring is normal, replace the AUTO
temperature control.
temperature control.
• If the voltage value is outside the specified value, 6. If the value is the specified value, replace the Mtr-
replace the I/A mode motor. Act, AI.
• Check the motor operation connecting the (+) 7. Check the motor operation connecting the (+)
terminal to No.4 of the motor connector and terminal to No.4 of the motor connector and
connecting No.5 and No.7 to (-) terminal sequentially connecting No.5 and No.7 to (-) terminal sequentially
using 12 V power. 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

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-11

YAD7D130 YAD7D140

Inspection Inspection
When the vent inlet mode displayed in the AUTO When the air mix door motor error displays, check the
temperature control is different from the actual mode, followings;
check the followings; 1. Turn the ignition ON.
1. Turn the ignition ON. 2. Measure the voltage within P1, P2 terminals
2. Measure the voltage between P1 - P5 and (+) (specified value; 12 V) and a,b (specified value;
terminal. (If it changes from 0V before the mode 5).
selection to 12 V after the mode selection, it’s 3. If the value is outside the specified value, check
normal) the open or short circuit.
3. If the value is outside the specified value, check 4. If the wiring is normal, replace the Mtr-Act, Temp.
the open or short circuit.
5. If the (+) (-) terminal connects to P1 and P2 of the
4. If the wiring is normal, replace the AUTO Mtr-Act, Temp alternately, the output by the each
temperature control. mode is following;
5. If the value is the specified value, replace the Mtr-
Act, AI. AMD Mode Bc Resistance
6. Check the motor operation connecting the (+) (-) Cool P1 (-), P2 (+) Below 300 Ω
terminal to the Mtr-Act mode and each terminal P1
Hot P1 (+), P2 (-) Above 2.4 KΩ
- P5 to (-) terminal sequentially using 12 V power.

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.

SSANGYONG Y200
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 2nd 3rd 4th 5th 6th

4.5 V 6.0 V 7.5 V 9.0 V 11.0 V Relay Hi

5. When there is no problem in the wiring harness,

replace the power transistor.

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-13

SPECIFICATIONS
Component Description
Compressor Type Variable Displacement
Model V-5 Compressor
Displacement 9.8 - 151 cc/rev
Max. RPM 6,000 - 6,500 rpm
Receiver-Drier Material AL R/DRIER
Capacity 210 cc
Refrigerant Type R-134a
Capacity 750 ± 20 g
Oil Type Synthetic PAG Oil
Capacity 220 cc
Condenser Max. Capacity 11,400 Kcal/h
A/C Pressure Sensor High (Gauge Pressure) A/C ON 305 psi
A/C OFF 425 psi
Low (Gauge Pressure) A/C ON 39 psi
A/C OFF 30 psi
Blower Motor Max. Capacity 7,475 - 9,075 Kcal/h
Heater Core Fin Pitch 1.52 mm
Size 200.5 x 168.2 x 25.0 mm
Capacity 8,250 Kcal/h

SSANGYONG Y200
7D-14 AUTOMATIC CONTROL HVAC SYSTEM

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS General A/C Diagnosis
The full automatic temperature control (FATC) air Refer to Section 7B, Manual Control Heating,
conditioning controller contains a self-diagnosis Ventilation, and Air Conditioning System for details of
function to aid in finding any problem with the system. the following procedures:
• 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).

YAD7D150

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.

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-15

INSUFFICIENT COOLING DIAGNOSIS

Step Action Yes No

1. Check the A/C fuse.
2. Check the operation of the blower motor and cooling fan.
3. Check the accessory belt.
1 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? System OK Go to Step 2
1. Turn the ignition to LOCK.
2 2. Connect the high/low pressure gauges.
Are both pressures within the specified value? Go to Step 4 Go to Step 3
1. If it’s above the specified value, discharge the refrigerant.
2. If it’s below the specified value, add 0.45 kg (1 pound) of the
3 refrigerant and repair any leaks as needed.
3. Recover, evacuate and recharge the A/C system.
Is the repair complete? System OK -
1. Start the engine and allow it to run at idle.
2. Turn the A/C switch to ON.
4 3. Set the blower motor switch to 4th.
4. Set the temperature control lever to full cold.
Does the A/C compressor clutch engage? Go to Step 8 Go to Step 5
1. Turn the ignition to LOCK.
5 2. Check the open or short in the compressor wiring.
Is there any open or short in the wiring? Go to Step 6 Go to Step 7
Repair the faulty wiring as needed.
6
Is the repair complete? System OK -
Replace the compressor clutch coil.
7
Is the replacement complete? System OK -
Check for a knocking noise from the A/C compressor. Cycle the A/C
8 compressor ON and OFF in order to verify the source of the noise.
Do you hear a loud knocking noise? Go to Step 9 Go to Step 10
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
9 3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the compressor running normally? System OK -
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.
10 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? Go to Step 11 Go to Step 13

SSANGYONG Y200
7D-16 AUTOMATIC CONTROL HVAC SYSTEM

Insufficient Cooling Diagnosis (Cont’d)

Step Action Yes No

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-17

FULL AUTOMATIC TEMPERATURE CONTROL (FATC) DOES NOT

OPERATE WHEN THE IGNITION IS ON

Step Action Yes No

Check the fuse F18.
1
Are the fuses blown? Go to Step 3 Go to Step 2
Replace the fuse.
2 Is the repair complete? System OK -
1. Remove the controller with connecting ATC wiring connector.
2. Turn the ignition switch to ON.
3
3. Measure the voltage between terminal A1 and A5 of the connectors Go to Step 15
Is the voltage within specified value? 11 - 14 V Go to Step 4
Replace the controller.
4
Is the repair complete? System OK -
Measure the voltage between terminal A5 of the connector and ground.
5 Is the voltage within specified value? Go to Step 6 Go to Step 7
Repair the faulty circuit between fuse F18 and terminal A5 of the ATC
6 wiring connector.
Is the repair complete? System OK -
Repair the faulty circuit between the ground G203 and terminal A1 of
7 the ATC wiring connector.
Is the repair complete? System OK -

CONTROLLER DOES NOT ILLUMINATE WHEN LIGHT SWITCH IS ON

Step Action Yes No
1. Remove the controller with connecting ATC wiring connector.
1 2. Turn the ignition switch to ON.
3. Measure the voltage between terminal A4 and A3 of the controller. Go to Step 3
Is the voltage within the specified value? 11 V - 14 V Go to Step 2
Repair the wiring harness between splice S206 and terminal A3 of the
controller connector or between splice S206 and terminal A4 of the
2 controller connector.
Is the repair complete? System OK -
Check the illumination bulb.
3
Is the bulb burned out? Go to Step 4 Go to Step 5
Check the illumination bulb.
4
Is the repair complete? System OK -
Replace the controller.
5
Is the repair complete? System OK -

SSANGYONG Y200
7D-18 AUTOMATIC CONTROL HVAC SYSTEM

NO HOT AIR FROM BLOWER

Step Action Yes No
Check the coolant level.
1
Is the coolant level within the specified value? Go to Step 3 Go to Step 2
Add coolant as needed.
2
Is the repair complete? System OK -
1. Turn the ignition to ON.
3 2. Observe the temperature indication screen of the controller.
Does the digit flash? Go to Step 6 Go to Step 4
Observe the blower motor operation. Go to “Blower
4 Is the blower motor functioning at all? Motor Does Not
Go to Step 5 Run At All”
Use the blower push switch to cycle the blower through its different Go to “the
speeds. Applicable
5
Does the motor function at different speeds? Diagnostic
Go to Step 7 Table”
Run a self diagnosis circuit check. Go to “the
6 Does the display indicate a defect code? Applicable
Diagnostic
Go to Step 7 Table”
Check the airflow of the ducts at each mode.
7
Is the airflow normal? Go to Step 9 Go to Step 8
Check inside the heater duct for obstructions and repair as needed.
8
Is the repair complete? System OK -
Observe the air mix door motor while changing the temperature setting Go to “the
from LO to HI and then from HI to LO. Applicable
9
Is the air mix door actuator functioning properly? Diagnostic
Go to Step 10 Table”
Check the coolant hoses for leaks or kinks.
10
Are the coolant hoses in good condition? Go to Step 12 Go to Step 11
Replace the coolant hoses.
11
Is the repair complete? System OK -
Check the coolant reservoir cap.
12
Is the coolant tank cap in hood condition? Go to Step 14 Go to Step 13
Replace the coolant reservoir cap.
13
Is the repair complete? System OK -
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.
14 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? Go to Step 16 Go to Step 15
1. Check for
• faulty thermostat.
• failed coolant pump impeller.
15
• restriction in the cooling system.
2. Make repairs, as needed.
Is the repair complete? System OK -

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-19

No Hot Air From Blower (Cont’d)

Step Action Yes No

Check the temperature of the heater inlet and outlet hoses by feel.
16
Is the heater inlet hose hot and the outlet hose warm? Go to Step 18 Go to Step 17
Back flush or replace the heater core.
17 Is the repair complete? System OK -
Check the vehicle for cold air leaks the
• Dash.
18 • Heater cases.
• Vents.
Are any leaks found? Go to Step 20 Go to Step 19
Repair any cold air leaks.
19 Is the repair complete? System OK -
Check the coolant temperature sensor using the tests in “DTC Coolant
Temperature Sensor Error.”
20 Is there a problem indicated in the sensor, the sensor wiring or the
controller? Go to Step 21 Go to Step 22
Repair, or replace the sensor, the wiring, or the controller as required.
21 Is the repair complete? System OK -
Replace the controller.
22 Is the repair complete? System OK -

BLOWER MOTOR DOES NOT RUN AT ALL

Step Action Yes No
1. Turn the ignition switch to ON. Go to “the
2. Observe the temperature indication screen of the controller. Applicable
1
Dose the digit on and off? Diagnostic
Table” Go to Step 2
Check the fuses.
2 Go to Step 3 Go to Step 4
Are the fuses blown?
Replace the fuse.
3
Is the repair complete? System OK -
1. Turn the ignition switch to ON.
4 2. Measure the voltage between ground and terminal 87 of blower relay. Go to Step 7
Is the voltage within the specified value? 11 - 14 V Go to Step 5
1. Measure the voltage between ground and terminal 86 of blower relay. Go to Step 9
5
Is the voltage within the specified value? 11 - 14 V Go to Step 6
1. Check the circuit between terminal 86 of the blower relay and fuse
SB7 in the I/P fuse block.
6 2. Repair any problem found in the wiring or terminals at the relay
socket or connectors.
Is the repair complete? System OK -
1. Turn the ignition to OFF.
2. Disconnect the wiring connector of the blower motor.
3. Turn the ignition to ON.
7
4. Measure voltage between the wiring connector of the blower motor
and ground. Go to Step 11
Is the voltage within the specified value? 11 - 14 V Go to Step 10

SSANGYONG Y200
7D-20 AUTOMATIC CONTROL HVAC SYSTEM

Blower Motor Does Not Run At All (Cont’d)

Step Action Yes No

Repair the faulty circuit between the wiring connector of the blower
8 relay, wiring, blower motor, connector C203, C107.
Is the repair complete? System OK -
Measure voltage between terminal 30 of the blower relay and ground. Go to Step 9
9
Is the voltage within the specified value? 11 - 14 V Go to Step 10
1. Repair the circuit between terminal 86 of the blower relay and fuse
SB7 in the I/P fuse block.
10 2. Repair the wiring connector of the blower relay, wiring, blower
motor, connector C203, C107.
Is the repair complete? System OK -
1. Turn the ignition switch to OFF.
11 2. Using an ohmmeter, measure the resistance between terminal 85 of
the blower relay and ground.
Does the measured resistance indicate 0 Ω? Go to Step 13 Go to Step 12
Repair the faulty circuit between terminal 85 of the blower relay, C104
12 and ground G101.
Is the repair complete? System OK -
Replace the blower motor relay.
13
Is the repair complete? System OK -
Measure the resistance of the blower motor.
14
Does the measured resistance indicate 0.5 Ω? Go to Step 15 Go to Step 16
Replace the blower motor.
15
Is the repair complete? System OK -
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
16
6 of the power transistor.
Is there any open or short circuit? Go to Step 17 Go to Step 18
Repair the problem in the circuit.
17
Is the repair complete? System OK -
Measure the resistance of the circuit from terminal 3 of the power
18 transistor connector and ground.
Does the measured resistance indicate 0 Ω? Go to Step 19 Go to Step 20
Replace the controller.
19
Is the repair complete? System OK -
1. Repair the faulty circuit from terminal 3 of the power transistor
connector and terminal 87 of the high blower relay to ground.
20 2. Repair the faulty in the wiring, connector, C109, C209, C104 or
ground G104.
Is the repair complete? System OK -

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-21

NO COOL AIR FROM BLOWER

Step Action Yes No
1. Turn the ignition switch to ON.
1 2. Observe the temperature indication screen of the controller.
Does the digit flash? Go to Step 2 Go to Step 3
Run a self-diagnosis circuit check. Go to “the
Does the display indicate a defect code? Applicable
2 Diagnostic
Table” Go to Step 4
Observe the blower motor operation. Go to “Blower
3 Is the blower motor functioning at all? Motor Does Not
Go to Step 4 Run At All”
Use the blower push switch to cycle the blower through its different Go to “the
speeds. Applicable
4 Does the motor function at different speeds? Diagnostic
Go to Step 5 Table”
Check the airflow of the ducts at each mode.
5
Is the airflow normal? Go to Step 8 Go to Step 6
Check inside the heater duct for obstructions and repair as needed.
6
Is the repair complete? System OK -
Observe the air mix door motor while changing the temperature setting Go to “the
from LO to HI and then from HI to LO. Applicable
7
Is the air mix door actuator functioning properly? Diagnostic
Go to Step 8 Table”
Perform the checks found in “Insufficient Cooling Diagnosis.”
8
Is the system operating normally now? System OK Go to Step 9
Place the controller in the AUTO mode.
9
Is smoke taken into the intake port of the inside air sensor? Go to Step 11 Go to Step 10
Replace the intake hose.
10
Is the repair complete? System OK -
Check the each sensor and sensor wiring using the Diagnostic Table.
11 Is there a problem indicated in the sensor, the sensor wiring or the
controller? Go to Step 12 Go to Step 13
Repair, or replace the sensor, the wiring, or the controller as required.
12
Is the repair complete? System OK -
Replace the controller.
13
Is the repair complete? System OK -

SSANGYONG Y200
7D-22 AUTOMATIC CONTROL HVAC SYSTEM

MODE CONTROLS DOES NOT WORK

Step Action Yes No
Measure the voltage between terminal 4 of the blower motor and mode
1 door motor ground. Go to Step 3
Is the voltage within the specified value? 11 - 14 V Go to Step 17
Repair the connector and the circuit for any wiring or terminal problems.
2
Is the repair complete? System OK -
1. Using the Motor Control Table, measure the voltages at the speci-
fied terminals of the specified motor connectors.
3 2. Change the mode settings and observe the voltage changes.
Is the voltage within the specified value? Go to Step 5 Go to Step 4
Repair or replace the wiring harness or the defective terminal.
4
Is the repair complete? System OK -
1. Measure the voltages of the connector terminal.
5 2. Change the mode settings and observe the voltage changes.
Is the voltage within the specified value? Go to Step 7 Go to Step 6
6 Replace the fuel filter or the fuel line. System OK -
Check the connector at the controller.
7
Is there a defective terminal? Go to Step 8 Go to Step 9
Repair the terminal and replace as needed.
8
Is the repair complete? System OK -
Replace the controller.
9
Is the repair complete? System OK -

MODE CONTROLS DOES NOT WORK

Step Action Yes No
Measure the voltage between terminal 4 of the intake control door
1 motor and ground. Go to Step 3
Is the voltage within the specified value? 11 - 14 V Go to Step 2
Repair the connector and the circuit for any wiring or terminal problems.
2
Is the repair complete? System OK -
1. Measure the voltages at the specified terminals of the specified
motor connectors.
3 2. Change the mode settings and observe the voltage changes
Is the voltage within the specified value? Go to Step 5 Go to Step 4
1. Repair the wiring harness or the defective terminal.
4 2. Replace the fuel filter or the fuel line as needed.
Is the repair complete? System OK -
Check the connector at the controller.
5
Is there a defective terminal? Go to Step 6 Go to Step 7
Repair the terminal and replace as needed.
6
Is the repair complete? System OK -
Replace the controller.
7
Is the repair complete? System OK -

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-23

ABNORMAL REFRIGERANT PRESSURE

Step Action Yes No
1. Verify whether airflow and excessive refrigerant.
2. Check any restriction at the condenser or radiator.
1 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? Go to Step 2 Go to Step 3
1. Recover, evacuate and recharge the A/C system according to the
specified value.
2. Clean the condenser or radiator core.
2
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? System OK -
1. Check the amount of the refrigerant.
2. Check the internal faulty of the compressor.
3 3. Check the faulty of the expansion valve.
4. Check the moisture mix into the system.
Is the high-side refrigerant pressure low abnormally? Go to Step 4 Go to Step 5
1. Replace the compressor and the expansion valve as needed.
2. Recover, evacuate and recharge the A/C system according to the
4 specified value.
3. Repair any leaks as needed.
Is the repair complete? System OK -
1. Check the freezing/clogging of the expansion valve
2. Check the clogging of the receiver-drier.
5
3. Check the amount of the refrigerant.
Is the low-side refrigerant pressure low abnormally? Go to Step 6 Go to Step 7
1. Clean the expansion valve and replace it as needed.
6 2. Replace the receiver-drier as needed.
Is the repair complete? System OK -
1. Check the expansion valve and the compressor for any faulty.
7 2. Check the excessive amount of the refrigerant.
Is the low-side refrigerant pressure high abnormally? Go to Step 8 Go to Step 9
1. Replace the expansion valve and the compressor as needed.
8 2. Add the specified amount of the refrigerant.
Is the repair complete? System OK -
1. Check the tightening condition of the refrigerant line coupling and
bolts.
9 2. Check the faulty O-ring.
3. Check the faulty gasket or seal of the compressor.
Is there any refrigerant leak? Go to Step 10 System OK
1. Tighten the bolts.
2. Replace the faulty O-ring.
10 3. Replace the faulty compressor.
Is the repair complete? System OK -

SSANGYONG Y200
7D-24 AUTOMATIC CONTROL HVAC SYSTEM

COMPRESSOR MAGNETIC CLUTCH DOES NOT ENGAGE

Step Action Yes No
1. Remove the controller with connecting the connector.
2. Turn the ignition switch to ON. Go to
3. Set the A/C switch to ON. “Insufficient
1
4. Measure the voltage between the controller connector A12 (or all for Cooling
GSL) and the ground. Diagnosis”
Is the voltage within the specified value? 11 - 14 V Go to Step 2
Replace the defective motor.
2
Is the repair complete? System OK -

INSIDE AIR TEMPERATURE SENSOR ERROR

Step Action Yes No
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.
1 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? Go to Step 3 Go to Step 2
Repair the open or short of the wiring harness.
2
Is the repair complete? System OK -
1. Remove the inside air temperature sensor.
2. Measure the resistance between the inside air sensor connector
3 terminals.
Does the measured resistance indicate 2.2 kΩ at 25 °C? Go to Step 5 Go to Step 4
Replace the inside air sensor.
4
Is the repair complete? System OK -
Replace the controller.
5
Is the repair complete? System OK -

AMBIENT AIR TEMPERATURE SENSOR ERROR

Step Action Yes No
1. Remove the ambient air temperature sensor.
2. Measure the resistance between the ambient air temperature sensor
1
connector terminals.
Does the measured resistance indicate 2.2 kΩ at 25 °C? Go to Step 3 Go to Step 2
Replace the ambient air temperature sensor.
2
Is the repair complete? System OK -
1. Remove the controller with connecting the connector.
2. Turn the ignition switch to ON.
3
3. Measure the voltage between terminal B8 and connector A13.
Does the measured voltage indicate 2.2 V at 25 °C? Go to Step 5 Go to Step 4
Repair the open or short of the wiring harness.
4
Is the repair complete? System OK -
Replace the controller.
5
Is the repair complete? System OK -

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-25

COOLANT TEMPERATURE SENSOR ERROR

Step Action Yes No
1. Disconnect the coolant temperature sensor connector from the
FATC harness.
1 2. Measure the resistance between the coolant temperature sensor
connector terminals..
Does the measured resistance indicate 2.2 kΩ at 25 °C? Go to Step 3 Go to Step 2
Replace the coolant temperature sensor.
2
Is the repair complete? System OK -
1. Remove the controller with connecting the connector.
3 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? Go to Step 5 Go to Step 4
Repair the open or short of the wiring harness.
4
Is the repair complete? System OK -
Replace the controller.
5
Is the repair complete? System OK -

AIR MIX DOOR ERROR

Step Action Yes No
1. Disconnect the I/P wiring harness connector form the air mix door
motor.
1 2. Use an ohmmeter to measure the resistance between terminals 5 Go to step 3
and 7 on the air mix door motor. open : ∞
Is the resistance within the specified value? short : 0 Ω Go to Step 2
Replace the air mix door motor.
2
Is the repair complete? System OK -
Use an ohmmeter to measure the resistance between terminals 2 and 3
3 on the air mix door motor.
Does the measured resistance indicate approximately 3 kΩ? Go to Step 5 Go to Step 4
Replace the air mix door motor.
4
Is the repair complete? System OK -
Use an ohmmeter to measure the resistance between terminals 6 and
5 3, 6 and 2 on the air mix door motor.
Does the measured resistance indicate approximately 3 kΩ? Go to Step 7 Go to Step 6
Replace the air mix door motor.
6
Is the repair complete? System OK -
Check the connector terminals at the air mix door motor and the wiring
in the FATC harness.
7
Is there a problem with any terminal on either the harness connector or
the motor connector or the wiring? Go to Step 9 Go to Step 8
1. Remove the FATC controller from the instrument panel.
2. Disconnect the harness connectors of the controller.
8 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? Go to Step 9 Go to Step 10
Repair the problem found with a connector terminal or wiring.
9
Is the repair complete? System OK -

SSANGYONG Y200
7D-26 AUTOMATIC CONTROL HVAC SYSTEM

Air Mix Door Error (Cont’d)

Step Action Yes No

Check continuity in the harness between the controller connectors and
10 the air mix door motor connector.
Is there a problem with the wiring? Go to Step 11 Go to Step 12
Repair the problem found with the wiring and replace as needed.
11
Is the repair complete? System OK -
1. Reconnect the FATC harness connectors to the controller.
2. Reconnect the air mix door motor to the FATC harness.
12 3. Turn the ignition to ON.
4. Measure the voltage between ground and terminal B5 at the control-
ler by backprobing the connector. Go to Step 14
Is the voltage within the specified value? 0-5V Go to Step 13
Repair the problem found between the controller connector wiring and
13 air mix door connector wiring.
Is the repair complete? System OK -
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)
14
4. Measure the voltage between ground and terminal A9 at the control-
ler. (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? Go to Step 15 Go to Step 17
Recheck all wiring circuits between the controller and the air mix door
15 motor with changing the temperature setting.
Does the air mix door operate normally? System OK Go to Step 6
Replace the air mix door motor.
16
Is the repair complete? System OK -
Recheck all wiring circuits between the controller and the air mix door
17 motor.
Is there a problem in the wiring or the connectors? Go to Step 18 Go to Step 19
Repair the problem in the wiring between the FATC controller and the
18 air mix door motor.
Is the repair complete? System OK -
Recheck the air mix door motor.
19
Is there a problem in the air mix door motor? Go to Step 16 Go to Step 21
Replace the air mix door motor.
20
Is the repair complete? System OK -
1. Install the components.
21 2. Perform the diagnostic test of the controller.
Does the DTC reset? Go to Step 16 System OK

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-27

SUN SENSOR ERROR

Step Action Yes No
1. Disconnect the Sun sensor connector.
2. Place the sun sensor under the sun light and measure the current
between the connector terminals.
1
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? Go to Step 3 Go to Step 2
replace the sun sensor.
2
Is the repair complete? System OK -
1. Remove the controller with connecting the connectors.
2. Turn the ignition switch to ON.
3 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? Go to Step 5 Go to Step 4
Repair open or short circuit.
4
Is the repair complete? System OK -
Replace the FATC controller.
5
Is the repair complete? System OK -

POWER TRANSISTOR ERROR

Step Action Yes No
1. Remove the controller and disconnect the controller connector.
2. Disconnect power transistor connector.
1 3. Examine the open or short circuit between controller connector and
power transistor connector.
Is there a problem in the wiring or the connectors? Go to Step 2 Go to Step 3
Repair the faulty wiring and replace as needed.
2
Is the repair complete? System OK -
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.
3
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? Go to Step 5 Go to Step 4
Replace the power transistor.
4
Is the repair complete? System OK -
Replace the FATC controller.
5
Is the repair complete? System OK -

SSANGYONG Y200
7D-28 AUTOMATIC CONTROL HVAC SYSTEM

MAX-HIGH RELAY ERROR

Step Action Yes No

1. Remove the controller with connecting the connectors.
2. Turn the ignition switch to ON.
1 3. Set the blower speed for 5th speed manually.
4. Measure the voltage at terminal A10 and ground.
Does the measured voltage indicate 0V? Go to Step 3 Go to Step 2
Replace the FATC controller.
2
Is the repair complete? System OK -
1. Check the wiring harness associated with blower high relay and
terminals.
2. Repair any defects found.
3
3. Install the component.
Is DTC retrieved as a current DTC? Go to Step 4 System OK
Replace blower high relay.
4
Is the repair complete? System OK -

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-29

REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
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
7D-30 AUTOMATIC CONTROL HVAC SYSTEM

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

4. Installation should follow the removal procedure

in the reverse order.

YAD7D220

SSANGYONG Y200
AUTOMATIC CONTROL HVAC SYSTEM 7D-31

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

4. Installation should follow the removal procedure

in the reverse order.

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
7D-32 AUTOMATIC CONTROL HVAC SYSTEM

MODE CONTROL DOOR

ACTUATOR
1. Disconnect the negative battery cable.
2. Remove the driver’s 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.
6. Installation should follow the removal procedure
YAD7D260
in the reverse order.

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
AUTOMATIC CONTROL HVAC SYSTEM 7D-33

3. Remove the inside air temperature sensor sub from

the instrument panel.

YAD7D300

4. Installation should follow the removal procedure

in the reverse order.

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
7D-34 AUTOMATIC CONTROL HVAC SYSTEM

3. Installation should follow the removal procedure

in the reverse order.

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 Maintenance and Repair ..................................... 8A-5
Fastener Tightening Specifications ....................... 8A-2 On-Vehicle Service ............................................... 8A-5
Diagnosis .............................................................. 8A-3 Front Seat Belt ..................................................... 8A-5
Seat Belt Warning Lamp is Inoperative ................. 8A-3 Front Seat Belt Buckle ......................................... 8A-6
Component Locator ............................................. 8A-4 2nd-Row Seat Belt ............................................... 8A-7
Seat Belt Assembly ............................................. 8A-4 3rd-Row Seat Belt ................................................ 8A-8
8A-2 SEAT BELTS

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application N•m Lb-Ft Lb-In
Front Seat Belt Adjuster Mounting Bolt 30 - 40 22 - 30 -
Retractor Mounting Bolt 30 - 45 22 - 33 -
Upper Bolt 30 - 45 22 - 33 -
Lower Bolt 30 - 45 22 - 33 -
Belt Buckle Bolt 30 - 45 22 - 33 -
2nd-Row Seat Retractor Mounting Bolt 30 - 45 22 - 33 -
Belt Upper Bolt 30 - 45 22 - 33 -
3rd-Row Seat Upper Bolt 30 - 45 22 - 33 -
Belt Lower Bolt 30 - 45 22 - 33 -
Retractor Bolt 30 - 45 22 - 33 -

SSANGYONG Y200
SEAT BELTS 8A-3

DIAGNOSIS
SEAT BELT WARNING LAMP IS INOPERATIVE

Condition Probable Cause Correction

Seat belt warning lamp Seat belt warning lamp wiring harness is Repair the wiring harness.
is inoperative open circuit or a short circuit.
The continuity between the two terminals Replace the seat belt switch.
at the switch side of the connector is fail.
The continuity between the terminal for Repair the open ground.
the BLK wire and ground is fail.
The warning lamp bulb in the instrument Replace the warning lamp bulb.
cluster is blown.

SSANGYONG Y200
8A-4 SEAT BELTS

COMPONENT LOCATOR
SEAT BELT ASSEMBLY

YAD8A010

1 Upper anchor plate 5 Retractor

2 Seat Belt 6 Rear Seat Belt
3 Retractor 7 Seat Belt
4 Buckle

SSANGYONG Y200
SEAT BELTS 8A-5

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
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

Installation Procedure
1. Tighten the adjuster and the seat belt retractor
bolt as specified torque.
Installation Notice

Adjuster Mounting 30 - 40 N•m

Bolt (1) (22 - 30 lb-ft)

Retractor Mounting 30 - 45 N•m

Bolt (2) (22 - 33 lb-ft)

YAD8A060

2. Tighten the upper/lower bolt as specified torque.

Installation Notice

30 - 45 N•m
Upper Bolt (1)
(22 - 33 lb-ft)
30 - 45 N•m
Lower Bolt (2)
(22 - 33 lb-ft)

YAD8A070

FRONT SEAT BELT BUCKLE

Removal and Installation Procedure
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
30 - 45 N•m
Tightening Torque
(22 - 33 lb-ft)

YAD8A090

2ND-ROW SEAT BELT

Removal and Installation Procedure
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 30 - 45 N•m

Bolt (1) (22 - 33 lb-ft)
30 - 45 N•m
Upper Bolt (2)
(22 - 33 lb-ft)

YAD8A130

• Tighten seat belt lower bolt as specified torque.

YAD8A140

3RD-ROW SEAT BELT

Removal and Installation Procedure
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

30 - 45 N•m
Upper Bolt (1)
(22 - 33 lb-ft)
30 - 45 N•m
Lower Bolt (2)
(22 - 33 lb-ft)
30 - 45 N•m
Retractor Bolt (3)
(22 - 33 lb-ft)
YAD8A170

SSANGYONG Y200
SECTION 8B

RESTRAINTS
TABLE OF CONTENTS
General Description and Operation ..................... 8B-2 Diagnosis .......................................................... 8B-12
General Precautions ............................................. 8B-2 Diagnostic Trouble Codes .................................. 8B-13
SIR System ......................................................... 8B-3 Maintenance and Repair ................................... 8B-16
SIR System Operation ......................................... 8B-3 On-Vehicle Service ............................................. 8B-16
Airbag Module Discard ........................................ 8B-3 Airbag Module (Driver) ....................................... 8B-16
Component Function ............................................ 8B-5 Contact Coil ....................................................... 8B-17
Front Airbag ........................................................ 8B-7 Airbag Module (Passenger) ................................ 8B-18
Side Airbag ......................................................... 8B-8 Belt Pretensioner ............................................... 8B-19
Component Locator ............................................. 8B-9 Sensing and Diagnostic Module (SDM) .............. 8B-19
Driver Airbag Assembly ....................................... 8B-9 Special Tool and Equipment.............................. 8B-20
Passenger Airbag Assembly ............................. 8B-10 Special Tools Table ........................................... 8B-20
Diagnostic Information and Procedures ............ 8B-11
General Diagnosis ............................................. 8B-11
8B-2 RESTRAINTS

GENERAL DESCRIPTION AND OPERATION

GENERAL PRECAUTIONS SIR SYSTEM
When the ignition is switched ON, the supplemental SIR system consists of 6-Loop (DAB, PAB, 2*SAB,
inflatable restraints (SIR) warning lamp must blink at 2*PRET) fully and the block diagram is as shown below.
seven times for 7 seconds and then turn off. On this diagram, SDM sends the output signal to DAB,
There is a fault in the airbag system if the warning PAB, 2*SAB, 2*PRET and receives the input of side
lamp does not turn OFF or the warning lamp illuminates impact from 2*SIS (Side Impact Seasor).
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.
• Never attempt to disassemble, repair or reuse the
following component;
- Airbag modules YAD8B010

- Clock spring
- Sensing and diagnostic module Abbreviation
- Wiring harness
1 SDM Sensing and Diagnostic Module
• When repairing SIR component, follow the service
(SDM)
notice;
- Inspect any SIR part before it is installed. 2 DAB Driver-side Airbag Module
- Use only new parts. 3 PAB Passenger-side Airbag Module
- Do not install used SIR parts from other vehicles. 4 SAB Side Airbag Module
- Do not install any part that has been dropped or (Driver, Passenger)
that has dents, cracks or other defects. 5 PRET Seatbelt Pretensioner
• Before testing, disconnect the negative battery (Driver, Passenger)
cable. Wait one minute for the SDM capacitor to
6 SIS Side Impact Sensor
discharge. The capacitor supplies reserve power
to deploy the airbags, even if the battery is (Driver, passenger)
disconnected. Unintentional deployment of the
airbags can cause injury.

SSANGYONG Y200
RESTRAINTS 8B-3

SIR SYSTEM OPERATION AIRBAG MODULE DISCARD

The supplemental inflatable restraints (SIR) system is Airbag Module Deployment (Inside Vehicle)
a safety device used in conjunction with the seat belts.
Deploy the airbag before disposing of them. If a vehicle
The airbag does not replace the function of the seat
to be scraped, the airbag may be deployed inside the
belt. The driver and the passengers must always fasten
vehicle.
their seat belts and adjust them for a proper fit.
• Before deploying the airbags, remove all loose
objects from the airbag’s 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
YAD8B020 cool for at least 30 minutes before handling.
• If the deployment fails, disconnect the voltage
Deployment Condition source and wait 5 minutes before approaching the
vehicle.
Airbag is designed to protect the driver and the front
seat passenger in the event of a significant frontal Airbag Module Discard (Driver)
impact to the vehicle. The airbags deploy if the force 1. Disconnect the battery cable and place the vehicle
is applied from a direction within 30 degrees of the battery at least 10 meters (33 feet) away from the
vehicle’s centerline and above 25 km/h (15 mph) airbag module.
speed. In case of the 0 degree frontal concrete barrier,
Notice: If the airbags are not disconnected, service
airbag may deploy above 25 km/h (15 mph) speed.
cannot begin until one minute has passed after
The side airbag deploys if the side impact is applied disconnecting power to the SDM. If the airbags are
above 30 km/h. 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
YAD8B040
• Slight impact or partial impact
• Incline impact 3. Cut two wires between the airbag and the contact
coil.
• Overturn and fall accident
4. Strip 13 mm (0.5 inch) of the insulation from the
• Impact on the material that may be possible to
end of the wires leading to the contact coil.
absorb a lot of impact energy (styrofoam, empty
drum can, etc.)

SSANGYONG Y200
8B-4 RESTRAINTS

5. Use two additional wires, each at least 10 meters Observe following precaution if the airbag is
(33 feet) long, to reach from the deployment battery deployed:
to the airbag module. • Deploy the airbags only in an evacuated area.
6. Strip 13 mm (0.5 inch) of the insulation from the Service mechanics should be at least 10 meters
ends of these two additional wires. (33 feet).
7. Twist the two wires together at one end. • Do not connect the voltage source until after having
8. Place the twisted ends of the two wires near the completed all other preparations for the deployment
deployment battery. Do not connect the wires to of the airbags.
the battery at this time. • Allow a deployed airbag module or pretensioner to
9. Using the free ends of the 10 meters (33 feet) wires cool for at least 30 minutes before handling.
leading to the airbag module, make two splices, • If the deployment fails, disconnect the voltage
one at each wires from the airbag module. source and wait 5 minutes before approaching the
10. Wrap the splices with insulating tape. vehicle.
11. Now that the free ends of the 10 meters (33 feet) 1. Position the airbag module face up, on flat
wires are spliced to the airbag module wires and ground outdoors, at least 10 meters (33 feet)
the ends that are twisted together are near the from any obstacle or people.
deployment battery, clear the area. 2. Place a vehicle battery at least 10 meters (33
12. Untwist the wires that near the deployment feet) away from the airbag module.
battery. 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
YAD8B050 hydroxide dust (similar to lye soap) is produced as a
by-product of the deployment reaction. The sodium
13. Touch one wire to the positive battery terminal and
hydroxide then quickly reacts with atmospheric
touch the other wire to the negative battery
moisture and is converted to sodium carbonate and
terminal. The airbag module will deploy.
sodium bicarbonate also known as baking soda}.
14. Refer to “DEPLOYED AIRBAG MODULE Therefore, it is unlikely that sodium hydroxide will be
DISPOSAL PROCEDURE” in this section. present after deployment. Wear gloves and eye
Airbag Module Discard (Passenger) protection during the disposal procedure.
The passenger airbag deployment is the same After deployment, the metal surfaces of the airbag
procedure of the driver’s. Remove the glove box module will be hot. In order to avoid the risk of an
instead of the contact coil and cut two passenger injury or a fire, do not place the deployed airbag module
airbag wires. near any flammable objects, and allow the airbag
module to cool for 30 minutes before handling. Deploy
Refer to “AIRBAG MODULE DISCARD (DRIVER)” in an airbag or pretensioner before disposing of it.
this section for more information.
This includes those in a whole vehicle being scrapped.
Airbag Module Deployment (Outside Vehicle) If the vehicle is still within the warranty period contact
Deploy airbag modules in following situations: the SsangYong regional service manager for approval
or special instructions before deploying an airbag
• If the airbag module is removed in the discarded
vehicle. module or pretensioner.

• 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 cushion’s material and folding function to control
the cushion deployment direction and the YAD8B060

performance to protect passenger’s face.

Module Cover/Housing SDM (Sensing and Diagnostic Module)
1. The airbag system consists of the module section
• It is a type of a container that includes the cushion
(driver, passenger and side), seat belt section and
and the inflator.
SDM.
• The module housing functions to deliver the reaction
2. The SDM has no user-serviceable parts and
force between the body structure and the airbag
(The airbag reaction is absorbed generally to the monitors the system components continuously. The
steering wheel or instrument panel). SDM also records any faults which are discovered.
3. The SDM allows the fault codes to be retrieved with
• The module cover must be considered in a viewpoint
a scan tool and illuminates a warning lamp that
of protection between exterior, internal units and
cushion. Also the module cover should be designed alerts the driver to any faults.
not to cause any personal injury for deployment. The SDM located on floor beneath the floor console
assembly. The SDM performs the following functions:
Inflator
• Impact decision processor function.
• The inflator is a type of the direct gas generated
Determine the airbag deployment through the
device.
impact signal of the accelerometer sensor and the
• The inflator with initial low pressure provides safety sensor.
negative restraint effect regarding passengers
moving and time. • Malfunction detection and recording any faults that
are detected.
On the contrary, the inflator with initial high pressure
Monitor the supplemental restrain system electrical
allows other components of the airbag to make a
components and set a diagnostic trouble code
excessive impact resulting in any personal injury.
when malfunction is detected.
Thus, the inflator output must be optimized
according to the characteristic of the vehicle and • Display airbag fault codes
passenger moving. Display airbag fault codes and system status
information when connected to a scan tool.
• The discharge gas has no toxicity or inflammability
and also it is the important parameter to control the • Self-diagnosis function
high temperature for gas firing. Illuminate the AIRBAG indicator to alert the driver
to any fault.
Airbag Module
The driver airbag module is under the center pad of • Power supply function
the steering wheel. Provide a reserve power source to deploy the
airbags and pretensioners if an accident has
The passenger airbag module is installed in the
disabled the normal power source.
instrument panel at passenger side.
The driver and passenger side airbag is inside each Acceleromenter Sensor
seat. The accelerometer sensor electronically represents the
Notice: Do not disassemble the airbag module acceleration or deceleration of the vehicle during a
because unintentional deployment of the airbags frontal impact.
resulting from any damage or interference of the module In this electronic representation, the electrical signal
can cause injury. is proportional to the acceleration or deceleration of
the vehicle.

SSANGYONG Y200
8B-6 RESTRAINTS

Safety Sensor The SDM performs a turn-on test when the ignition is
turned ON. The SDM flashes the AIRBAG indicator
The safety sensor is safety device made up of a dual-
seven tomes by supplying an intermittent ground to
contact, electro-mechanical switch that:
the indicator lamp circuit. After flashing seven times,
1. Acts independently of the electronic components. the AIRBAG indicator will turn off if no more
2. Connects the acceleration sensor in series in order malfunctions have been detected.
to make up for the weak points in the current
electronic sensor.
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 Warning lamp Fault contents
and the steering column and contains a coil that enables status
to contact electrically between the airbag wiring Flash at seven System OK
harness, the driver airbag module and the horn switch.
times for 7 seconds
Notice: Turning the steering wheel more than three
and one-quarter turns may damage the clock spring. and then turn off
The contact coil should never be disassembled and Warning lamp stays System fault
must be replaced if the airbag have been deployed. ON Internal SDM fault
No turn on Power supply circuit open
and fuse open
Warning lamp circuit open
SDM fault

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.
YAD8B070
To prevent deployment during servicing, additional
shorting bars are located in following locations:
Notice: Turn the label of the clock spring clockwise to
lock and turn the label of the clock spring
• Driver airbag module connector
counterclockwise approximately 2.9 ± 0.2 turns to the • Passenger airbag module connector
neutral positions with the front wheels ahead. • Driver and passenger side airbag module connector
Align the pointed marks “ "!” . • SDM wiring harness connector
Airbag Warning Lamp • Contact coil connector to airbag wiring harness
The shorting bar is only a backup safety device. Always
The instrument cluster contains an airbag warning
disable the supplemental restraints system (SRS)
indicator bulb to verify the operation of the AIRBAG
before beginning any service procedure.
indicator and sensing and diagnostic module (SDM).
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 Cushion

• Cushion is made mainly of nylon 66 material.
General Description
• It is made by assembling various panel pieces and
• The frontal airbag system is a safety device used sometimes, some surfaces of these panel pieces
in conjunction with the seat belts. handled by coating. The coating material is used
The airbag does not replace the function of the seat as silicon rubber generally.
belt. The driver and the passengers must always
Inflator
fasten their seat belts and adjust them for a proper
fit. • The inflator generates gas to fill the cushion with it.
There are two type of ALL-PYRO TECHNIC TYPE
The front seat airbag is designed to protect the driver
and HYBRID TYPE according to gas generated type.
and the front seat passenger in the event of a
significant frontal impact to the vehicle. • Now, the driver airbag uses the “all-pyro technic
type” and the passenger airbag uses both “all-pyro
• The driver airbag is installed on the steering wheel
technic type” and “hybrid type”.
and the passenger airbag is in the instrument panel.
• The inflator has the ignitor at one side of the inflator.
Airbag Component The ignitor receives a electrical signal from the
Cover sensor and ignites powders continuously.
It is a part of the airbag steering section and is made Housing
by injection molding. It is a part of airbag steel plate structure.
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
Related System Component
1 Vehicle Structure and B/W 1 Side Airbag Module (LH/RH)
2 Seat System 2 Side Airbag Sensor (LH/RH)
3 Seat Belt System 3 SDM (Common use the SDM for frontal airbag)
4 Door Trim and Door Structure
5 B - Pillar Trim and Structure
6 Airbag Wiring Harness

Side Airbag Module (SAB) Side Airbag Module (SAB)

• Chest, Head and Gas Airbag • Chest, Head and Gas Airbag
• Installed on door or seatback • Installed on door or seatback

SDM

• Operation Circuit
• Safety Sensor
• External Diagnosis

Side Airbag Sensor Side Airbag Sensor

• Side Impact Detection • Side Impact Detection

• Deployment Decision • Deployment Decision
• Self-Diagnosis • Self-Diagnosis
• Installed on Inner B - Pillar or Side • Installed on Inner B - Pillar or Side
underbody underbody

SSANGYONG Y200
RESTRAINTS 8B-9

FRONTAL AIRBAG CROSS SECTIONAL VIEW

DRIVER AIRBAG ASSEMBLY

YAD8B090

1 Cover 6 Inflator assembly

2 Carrier 7 Membrane switch assembly
3 Retainer cover assembly 8 Reaction plate
4 Retainer cushion assembly 9 Steering wheel
5 Cushion assembly 10 Remote control switch

SSANGYONG Y200
8B-10 RESTRAINTS

PASSENGER AIRBAG ASSEMBLY

YAD8B100

1 Cover assembly 4 Lower Door Retainer

2 Housing assembly 5 Cushion assembly
3 Upper Door Retainer 6 Inflator assembly

SSANGYONG Y200
RESTRAINTS 8B-11

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS • Warning lamp stays ON : Connection fault between
the SDM wiring harness connector and the SDM
Warning Lamp Check connector, or the airbag wiring harness fault.
As soon as the opening voltage is applied to the • No the indicator turn ON : Power supply malfunction,
sensing and diagnostic module (SDM) ignition input, indicator circuit open, bulb fault, SDM internal
the SDM activates the warning lamp for a bulb check. defect.
The SDM allows the lamp to blink at seven times for 7
Diagnosis by Using Scan Tool
seconds and then turn off.
During the bulb check, the SDM is not ready to detect • Check the fault code by connecting the diagnostic
(ALDL) connector.
a crash or deploy the supplemental inflatable
restraints. • 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
External Fault
Fault Indication Service personnel can reset the SDM and turn OFF the
The sensing and diagnostic module records the warning lamp if the fault is an external fault.
system’s faults in two categories: Internal Fault
• Active Fault An internal fault of the SDM or a CRASH RECORDED
Current detected faults and the “C” appears the fault code cannot be reset.
first digit of the fault code on the scan tool display In the case of an internal fault of the SDM or a CRASH
(example: “C16”). RECORDED fault code, the SDM must be replaced.
• History Fault Microprocessor-Independent Lamp
These faults that were detected in the past, but are Activation
no longer active. The “H” appears the first digit of
the fault code on the scan tool display (example: If the sensing and diagnostic module (SDM) electrical
“H17”). connector is not properly attached, the SDM cannot
function and cannot control the warning lamp.
Diagnosis by Using Warning Lamp
If this fault is present, the warning lamp will operate
• The warning lamp flashes for 7 seconds at seven independently from the SDM through the use of shorting
times and turn off : Normal Status - There is not bars that are built into the SDM connector.
any history or current fault code.
Notice: Do not measure the resistance of the airbag
• The indicator turns on for 7 seconds and then turn module because the multimeter’s battery may deploy
off : Normal Status - A fault has been detected the air bag causing any personal injury.
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.

SSANGYONG Y200
8B-12 RESTRAINTS

DIAGNOSIS

Possible Cause Action

Ignition “ON” Does the warning lamp Yes System OK
Check warning blink at seven times for No Connect the scan tool to diagnostic connector (ALDL).
lamp on I/P 7 seconds and then turn Select the fault code display menu and clear code
off? menu.
Does the fault code Yes Perform “Diagnostic System Check”.
display on the scan tool No Check any fuse open.
display?
Is there any open in Yes Replace fuse.
fuse? No Disconnect wiring connector.
Check any wiring short between fuse and wiring
connector.
Is there any short in Yes Repair wiring.
fuse? No Disconnect SDM wiring connector.
Check wiring short between connector terminal and
SDM connector terminal.
Is there any short in Yes Replace airbag wiring.
wiring? No Check any open between ALDL connector No.4, No.5
terminal and ground.
Is there any open in Yes Repair wiring
wiring? No Ignition “ON”
Measure voltage at the cigar lighter socket.
Does the voltage Yes Check any open or short between ALDL connector
indicate 11~14V? terminal and wiring connector terminal.
No Repair the wiring of the cigar lighter socket.
Is there any open or Yes Repair wiring
short in wiring? No Check any open or short between SDM connector
terminal and wiring connector terminal.
Is there any open or Yes Replace the airbag wiring.
short in wiring? No Replace the SDM.

SSANGYONG Y200
RESTRAINTS 8B-13

DIAGNOSTIC TROUBLE CODES

Code Fault Contents Check

01h Driver airbag circuit, resistance Check the connection of the driver airbag connector.
too high Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
02h Driver airbag circuit, resistance Check the connection of the driver airbag connector.
too low Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
03h Driver airbag circuit, short to Check the connection of the driver airbag connector.
ground Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
04h Driver airbag circuit, short to Check the connection of the driver airbag connector.
battery voltage Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
05h Passenger airbag circuit, Check the connection of the passenger airbag connector.
resistance too high Check the wiring condition of the passenger airbag.
Check the bending of the airbag terminal.
06h Passenger airbag circuit, Check the connection of the passenger airbag connector.
resistance too low Check the wiring condition of the passenger airbag.
Check the bending of the airbag terminal.
07h Passenger airbag circuit, short Check the connection of the passenger airbag connector.
to ground Check the wiring condition of the passenger airbag.
Check the bending of the airbag terminal.
08h Passenger airbag circuit, short Check the connection of the passenger airbag connector.
to battery voltage Check the wiring condition of the passenger airbag.
Check the bending of the airbag terminal.
09h Driver pretensioner circuit, Check the connection of the driver pretensioner connector.
resistance too high Check the wiring condition of the driver pretensioner.
Check the bending of the airbag terminal.
0Ah Driver pretensioner circuit, Check the connection of the driver pretensioner connector.
resistance too low Check the wiring condition of the driver pretensioner.
Check the bending of the airbag terminal.
0Bh Driver pretensioner circuit, short Check the connection of the driver pretensioner connector.
to ground Check the wiring condition of the driver pretensioner.
Check the bending of the airbag terminal.
0Ch Driver pretensioner circuit, short Check the connection of the driver pretensioner connector.
to battery voltage Check the wiring condition of the driver pretensioner.
Check the bending of the airbag terminal.

SSANGYONG Y200
8B-14 RESTRAINTS

Code Fault Contents Check

0Dh Passenger pretensioner circuit, Check the connection of the passenger pretensioner connector.
resistance too high Check the wiring condition of the passenger pretensioner.
Check the bending of the airbag terminal.
0Eh Passenger pretensioner circuit, Check the connection of the passenger pretensioner connector.
resistance too low Check the wiring condition of the passenger pretensioner.
Check the bending of the airbag terminal.
0Fh Passenger pretensioner circuit, Check the connection of the passenger pretensioner connector.
short to ground Check the wiring condition of the passenger pretensioner.
Check the bending of the airbag terminal.
10h Passenger pretensioner circuit, Check the connection of the passenger pretensioner connector.
short to battery voltage Check the wiring condition of the passenger pretensioner.
Check the bending of the airbag terminal.
34h Driver side airbag circuit, Check the connection of the driver side airbag connector.
resistance too high Check the wiring condition of the driver side airbag.
Check the bending of the airbag terminal.
35h Driver side airbag circuit, Check the connection of the driver side airbag connector.
resistance too low Check the wiring condition of the driver side airbag.
Check the bending of the airbag terminal.
36h Driver side airbag circuit, short Check the connection of the driver side airbag connector.
to ground Check the wiring condition of the driver side airbag.
Check the bending of the airbag terminal.
37h Driver side airbag circuit, short Check the connection of the driver side airbag connector.
to battery voltage Check the wiring condition of the driver side airbag.
Check the bending of the airbag terminal.
38h Passenger side airbag circuit, Check the connection of the passenger side airbag connector.
resistance too high Check the wiring condition of the passenger side airbag.
Check the bending of the airbag terminal.
39h Passenger side airbag circuit, Check the connection of the passenger side airbag connector.
resistance too low Check the wiring condition of the passenger side airbag.
Check the bending of the airbag terminal.
3Ah Passenger side airbag circuit, Check the connection of the passenger side airbag connector.
short to ground Check the wiring condition of the passenger side airbag.
Check the bending of the airbag terminal.
3Bh Passenger side airbag circuit, Check the connection of the passenger side airbag connector.
short to battery voltage Check the wiring condition of the passenger side airbag.
Check the bending of the airbag terminal.
50h Driver side airbag sensor, open/ Check the connection of the driver side airbag sensor connector.
short to battery voltage Check the wiring condition of the driver side airbag sensor.
Check the bending of the airbag terminal.

SSANGYONG Y200
RESTRAINTS 8B-15

Code Fault Contents Check

51h Passenger side airbag circuit, Check the connection of the driver side airbag sensor connector.
short to ground Check the wiring condition of the driver side airbag sensor.
Check the bending of the airbag terminal.
52h Communication malfunction of Check the connection of the driver side airbag sensor connector.
the driver side airbag Check the wiring condition of the driver side airbag sensor.
Check the bending of the airbag terminal.
53h Internal fault of the driver side Check the connection of the driver side airbag sensor connector.
airbag sensor Check the wiring condition of the driver side airbag sensor.
Check the bending of the airbag terminal.
54h Passenger side airbag sensor, Check the connection of the passenger side airbag sensor
open/short to battery voltage connector.
Check the wiring condition of the passenger side airbag sensor.
Check the bending of the airbag terminal.
55h Passenger side airbag sensor, Check the connection of the passenger side airbag sensor
short to ground connector.
Check the wiring condition of the passenger side airbag sensor.
Check the bending of the airbag terminal.
56h Communication malfunction of Check the connection of the passenger side airbag sensor
the passenger side airbag connector.
Check the wiring condition of the passenger side airbag sensor.
Check the bending of the airbag terminal.
57h Internal fault of the passenger Check the connection of the passenger side airbag sensor
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 SDM internal fault Replace the SDM.
(Initialization fault)
1Fh SDM internal fault Replace the SDM.

Caution:
• Use only the scan tool to check the airbag disconnected. Unintentional deployment of the
module and the sensing and diagnostic module airbags can cause injury.
(SDM). Never measure the resistance of an airbag
module with an ohmmeter. An ohmmeter’s
• Do not attempt to repair the supplemental
inflatable restraints (SIR) wiring harness. An SIR
battery can deploy the airbag and cause injury. repair can create a high-resistance connection
• Before testing, disconnect the negative battery which can keep the airbags from deploying when
cable. Wait 1 minute for the SDM capacitor to needed, resulting in injury.
discharge. The capacitor supplies reserve power
to deploy the airbags, even if the battery is

SSANGYONG Y200
8B-16 RESTRAINTS

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
AIRBAG MODULE (DRIVER)
Removal and Installation Procedure
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
Removal and Installation Procedure
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
YAD8B180 counterclockwise approximately 2.9 ¡¾ 0.2 turns
to the neutral positions with the front wheels ahead.
And also Align the pointed marks “ "!” .

yyyy
;;;; AIRBAG MODULE (PASSENGER)
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the glove box.
3. Disconnect the airbag module connector.

YAD8B190

4. Remove the airbag module.

5. Installation should follow the removal procedure
in the reverse order.

YAD8B200

SSANGYONG Y200
RESTRAINTS 8B-19

BELT PRETENSIONER
Removal and Installation Procedure
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)
Removal and Installation Procedure
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 AND EQUIPMENT

SPECIAL TOOLS TABLE

Scan Tool Wheel Wrench

YAD8B250 YAD8B260

SSANGYONG Y200
SECTION 9A

GENERAL BODY
TABLE OF CONTENTS
Specification ........................................................ 9A-2 Check ................................................................. 9A-4
Dignosis and Action Taken ................................... 9A-3 Repair ................................................................. 9A-7
Diagnosis for Leaking Water ................................ 9A-3 Special Tool and Equipment................................ 9A-9
Check and Repair ................................................. 9A-4 Special Tools Table .............................................. 9A-9
9A-2 GENERAL BODY

SPECIFICATION
Application Specification
Hood Type Rear Hinge and Type of Front Opening, Gas Lifter
Front Door Structure Front Hinge and Frame Door
Type of Regulator Wire and Drum
Lock System Pin and Fork
Rear Door Structure Front Hinge and Frame Door
Type of Regulator Wire and Drum
Lock System Pin and Fork
Tail Gate Type Internal Hinge, Gas Lifter
Thickness of Wind Shield 5 mm
Glass Front Door Glass 4.0 mm
Rear Door Glass 4.0 mm
Rear Fix Glass 4.0 mm
Glass of Tail Gate Fixing Type 4.0 mm
Opening Type 5.0 mm
Specification Type of Nozzle Spray Nozzle of #1/2 GG-25 or Nozzle with Sloping
of Test Water Angle 60° Equivalent
Leaking Height of Nozzle Keep Distance 1,600 mm from Ground
Quantity of Injecting 14L Per Mir
Pressure 155kPa(22.5 psi): Checking Pressure from nozzle
Position of a Piller Test Stand and Keep Injecting Water, 30° of Lower Direction and 45°
Wing Shield of Backwards, Approximately at the corner of Wind-
shield
Position of “B” Piller Test Stand 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 Keep Injecting Water, 30° of Lower Direction and 45°
Gate Glass of Forwards, Approximately at Distance of 60mm to
the Corner of Rear Door

SSANGYONG Y200
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
YAD9A070
and nut should be, used or similar material of bolt and
nut.
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
YAD9A090 the glass external area.
3. Mark accurate position of leaking water.
4. Wash section of leaking water and dry up air hose.

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

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
vehicle’s moving.
• Repair clearance of moving parts under vehicle’s
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 AND EQUIPMENT

SPECIAL TOOLS TABLE

09793-21000 09800-21000
Adjusting Wrench of Ornament Remover
Door Wrench

YAD9A120 YAD9A130

09853-31000 09861-31100
Remover of Headlning Cutting Tool of Sealant
Clip

YAD9A140 YAD9A150

09861- 31200 09861-31300

Cuttibg Knife of Sealant Sealant Gun

YAD9A160 YAD9A170

09861-31400 09861-31000
Glass Holder Remover of Wind Shield
Molding

YAD9A180 YAD9A190

SSANGYONG Y200
SECTION 9B

BODY INTERIOR
TABLE OF CONTENTS
Components Location ......................................... 9B-2 Trim and Roof .................................................... 9B-10
Instrument Assembly ........................................... 9B-2 Handler ............................................................. 9B-15
Side Trim and Roof Assembly .............................. 9B-3 Sunvisor ............................................................ 9B-15
Seat .................................................................... 9B-4 Room Miror ........................................................ 9B-15
Console ............................................................... 9B-5 Seat .................................................................. 9B-16
Removal and Installation ..................................... 9B-6 Removal and Installation ................................... 9B-18
Instrument ........................................................... 9B-6 Front Seat .......................................................... 9B-18
Console Box ........................................................ 9B-9 Two Row Seat .................................................... 9B-19
Groove Box ....................................................... 9B-10 Seat of Three Row.............................................. 9B-20
9B-2 BODY INTERIOR

COMPONENTS LOCATION
INSTRUMENTS ASSEMBLY

YAD9B010

1 Fuse Box Cover 7 Groove Box

2 Side Facia Panel 8 Side Facia Panel
3 Instrument Panel 9 Duct
4 Instrument Lower Main Panel 10 Instrument Assembly
5 Cluster Facia Panel 11 Center Facia Upper Panel
6 Center Facia Lower Panel

SSANGYONG Y200
BODY INTERIOR 9B-3

SIDE TRIM AND ROOF ASSEMBLY

YAD9B020

1 Door Scuff Front 10 Upper Quarter

2 Door Scuff Rear 11 Rear Aircon (Facia)
3 A-Pillar 12 Lower Quarter
4 B-Upper Pillar 13 Jack Cover
5 B-Lower Pillar 14 Lower Quarter (Cover)
6 Side Cowl 15 Lower Quarter
7 Side Cowl 16 Rear Transverse Trim
8 Out Side Step Front 17 Baggage Room Cover
9 Out Side Step Rear 18 Roof Panel

SSANGYONG Y200
9B-4 BODY INTERIOR

SEAT

YAD9B030

1 Front Seat - Right Side 4 Rear Seat - Left Side

2 Rear Seat - Right Side 5 Front Seat - Left Side
3 3 Row Seat

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
Removal / Installation
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
Removal / Installation
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

Removal / Installation
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
Removal / Installation
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 N•m

(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 35 - 55 N•m
Torque fo front fixing bolt 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 41.2 - 49 N•m
Torque fo front fixing bolt 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 Door Lock Assembly ........................................ 9C-25
Front Bumper ...................................................... 9C-2 Door Handle ..................................................... 9C-26
Tail Gate .............................................................. 9C-3 Door Trim .......................................................... 9C-27
Hood ................................................................... 9C-6 Door Opening Weathr Strip ............................... 9C-28
Sun Roof And Roof Rack ..................................... 9C-7 Fork Striker ....................................................... 9C-29
Moulding ............................................................. 9C-8 Tail Gate Crank .................................................. 9C-31
Repair Procedure ................................................. 9C-9 Tail Gate ............................................................ 9C-32
Hood Assembly ................................................. .9C-9 Tail Gate Flip Up System ................................... 9C-33
Cowl Grill ......................................................... ..9C-12 Tail Gate Air Spoiler ........................................... 9C-34
Radiator. Grill .................................................... 9C-13 Check and Adjust Tail Gate ............................... 9C-35
Front Bumper Assembly .................................... 9C-14 Front Door Window ............................................ 9C-37
Rear Bumper Assembly ..................................... 9C-17 Front Door Glass Run And Regulator .................. 9C-38
Back Beam ....................................................... 9C-17 Rear Window ..................................................... 9C-39
Fender ............................................................... 9C-18 Rear Glass Run / Regulator / Channel ................ 9C-40
Fuel Filler Opening System ................................ 9C-20 Wind Shield Glass ............................................. 9C-42
Roof Carrier ....................................................... 9C-21 Front Quarter Glass ............................................ 9C-45
Side Step .......................................................... 9C-21 Rear Quarter Glass ............................................ 9C-48
Side Moulding .................................................. 9C-22 Tail Gate Glass .................................................. 9C-49
Out Side Mirror ................................................. 9C-22 Sun Roof ........................................................... 9C-53
Door Assembly ................................................. 9C-23 Motor And Relay Box ......................................... 9C-54
Door Hinge ....................................................... 9C-24 Glass Panel ....................................................... 9C-56
Door Check Link ............................................... 9C-24 Sun Shade ......................................................... 9C-57
9C-2 BODY EXTERIOR

PARTS COMPONENTS
FRONT BUMPER

YAD9C010

1 Front Bumper Facia Assembly 3 Front Nudge Bar Assembly

2 Energy Absorber 4 Bumper

SSANGYONG Y200
BODY EXTERIOR 9C-3

TAIL GATE
Mechanism

YAD9C020

1 Hinge 9 Door Safety Rod Box Crank

2 Key 10 Safety Nob
3 Tail Gate Release Handle 11 Glass Open Latch
4 Garnish 12 Key Rod
5 Glass Handle 13 Over Slam Bumper
6 Guide Bumper 14 Ball Stud
7 Body Side Guide Bumper 15 Lifter
8 Tail Gate Latch 16 Ball Stud

SSANGYONG Y200
9C-4 BODY EXTERIOR

FLIP- UP SYSTEM

YAD9C030

SSANGYONG Y200
BODY EXTERIOR 9C-5

1 Glass Lifter 9 Over Slam Bumper

2 Ball Stud Bracket 10 Latch
3 Bolt Pad 11 Striker
4 Spoiler 12 Panel
5 Glass Open Hinge 13 Glass (Standard : 4.0 T Flip-Up : 5.0 T)
6 Glass Handle 14 Bracket Cover Of Ball Stud
7 Glass Weather Strip 15 Bolt
8 Glass Release Handle

SSANGYONG Y200
9C-6 BODY EXTERIOR

HOOD

YAD9C040

1 Bolt 4 Hood
2 Shock Absorber 5 Hood Striker
3 Hood Hinge

SSANGYONG Y200
BODY EXTERIOR 9C-7

SUN-ROOF AND ROOF RACK

YAD9C050

1 Sun-Roof Glass 5 Sun-Roof Glass Panel

2 Glass Moulding 6 Roof Carrier
3 Head-Lining Assembly 7 Nut
4 Roof Channel 8 Motor And Relay Box

SSANGYONG Y200
9C-8 BODY EXTERIOR

MOULDING

YAD9C060

1 Nut (M5) 5 Wheel Arch Rear Moulding

2 Wheel Arch Front Moulding 6 Moulding
3 Front Door Garnish 7 Side Step
4 Rear Door Garnish

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 N•m

(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 N•m

(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
Removal and Installation
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
Removal and Installation
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

Removal and Installation
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 76 - 114 N•m
Bolt of Bumper cover 2.8 - 5.2 N•m
Bolt of Bumper Guide 16.8 - 31.2 N•m

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
Removal and Installation
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
Removal and Installation
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
Removal and Installation
1. After releasing bolt and nut of side step , remove
side step assembly.
2. Install reverse order of removal.
Bolt and Nut of Side 16.8 - 31.2 N•m
Step (44 - 52 lb-ft)

YAD9C550

SSANGYONG Y200
9C-22 BODY EXTERIOR

SIDE MOULDING
Removal and Installation
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
Removal and Installation
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
Removal and Installation
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 44 - 54 N•m
Bolt of Door Check Link 20 - 30 N•m

YAD9C630

YAD9C640

DOOR HINGE
Removal and Installation
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

Removal and Installation
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

Removal and Installation
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 N•m

(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
Removal and Installation
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 N•m

(44 - 52 lb-ft)

YAD9C740

SSANGYONG Y200
BODY EXTERIOR 9C-27

DOOR TRIM
Removal and Installation
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

Removal and Installation
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.

Screw of Door Lock 20 - 28 N•m

YAD9C860 (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
YAD9C910 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.

TAIL GATE CRANK

Removal and Installation
1. Separate the negative (-) terminal of battery.
2. Remove inner panel trim cover of tail gate.

YAD9C920

3. Remove inner panel trim vinyl seal of tail gate.

4. Separate wiring connector of actuator.
5. Separate outside handle, glass handle.
6. Separate safety rod.
7. 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
Removal and Installation
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

Removal and Installation
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

Removal and Installation
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
YAD9C0H0
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.

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 A B C D E
Gap 11 5 5 5.7 4.2

YAD9C0R0

FRONT DOOR WINDOW

Removal and Installation
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
Removal and Installation
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
Removal and Installation
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.

;;;;;;
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.
YAD9C1Q0 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.

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

;;
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.
YAD9C1T0 • 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

;
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.

;;;;
YAD9C1Z0

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
;;
;;
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
YAD9C2M0 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
YAD9C2N0
vehicle : after 3 hour.

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

;;;;;;;
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.
YAD9C2P0 • 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
Removal and Installation
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 25 - 35 N•m
Fixing Bolt of Sun Roof 25 - 35 N•m

YAD9C3A0

MOTOR AND RELAY BOX

Removal and Installation
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 3 N•m (26 lb-ft)
YAD9C3E0

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 Component Of Lighting ...................................... 9D-27
Notice : Repairing Electrical System ..................... 9D-2 Location Of Lamp .............................................. 9D-31
Specification ........................................................ 9D-6 Horn And Audio System .................................... 9D-39
Diagnosis And Action Taken ................................ 9D-8 Wiper And Washer ............................................ 9D-44
Check And Adjust ............................................. 9D-10 Power Window ................................................... 9D-61
Repair Of Each System ...................................... 9D-13 Switch And Electrical System ............................. 9D-70
Instrument Panel Assembly ............................... 9D-13 Function Of Operation And The Characteristic .... 9D-76
Check And Repair ............................................. 9D-17 Self Diagnosis ................................................... 9D-84
Removal And Installation Of Instrument Panel .... 9D-20 Chart Of Diagnosis ............................................ 9D-85
Switch Of Multi - Function................................... 9D-22 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 semi-
conductor may be impaired).

Notice: Memory values of electrical parts may be

erased, so those value should be kept another
YAD9D010
place.

2. If harness is interfered by other sharp section, wrap

them, and then, for protecting of harness.

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
8°C, 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
9D-4 BODY ELECTRICAL

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
BODY ELECTRICAL 9D-5

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
9D-6 BODY ELECTRICAL

SPECIFICATION

Description Spec
Multi - function Rated voltage DC 12 V
switch Range for operating temp -30 °C ~ +80 °C
Light switch Illumination: 1 A (Load of relay)
Rated load
Dimmer and passing High beam: 9.2 A
switch Lower beam: 1 A
Passing: 10 A
Switch of turn signal 6.6 ± 0.5
Wiper switch Lower: 5 A, High: 7 A
Intermittemt: 0.22 ± 0.05 A
Fixing: MA X 28 A
Washer switch :4A
Intermittent wiper switch MAX: 25 mmA
Horn connector 1A
Instrument panel Turn signal lamp 14 V,1.4 W Green
Seat belt 2.2 V, 20 mA Red
Charging lamp 2.2 V, 20 mA Red
Fuel indicator lamp 2.2 V, 20 mA Orange
High beam 14 V, 3 W Blue
Oil pressure lamp 2.2 V, 20mA Red
Brake lamp 2.2 V, 20 mA Red
Door open warning lamp 2.2 V, 20 mA Red
ABS warning lamp 14 V, 1.4 W Orange
Pre heating lamp 2.2 V, 20 mA Orange
Air bag warning lamp 14 V, 1.4 W Red
Hazard lamp 2.2 V, 20 mA Red
4WD check lamp 2.2 V, 20 mA Red
4WD high lamp 14 V, 1.4 W Green
4WD low lamp 2.2 V, 20 mA Orange
Winter lamp 14 V, 1.4 W Green
Power lamp 2.2 V, 20 mA Orange
EBD lamp 14 V, 1.4 W Red
Engine check warning lamp 2.2 V, 20 mA Orange
TCS lamp 14 V, 1.4 W Orange
Rear defogger lamp 2.2 V, 20 mA Orange
Lamp Head lamp High beam 55 W X 2
Low beam 55 W X 2
Position lamp 5WX2
Front combi lamp Turn signal lamp 28 W X 2
Fog lamp 27 W X 2
Side mounted lamp 5WX2
High mounted lamp 5WX1

SSANGYONG Y200
BODY ELECTRICAL 9D-7

Description Spec
Lamp Rear combi lamp Tail/ Stop 27 W X 2
Tail lamp 8WX2
Stop lamp 27 W X 2
Turn signal lamp 27 W X 2
Brake lamp 27 W X 2
Licensee lamp 5WX2
Room lamp Front 8WX2
Center 10 W X 1
Rear 10 W X 1
Door lamp 5WX4
Glove box lamp 10 W

SSANGYONG Y200
9D-8 BODY ELECTRICAL

DIAGNOSIS AND ACTION TAKEN

Gauge Panel amd Warning System

Nature of Defect Cause of Defect Action Taken

Tacometer is not operated Cut of fuse Check short of fuse, replace fuse
Defective tacometer Check tacometer
Defective wiring If necessary, repair wiring
Gauge of fuel is not operated Cut of fuse Check short of fuse, replace fuse
Defective fuel gauge Check gauge
Defective fuel sender Check fuel sender
defective wiring If necessary,repair wiring
Warning lamp of fuel is not operated Cut of fuse Check short of fuse replace fuse
Failure of bulb Replace bulb
Defective sensor of fuel Check sensor
Defective wiring or defective grounding If necessary, repair wiring or grounding
Gauge of temperature is not Cut of fuse Check short of fuse, replace fuse
operated Defective gauge of coolant temp Check gauge
Defective coolant temp sender Check sender
Defective wiring or defective grounding If necessary, repair wiring or grounding
Warning lamp of oil pressure is not Cut of fuse Check short of fuse, replace fuse
turned on Failure of bulb Replace bulb
Defective sensor of oil pressure Check sensor
Defective wiring,and grounding If necessary, repair wiring or grounding
Warning lamp of brake is not turned on Cut of fuse Check short of fuse, replace fuse
Failure of bulb Replace bulb
Defective warning switch of brake Check switch
fluid
Defective parking brake switch Check switch
Defective wiring or defective
grounding If necessary, repair wiring or grounding
Warning lamp of opening door or Cut of fuse Check short of fuse, replace fuse
tail gate is not turned on Failure of bulb Replace bulb
Defective door switch Check switch
Defective wiring or defective grounding If necessary, repair wiring or grounding
Warning lamp of seat belt is not Cut of fuse Check short of fuse
turned on. Failure of bulb Replace bulb
Defective buckle switch Check switch
Defective wiring or defective grounding If necessary, repair wiring or grounding

SSANGYONG Y200
BODY ELECTRICAL 9D-9

Lighting System

Nature of Defect Cause of Defect Action Taken

On side of lamp only is turned on Failure of bulb Replace bulb
(All the lamp of outdoors) Defective socket, wiring defective If necessary replace socket, wiring
grounding
Head lamp is not turned on Failure of bulb Replace bulb
Defective fusible link Replace fusible link
Defective head lamp relay Check relay
Defective lighting switch Check switch
Defective wiring or grounding If necessary, replair wiring or grounding
Lamp of tail or lamp of license plate Cut of tail lamp fuse Replace fuse, check short of fuse
is not turned on Defective fusible link Replace fusible link
Defective relay of tail lamp Check relay
Defective lighting switch Check switch
Defective wiring or grounding If necessary, replair wiring or grounding
Stop lamp is not turned on Cut of fuse Replace fuse check short of fuse
Defective switch of stop lamp Adjust switch, or replace switch
Defective wiring or grounding If necessary, replair wiring or grounding
Stop lamp continue to turn on Malfunction of relay of stop lamp Replace relay
Malfunction of switch of stop lamp. Adjust switch or replace switch.
Gauge lamp is not turned on Malfunction of connector Check the state of connecting
Malfunction of wiring or grounding
One side of signal lamp is not The burned of bulb Replace bulb
turned on Malfunction of switch of turn signal Check switch
lamp
Malfunction of wiring or grounding If necessary, replair wiring or grounding
Turn signal lamp is not operated The burned of bulb Replace fuse, check short of fuse
Malfunction of flasher unit Check flasher unit
Malfunction of switch of turn signal Check switch of turn signal
Malfunction of wiring or grounding If necessary, replair wiring or grounding
Hazard lamp is not turned on Cut of fuse Check short of circuit replace fuse
Malfunction of flasher unit Check flasher unit
Malfunction of hazard lamp switch Check switch
Malfunction of wiring or grounding If necessary, replair wiring or grounding
Frequency of flash is too quick or Standard of bulb is out of specification Replace bulb
delaying Cut of bulb, malfunction of connecting Check cut of bulb or connecting
Malfunction of flasher unit Replace flasher unit
Lamp of back up is not turned on Cut of fuse Check short of circuit
Malfunction of switch of back up lamp Check switch
Malfunction of wiring or grounding If necessary, replair wiring or grounding
Console lamp of over head is not Cut of fusible link Replace fusible link
turned on Malfunction of wiring or grounding If necessary, replair wiring or grounding

SSANGYONG Y200
9D-10 BODY ELECTRICAL

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 manufacturer’s
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
BODY ELECTRICAL 9D-11

2. Keep line of center between through horizontal line

of center of head lamp and center of screen.

YAD9D170

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” .

;; ;;;
;;;;;
YAD9D180

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
9D-12 BODY ELECTRICAL

YAD9D190

SSANGYONG Y200
BODY ELECTRICAL 9D-13

REPAIR OF EACH SYSTEM

INSTRUMENT PANEL ASSEMBLY

YAD9D200

SSANGYONG Y200
9D-14 BODY ELECTRICAL

1 Fuel Gauge 18 Warning Lamp of Oil Pressure

2 Speed Gauge 19 Lamp of Pre Heating
3 Turn Signal Lamp (Left) 20 Lamp of Selector
4 Lamp of Operating of Brake or Flude Lever (Automatic Transmisson)
5 Lamp of Position And High Beam 21 Button of Reset
6 Turn Signal Lamp (Right) 22 Warning Lamp of Air Bag
7 Speedometer Gauge 23 Warning Lamp of ABS
8 Speed Gauge 24 Warning Lamp of EBD
9 Temperature Gauge 25 Lamp of TCS
10 Lamp of High Speed of 4WD 26 Warning Lamp of Door Opening
11 Lamp of Winter (Automatic Transmission) 27 Lamp of Outside And Lamp of Heat Line of
12 Lamp of Low Speed of 4WD Rear Glass
13 Check Lamp of 4WD (Gasoline) 28 Warning Lamp of fuel refilling
14 Power Lamp (Automatic Transmission) 29 Warning Lamp of Hazard
15 Lamp of Engine Check (for Gasoline) 30 Connector of White Color
16 Warning Lamp of Seat Belt 31 Colorless Connector (Auto)
17 Warning Lamp of Charge 32 Gray Connector

SSANGYONG Y200
BODY ELECTRICAL 9D-15

Component of Connector Pin

Layout of Connect Number of Pin Description
Color of connect : gray color A1 Opening of door
A2 Oil pressure
A3 Seat belt
A4 Charging
A5 ILL (-)
A6 EBD
A7 1GN (+), B
A8 Ground2
A9 ACC
YAD9D210 A10 B (+)
A11 Checking of 4 WD (+)
A12 Checking of 4 WD (-)
A13 Low speed of 4 WD
A14 ILL (+)
A15 High speed of 4 WD
A16 Turn signal lamp (Left)
A17 High beam (Lamp of position)
A18 Lamp of position
A19 Turn signal lamp (Right)
A20 Brake
Color of connect C1 Automatic transmission - D range
C2 Automatic transmission - 3 range
C3 Automatic transmission - 2 range
C4 Automatic transmission - 1 range
C5 -
C6 -
C7 Automatic transmission - R range
C8 Automatic transmission - N range
C9 Automatic transmission - NC
YAD9D220 C10 Automatic transmission - P range
C11 Winter
C12 Power

SSANGYONG Y200
9D-16 BODY ELECTRICAL

Layout of Connect Number of Pin Description

Color of connect B1 Unit of tacometer
B2 Speed sensor
B3 Chime bell
B4 Signal out of speed
B5 -
B6 -
B7 ABS
B8 Air bag
B9 Engine check
YAD9D230 B10 TCS
B11 Fuel sender
B12 Temp sender
B13 -
B14 Gnd (ground1)
B15 IGN (+), A
B16 Emegency
B17 -
B18 Rear defogger
B19 Pre - heat
B20 -

SSANGYONG Y200
BODY ELECTRICAL 9D-17

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 20 40 60 80 100 120

Error of allowance 3 +4 +4 +5 +5 +5.5
0 0 0 0 +0.5
Standard of speed 140 160 180 200 220 -
Error of allowance +5.5 +5.5 +6 +6 - -
YAD9D240
+0.5 +0.5 +1 +1

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 (rpm)

Standard of speed 1000 2000 3000 4000 5000 6000
Error of allowance +137 +199 +261 +298 +335 -
- 67 - 51 - 39 -2 +35

Gasoline vehicle (rpm)

Standard of speed 1000 2000 3000 4000 5000 6000 7000 8000
Error of allowance ± 100 ± 125 ± 150 ± 150 ± 150 ± 180 ± 180 -

SSANGYONG Y200
9D-18 BODY ELECTRICAL

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 Specified resistence
E approximately 285 Ω
1/2 approximately 101.5 Ω
F approximately 40 Ω

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
YAD9D270
completely.

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
BODY ELECTRICAL 9D-19

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) C (50) C (50) C (50) C (50)
resistence(Ω) 254 77 42.2 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
9D-20 BODY ELECTRICAL

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
YAD9D320
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

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
BODY ELECTRICAL 9D-21

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
9D-22 BODY ELECTRICAL

SWITCH OF MULTI – FUNCTION

YAD9D400

1 Multi - Function Switch Assembly 5 Switch of Light

2 Turn Signal Switch Assembly 6 Switch of Auto - Light
3 Turn Signal Switch Assembly 7 Connector
4 Screw 8 Switch of Wiper

SSANGYONG Y200
BODY ELECTRICAL 9D-23

Components of Connector Pin

Layout of connect Number of pin Name of connector

1 TL Switch of turn signal (LH)
2 TB Power of flasher unit
3 TR Switch of turn signal (RH)
4 HU Power of head lamp upper beam
5 HS (2) Switch passing of head lamp
6 W Front washer switch
7 EW Wiper and washer ground
8 AUTO Auto wiper
YAD9D410 9 P Wiper parking
10 ES Ground of light switch
11 A Auto light switch
12 HS (1) Switch of head lamp
13 TS Switch of tail lamp
14 EB Ground of dimmer and passing switch
15 - -
16 LO Low speed of wiper
17 HI High speed of wiper
18 ET Ground of intermittent wiper
19 INT Intermittent wiper
20 HORN Horn relay

SSANGYONG Y200
9D-24 BODY ELECTRICAL

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
BODY ELECTRICAL 9D-25

Removal and Installation

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
9D-26 BODY ELECTRICAL

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
BODY ELECTRICAL 9D-27

COMPONENTS OF LIGHTING Tail lamp

Tail lamp consists of rear back lamp, tail lamp, back
General Description up lamp and turn signal lamp in the assembling part.
Head lamp If position lamp or head lamp are turned, rear back
lamp is turned on. As rear back lamp and brake lamp
Head lamp is controlled by light switch which is located
consist of double lamp, if technician is put foot on the
in the left of steering column. If light switch is set on
brake pedal, brake lamp is turned brighter. If lever of
first stage, position lamp, lamp of license plate and
transmission is operated to backwards, back up lamp
lamp of instrument panel illumination is turned on, if
is turned on.
light switch is set on two stage, head lamp is turned
on.
Assistant brake lamp
If light switch is off, all the lamp are turned off.
Assistant brake lamp is located on the upper section
High beam and low beam is controlled by operation of of back glass, if pedal of brake is operated, assistant
light switch. brake lamp is turned on.
As light switch is pushed and pulled, is switched to
high beam and low beam, if head lamp is turned on by Lamp of license plate
high beam, high beam is displayed on the instrument If position lamp or head lamp is turned on, lamp of
panel. license is turned on, this lamp is attached rear deck
Aiming of head lamp is adjusted properly. lid of license plate.
If new head lamp is replaced, aiming of head lamp
Lamp for reading and room lamp
should be inspected.
Lamp for reading and room lamp is attached on the
Front turn signal lamp / position lamp head lining, if switch of lamp for reading is turned on,
If light switch is set on the first stage, lamp of position lamp for reading is “on” in the driver seat and
is turned on, if light switch is off, lamp of position is passenger seat, if switch is touched one, lamp is “on”,
turned off. if switch is touched twice, lamp is “off”. Switch of
room lamp is the type of three point, if open door, in
Turn signal lamp is controlled by light switch which is the state of pushing switch of door, room lamp is turned
located in the left of steering column, as light switch on, if door is closed, room lamp is gradually turned
is operated by moving up and down, and then turn off.
signal lamp is turned on and off.
In the state of switch “ off “, though door is opened,
Change of vehicle direction is finished completely, light yet room lamp is not turned.
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.

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 Description

Voltage of load 9 -16 V
Load MAX 200 mA
Sensor unit of auto light
Temp available - 30 ~ +85 ° C
Room temp for keeping - 40 ~ +120 °C
Position of attaching Upper right section of instrument panel

Input and Output of Diagram

YAD9D530

SSANGYONG Y200
BODY ELECTRICAL 9D-29

Sensor Unit Terminal of Auto Light

1 Power Supply For System
2 Auto Light Switch
3 Non-Use
4 Relay of Head Lamp
5 Relay of Tail Lamp
6 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
Condition of tail lamp Condition of head lamp Time of delaying
Illumination intensity
Illumination intensity of light on 30.5 ±¾5 (LUX) 8.9 ± 3 (LUX) 0.5 ± 0.1
Illumination intensity of light off 60.5 ±¾5 (LUX) 17.2 ± 3 (LUX) 3±1

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
BODY ELECTRICAL 9D-31

LOCATION OF LAMP

YAD9D570

1 Head Lamp - Low 8 Tail Lamp

2 Head Lamp - High Beam, Position Lamp 9 Stop Lamp
3 Position Lamp 10 Turn Signal Lamp
4 Turn Signal Lamp 11 Back up Lamp
5 Fog Lamp 12 Rear Back Mirror
6 High Mounted Stop Lamp Plate 13 Lamp of License
7 Tail and Stop Lamp

SSANGYONG Y200
9D-32 BODY ELECTRICAL

YAD9D580

1 Lamp of Glove 4 Door Lamp

2 Room Ramp 5 Turn Signal Lamp of Side
3 Lamp of Center Room 6 Lamp of Cosmetic Mirror

SSANGYONG Y200
BODY ELECTRICAL 9D-33

Specification of Lamp

Item Quantity Spe Item Quantity Spe

Head lamp Low beam (L, R) 55 W Rear combi Back up lamp (L, R) 27 W
(1, 1) lamp (1, 1)
High beam (L, R) 55 W Back mirror Rear (L, R) -
(1, 1) (1, 1)
Position lamp (L, R) 5W Lamp of Lamp of (2) 5W
(2, 2) license plate license plate
Front combi Fog lamp (L, R) 27/ 8 W Room Glove box (1) 10 W
lamp (1, 1)
Turn signal (L, R) 28 W Front room (2) 8W
lamp (1, 1) lamp
Rear High mounted 4 EA 5W Lamp of center (2) 10 W
stop lamp room
Rear combi Tail/ stop (L, R) 27/ 8 W Door lamp (4) 5W
lamp (1, 1)
Tail lamp (L, R) 8W Cosmetic (L, R)
(1, 1) mirror lamp (1, 1)
Stop lamp (L, R) 27 W Side combi Turn signal (L, R) 5W
(1, 1) lamp (1, 1)
Turn signal (L, R) 27 W
lamp (1, 1)

SSANGYONG Y200
9D-34 BODY ELECTRICAL

Removal and Installation

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
BODY ELECTRICAL 9D-35

• 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
9D-36 BODY ELECTRICAL

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
BODY ELECTRICAL 9D-37

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
9D-38 BODY ELECTRICAL

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
BODY ELECTRICAL 9D-39

HORN AND AUDIO SYSTEM Front and rear speaker

Eight of speaker is installed in the vehicle, two of
General Description speaker is installed on the front door, rear door, and
Horn tail gate and an speaker is installed each side mirror
(left, right).
Horn is located under the hood, is also installed near
radiator in the front. Horn is operated by pushing pad
Glass antenna
of steering wheel which is linking to the electric circuit.
Glass antenna is different from existing antenna, is
Audio system not appeared external shape of antenna,this one is
installed on the quarter glass, consists of module of
Audio glass antenna, harness, and connector. The sensitivity
Radio and cassette are installed in the audio system of reception are better than the existing antenna.
by standard specification, changer of cd is applied
option specification, which is installed on the room of
trunk.

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
BODY ELECTRICAL 9D-41

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
9D-42 BODY ELECTRICAL

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
BODY ELECTRICAL 9D-43

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
9D-44 BODY ELECTRICAL

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

Unit of sensing is sensing quantity of rain,
Quantity of rain Wiper motor
according to quantity of rain, this unit is controlling
operation of wiper,low and high speed.

SSANGYONG Y200
BODY ELECTRICAL 9D-45

Principle of Rain Sensor

(Wave drop of rain is contacting, loss

happen by transmitting electronic wave)

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Wave which is transmitted reflects and reinput

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YAD9D940

1. Unit of sensing rain is sensing by the LED and 3. Unit of sensing rain is correcting itself, so
the diode of photo. regardless of transmitting of windshield, this unit
2. As infrared ray is emitting from LED, diode of is constantly sensing rain.
photo which is reflected by drop of rain is sensing 4. This unit is sensing the area between the LED and
the quantity of rain. 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
9D-46 BODY ELECTRICAL

1. OFF Mode 2. Speed of wiper and control frequency of

If switch of wiper is turned off and switch of ignition revolution
is turned on, at this time, rain sensor is operating Main function of rain sensor is controlling wiper
with OFF MODE, under this mode, wiper mode is speed and delaying of time to between the driving
stopped, during rain sensor is OFF MODE, rain time, due to sensing and the accumulation of rain,
sensor is sensing the state of windshield, so that algorithm of rain sensor is deciding mode of motion,
turn switch to proper position. automatic intermittent, automatic low speed, and
automatic high speed.
2. Auto Mode
If the stage is set, without the operation of driver,
If wiper switch is transferred OFF MODE into AUTO wiper is continuously operating.
MODE, immediately wiper is operating once, that
means wiper system is operating, after wiper is 3. Transfer between the modes
operating once, is calcurated the time of gap Algorithm of rain sensor is transferred automatic
between drop of rain and speed of wiper operation. intermittent,automatic low speed, and automatic
After stoppng time, rain sensor transfer signal into high speed under low stage so doesn’t make noise.
wiper motor, wipe out rain.
4. Performance of sensing
3. Automatic Intermittent Mode
Sensing of rain sensor is set 5 stage, due to
At the automatic intermittent mode, wiper is accumulated drop of rain, driver can satisfy, range
operating once with low speed, and then this mode of adjusting can control from the short delaying time
has variable stopping time. to thelong delaying time, but, due to heavy rain,
4. Automatic Low Speed regardless of sensing which is set, is continuously
operating with high speed.
This mode is operating beyond value of limit of
automatic intermittent and automatic low speed. 5. Responding characteristic of automatic low
speed
5. Automatic High Speed
As wiper is operated from the zero state of
As quantity of rain beyond value of automatic low dropping of rain to the automatic low mode.
speed and automatic high speed is operating.
Time is needed within only 9 second for high
6. Washer Mode (48Page) required signal.
Rain sensor is sensing whether switch of wiper 6. Responding characteristic of automatic high
select function of washer or not. If switch of wiper speed
is turned on more than 0.6 sec, wiper is operating
for 2.5 - 3.8sec, under this value is operating only As wiper is operated from the zero state of dropping
once. At washer mode, motor of wiper is operating of rain to the automatic high mode.
with low speed. Time is needed within only 9 second for high
required signal
7. Manual Mode
7. Responding characteristic from the automatic
Switch operation of driver turn motor of wiper to low
low speed to the automatic high speed
speed, high speed, at this time, wiper is operated
by not rain sensor by but wiper switch. As wiper is operated from the automatic low speed
to the automatic high speed mode, time is needed
Notice: As rain sensor is out of order, wiper is within only 6 second for high required signal.
operating with low speed and high speed.
8. Responding characteristic from the automatic
Characteristic of rain sensor high speed to the state of off (48 Page)
1.Supply power As wiper is operated from the automatic high speed
mode to the the zero state of dropping of rain mode,
Power is supplying to rain sensor and within 250
times of wiper motion is under 19 times.
msec, rain sensor is emitting the signal “ OFF” , until
effective power is supplying, effective power is 9. The instant operating of wiper
available for supplying power, after 2 second. 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
BODY ELECTRICAL 9D-47

If the ignition switch is off and if wiper switch is Wiper blade

set on any position, turn ignition switch on, the Check the state of wear of wiper blade, due to
instant operation of wiper is occurred, signal to excessive wear of wiper blade, if is not cleaned up
driver beginning of wiper operating, due to lack of over section of sensor, quantity of rain is not sensed
rain drop, if wiper is not operated, rain sensor stay accurately.
on the automatic intermittent mode.
Coupler
Check unit of rain sensor Check if blister is shaped on the external section of
coupler which is stuck on the wind shield.
Check selection of sensing (check position of nob
of variable resistent) If there is a blister in the internal section of sensor, is
Check if variable resistent nob of multifunction switch not sensed accurately, check if coupler is installed
is positioned in the middle of between S of position the right position or not, specially check if section of
and F of position, if nob is positioned F (fast) or S coupler sensor is positioned on the section of ceramic
(slow),sensing is much higher or much lower, so coating or not, if the space of sensing is shielded,
customer can complain this. infrared of sensor is not passed so sensing is not
available accurately.
Self - diagnosis
Wind shield glass
1. Rain sensor has two kind of self diagnosis test
Check if wind shield glass surface of the external
mode.
sensor has excessive wear,damage, and scratch or
1) Self diagnosis of FAULT A not. Wear of sensor is compensated little bit, if there
In case operating point of rain sensor servo is come to beyond constant value, sensor is not sensing,
beyond range of soft ware, that means sensor such a kind of diagnosis is used self diagnosis.
has a fault, if part of wind shield glass has a
damage, or if sensor is removed from the Exterior cover
coupler. Check the state of exterior cover of rain sensor, check
2) Self diagnosis of FAULT B that sensor is impacted by shaking, owing to releasing
While rain sensor does not reaction with signal fixing section of cover, also check interference with
of rain, that means FAULT B, if wind shield glass wind shield glass or head lining.
which is equipped coupler has a damage or
sensor is out of order. Spring clip
2. Value of cohesion Check if rain sensor release from coupler or not, after
removing exterior cover, check the state of spring clip.
While FAULT A is sensed, the cohesion is decided,
the value of cohesion is 140,in this case, except Connector
heavily damage of wind shield glass, rain sensor
After check the state of tighting between terminal of
is operating in the all conditions.
connector and wiring, check that the terminal is inserted
3. Failure which is occurred with adjustment of into connector as the state of locking. Check the state
intermittent volume of combination between the connector of wiring and
Due to adjustment of sensing and motion of wiper, the connector of rain sensor, check interference between
self diagnosis is described as below. them.
1) Wiper switch is transferred the intermittent into
5 step stage, under the state of “ ignition on “ Relay
2) Under this state, sensing is changed 5 step Check if low relay of wiper and high relay of wiper is
stage into 4 step stage. operating normally, as relay is damaged by fire so
motor of wiper is not operated, at the auto mode, blade
3) At this time, wiper is moving once, that means
of wiper is not operated.
self diagnosis of FAULT A, check if wind shield
glass has a damage or not, also check if sensor Circuit
is installed completely on the coupler.
Check circuit, specially check if the value of variable
4) After check 3) article, sensing is changed 4 step resistence of multifunction switch is feeding properly
stage into 3 step stage. or not, this can see by moving nob of variable
5) If wiper is operating once, this means self resistence step by step from the state of slow to the
diagnosis of FAULT OF B. state of fast (This is called Instant Wipe ).
Replace new rain sensor.

SSANGYONG Y200
9D-48 BODY ELECTRICAL

If parking position of wipe motor is not feeding properly 3. On the turning, Applying the current between
or not, if parking position of wipe motor is not feeding, contact point of W of CAM switch and contact point
wiper motor can be operated quickly rather than the of C, relay 2 of CONT is “OFF” and relay 1 is
state of normal, intermittent speed shifting time of wiper “ON” and then, turn motor clock wise, wiper is
motor is not sensing, wiper motor is not operated operating between position of B and position of C
normally. by transfering pole of motor.
Notice: While unit of rain sensor is removed.
Operation of parking mode
1. Remove exterior cover, at this time, if exterior cover
1. Parking on the operation with the clockwise : Under
is removed by compulsion, keep in mind not to
the wiper is operating,switch of wiper is “off” On
break fixing hook of coupler, as exterior cover is
the turning,applying the current between contact
removed, using hole of cover by driver, after section
point of W of CAM switch and contact point C,
of fixing hook is pushing, and remove them.
after relay 1 is off, stopping the motor, within
2. As rain sensor is removed from coupler, using approximately 1 second, relay 2 of CONT is on,
driver after open up spring clip, remove them. turning motor counter-clockwise, apply the current
3. Remove connector to the wiring from the sensor. between “P” ground of CAM switch and C ground,
and then relay 2 of CONT is OFF, motor can stop.
Rear Wiper System Operation for washer mode
Turn washer switch on above 0.5 second, after
Summary
operation of wiper mode is operating twice, after
Controlling of existing rear wiper is controlled by relay operation of parking mode is operating and then motor
which is operated with switch, but rear wiper of Rexton is stopped, but if washer switch is on below 0.5 second,
is controlled by ECU, in the existing vehicle, brush of wiper motor is not operating.
rear wipe is installed on the rear glass, but rear glass
can is opened up, brush of rear wiper can not be Mode operation of limit switch ON
installed, so,this one is installed on the back panel, 1. Limit switch on: Under wiper is operating while
wiper motor is operating by second stage. 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
YAD9D960
is operating between position of (2) and position
Description of System Operation of (4) by transfering pole of motor. (operation order
:(2) → (3) → (4) → (3) → (2): motion of cycle)
Operation for wipping mode
3. Angle of DSP denote the angle between (1) and
1. Turn switch of wiper on, and then relay 1 of CONT (2) or the angle between (1) and (4).
is on, turn motor with clockwise
4. Turning motor from position of (3) to position of
2. On the turning, Applying the current between (4), stopping in the position of (1), turning from
contact point of W and contact point of C, after position of (3) to position of (2), stop in the position
relay 2 of CONT is “OFF” relay 1 is “ON”, turn of (1), namely, as motor is parking, such as below
motor counter clock-wise. the picture, contact point of W, C, and P are on
the one line.

SSANGYONG Y200
BODY ELECTRICAL 9D-49

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YAD9D970 YAD9D990

Position of (1) : Position of soft contact Function of rear wipe

Position of (2) and (4) : Reverse position 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)

ON
Ground of “W” is “ ON” ?

YES

1 of relay is “OFF” 2 of relay is “ON”

(Motor is turning to counter-clockwise)

ON
Ground of “W” is “ ON”?

YES

SSANGYONG Y200
BODY ELECTRICAL 9D-51

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

Motor is operating to the clock wise wiper
wise wiper switch is off or switch of
switch is off or switch of intermittent is off
intermittent is off

NO NO
Ground of “W is “ON” ? Ground of “W is “ON” ?

YES YES

1 of relay is OFF, 2 of relay is OFF 1 of relay is OFF, 2 of relay is OFF

(motor : stop), wate for 1 minute (motor : stop), wate for 1 minute

1 of relay is ON, 2 of relay is OFF 1 of relay is OFF, 2 of relay is ON

(motor is turning to clock wise) (motor is turning to counter-clock wise)

clockwise (motor : stop )

SSANGYONG Y200
BODY ELECTRICAL 9D-53

Operation of Limit Switch

Motor is operating : limit switch is ON Limit switch is ON

NO
Wiper switch is ON, or Intermittent is
Ground of W is ON?
ON

YES

1 of relay is OFF, 2 of relay is OFF 1 of relay is OFF, 2 of relay is OFF

(motor : stop) (motor : stop)

1 of relay is ON, 2 of relay is OFF

(motor : is turning clockwise)

NO
Ground of P is ON ?

YES

1 of relay is OFF, 2 of relay is OFF

(motor : stop)

SSANGYONG Y200
9D-54 BODY ELECTRICAL

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.

YAD9D0A0

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 )

YAD9D0B0

SSANGYONG Y200
BODY ELECTRICAL 9D-55

Specification

Description Specification
Motor Rated voltage DC 12 V ± 0.3 V
Test voltage DC 13.5 ± 0.3 V
Range of allowed voltage DC 10 - 15 V
Minimum operating voltage DC 8 V
Insulated resistence 500 V 1 MΩ
Restraint test Torque 1.1 Km
Current 14 A
YAD9D0C0
Range of atmosphere temp allowed - 40 °c ~ + 80°C
Control Rated voltage DC 12 V
Range of allowed voltage DC 9 ~ 16 V
Range of allowed temperature - 30 °C ~ + 80°C
Range of conserved temperature - 40 °C~ + 90°C
Insulated resistence 1 MΩ
(500 V)
Voltage dropping 0.5 V
YAD9D0D0
Test voltage 14.0 ± 0.5 A
Load allowed current 10 A

Circuit diagram

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YAD9D0E0

SSANGYONG Y200
9D-56 BODY ELECTRICAL

Components

YAD9D0F0

1 Wiper Blade 4 Wiper Blade

2 Wiper Motor And Link 5 Wiper Motor
3 Washer Tank Assembly

SSANGYONG Y200
BODY ELECTRICAL 9D-57

Removal and Installation

Front wiper Assembly
1. After opening up front hood, remove wiper arm.

YAD9D0G0

2. After cowl left is removed, remove wiper linkage

assembly. (At this time, separate connector of
wiper motor)

YAD9D0H0

3. From linkage separated, releasing fixing bolt of

wiper motor, separate linkage and motor.

YAD9D0J0

4. Install the reverse order of removal.

Fixing bolt of motor 7 -11 N•m
Nut of linkage 4 - 6 N•m
Nut of blade 19 - 28 N•m

YAD9D0K0

SSANGYONG Y200
9D-58 BODY ELECTRICAL

Rear wiper assembly

1. After cap of wiper arm, remove nut of wiper and
blade of wiper.

YAD9D0L0

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.

YAD9D0M0

5. Install the reverse order of removal.

Wiper motor assembly
Bolt of motor 7 - 11 N•m
Bolt of motor bracket 7 - 9 N•m

Rear wiper blade

Torque of Tightening 19 - 28 N•m

(44 - 52 lb-ft)

YAD9D0N0

SSANGYONG Y200
BODY ELECTRICAL 9D-59

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.

YAD9D0P0

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.

YAD9D0Q0

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.

YAD9D0R0

SSANGYONG Y200
9D-60 BODY ELECTRICAL

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

YAD9D0S0

SSANGYONG Y200
BODY ELECTRICAL 9D-61

POWER WINDOW
Components

YAD9D0T0

1 Power Window Switch Of Passenger Seat 5 Window Regulator

2 Power Window Switch Of Rr Seat (LH) 6 Window Motor
3 Power Window Switch Of Rr Seat (RH) 7 Window
4 Power Window Switch Of Driver Seat

SSANGYONG Y200
9D-62 BODY ELECTRICAL

Removal and Installation

1. After inserting switch of window in the door handle,
separate grip of fixing hook.

YAD9D0U0

2. After connector of window switch is separated,

remove window switch assembly.

YAD9D0V0

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.

YAD9D0W0

SSANGYONG Y200
BODY ELECTRICAL 9D-63

Check and Repair

Main switch of power window

YAD9D0Z0

1. After main switch of power window is removed in

the driver seat, check that applying an electric
current of each terminal.

YAD9D0X0

2. Lockong system of window.

YAD9D0Y0

SSANGYONG Y200
9D-64 BODY ELECTRICAL

Serve switch of passenger set and rear seat

1. After switch is removed, check that applying an
electric current of each terminal.

YAD9D1C0

Passenger seat

YAD9D1A0

Rear seat

YAD9D1B0

SSANGYONG Y200
BODY ELECTRICAL 9D-65

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.

YAD9D1D0

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.

YAD9D1E0

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.

YAD9D1F0

2) If defogger is damaged by a fire between

center and positive terminal, value of voltage
is indicated 12 V.

YAD9D1G0

SSANGYONG Y200
9D-66 BODY ELECTRICAL

3) If defogger is damaged by a fire between

center and negative terminal, value of voltage
is indicated 0 V.

YAD9D1H0

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.

YAD9D1J0

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.

YAD9D1K0

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

YAD9D1L0

SSANGYONG Y200
BODY ELECTRICAL 9D-67

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.

YAD9D1M0

YAD9D1N0

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.

YAD9D1P0

SSANGYONG Y200
9D-68 BODY ELECTRICAL

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.

YAD9D1Q0

7. Heat up the section which is repaired, keep

distance 25 mm from this section, with drier below
149¡É 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.
YAD9D1R0

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.

YAD9D1S0

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.

YAD9D1T0

SSANGYONG Y200
BODY ELECTRICAL 9D-69

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.

YAD9D1U0

SSANGYONG Y200
9D-70 BODY ELECTRICAL

SWITCH AND ELECTRICAL SYSTEM

Components

YAD9D1V0

1 Defogger Switch 11 Switch of Seat Warmer

2 Front Switch of Fog Lamp 12 Unit of Seat Position and Seat Warmer
3 Digital Watch 13 TCM
4 Switch of Hazard Warning Lamp 14 Switch of Position Memory
5 Sensing Unit of Auto Lighting 15 TOD, TCCU
6 Air Bag of Passenger 16 Internal Sensor of Temp
7 Unit of EGR 17 Connector of Self Dignosis
Unit of OVPR 18 Stics / Rekes
8 ECM 19 Fold Switch of Side Mirror
9 SDM 20 Sensor of Sun
10 Nevigation System

SSANGYONG Y200
BODY ELECTRICAL 9D-71

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.

YAD9D1W0

Function of Operation

Type Description Specification

SEAT Operating voltage DC 11 - 15 V
Regardless of ignition switch Rang of operating temp -30 °C - 80°C
Operating speed of Slide 20 ± 7 mm/sec
seat Tilt 10.6 ± 5 mm/sec
Height 7 ± 2 mm/sec
Operating distance Slide 228 ± 3 mm
of seat Recline 23 ° ↔ 0 ↔ 48 °
Lift 30 ± 3 mm
Operating current Slide 7A
(at 13.5 V) Tilt and lift 8A
Heater switch of Rated load DC 12 V / 1A
seat Range of operating temp 35 °c - 45 °c
Foce of switch operation 0.3 - 0.7 kgf
Outside mirror Angle of up and down -8 ° - 8 °
Angle of left and right -8 ° - 8 °
Angle of folding ± 67 °

SSANGYONG Y200
9D-72 BODY ELECTRICAL

Seat and Out Side Mirror, With Memory

Part of function Set memory Release mory

Seat Slide 1. Condition: If ignition is “ON” 1. After switch of set is“ON”
Recline position of selector lever is “P time is passed more than 5
and N seconds.
Lift (front/rear)
2. Parking brake is “ O N ” 2. While switch of seat or switch
Warmer (driver/passenger) 3. Switch of set is “ON of outside mirror (manual
Outside Up and down 4. Switch of 1/2/3 is operating operati on is set)
mirror Left and right within 5 seconds 3. Ignition switch is “OFF”

The characteristic of operation.

YAD9D1X0

Function of Memory Return

Item Description
Operation condition 1. Position of selector lever is “ P and N on condition that, ignition switch is
“ON”
2. Automatic vehicle: P/N or parking brake is “ON”
3. Manual transmission : parking brake is “ON”
4. Memory return is operating at the state of stop (vehicle speed : 0 km/h).
The state of operation: Another 1. If position button is operating while memory is returning, memory is
condition is set under function returnng as memory is set on before.
of memory is returning 2. While memory is returning, button of stop is set, return operation is stoping
immediately.

SSANGYONG Y200
BODY ELECTRICAL 9D-73

The characteristic of operation

YAD9D1Y0

Function of outside mirror(folding /unfolding )

YAD9D1Z0

Function of seat warmer

YAD9D2A0

SSANGYONG Y200
9D-74 BODY ELECTRICAL

Power seat
Connector and connected circuit

NO. Size / color Connected circuit

A1, A2 BW Battery
A3, A4 BLACK Ground
B1 WB Slide
B2 Y Slide
B3 GB Tilt
B4 RG Tilt
YAD9D2B0 B5 BY Recline
B6 GY Height
1 Slide Adjusting Motor 5 Driver Power Seat
B7 BR Height
2 Height Adjusting Recline Switch
Motor 6 Driver Power Seat B11 GB Recline
3 Tilt Adjusting Motor Switch
4 Recline Adjusting (Slide, Height, Tilt)
Motor 7 Seat Heater Control
Unit

YAD9D2C0

SSANGYONG Y200
BODY ELECTRICAL 9D-75

Seat warmer switch

Connected circuit

YAD9D2D0

YAD9D2E0

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.

YAD9D2F0

SSANGYONG Y200
9D-76 BODY ELECTRICAL

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
YAD9D2G0
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.

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”

YAD9D2H0

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

YAD9D2J0

SSANGYONG Y200
BODY ELECTRICAL 9D-77

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
YAD9D2K0 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.

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”.

YAD9D2L0

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
YAD9D2M0
of defogger is stopped.

SSANGYONG Y200
9D-78 BODY ELECTRICAL

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.
YAD9D2N0
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.

Warning lamp of parking breake

1. Parking brake is pulling under vehicle’s 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”
YAD9D2P0 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”)

SSANGYONG Y200
BODY ELECTRICAL 9D-79

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
YAD9D2Q0 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.

YAD9D2R0

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.)

YAD9D2S0

SSANGYONG Y200
9D-80 BODY ELECTRICAL

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”.

YAD9D2T0

YAD9D2U0

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.

YAD9D2V0

SSANGYONG Y200
BODY ELECTRICAL 9D-81

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.
YAD9D2W0

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.
YAD9D2X0

SSANGYONG Y200
9D-82 BODY ELECTRICAL

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
YAD9D2Y0
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.

YAD9D2Z0

YAD9D3A0

SSANGYONG Y200
BODY ELECTRICAL 9D-83

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

YAD9D3B0

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 )

YAD9D3C0

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”

YAD9D3D0

SSANGYONG Y200
9D-84 BODY ELECTRICAL

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.

YAD9D3E0

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 ± ¾0.1 seconds
T2: 0.3 ± ¾0.1 seconds
T: 0.6 ± ¾0.2 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.
YAD9D3F0

SSANGYONG Y200
BODY ELECTRICAL 9D-85

CHART OF DIAGNOSIS

NO Conditions Check Normal Remark

1 Switch of diagnosis is Confirm 0f beginning to dignose Buzzer,frequency: once
“ON”
2 Power of battery is Check battery Buzzer,frequency: twice
supplied
3 Battery plus: related Tail gate, rear door lock switch Buzzer,frequency: once
4 parts is operated Driver seat door lock switch Buzzer,frequency: once
5 Passenger seat door lock switch Buzzer,frequency: once
6 Driver seat door switch Buzzer,frequency: once
7 Passenger and rear door switch Buzzer,frequency: once
8 Rekes is operating Buzzer,frequency: once
9 Ignition switch is Switch of key reminder Buzzer,frequency: once
operating
10 Ignition plus related IGN and relay of power window IGN2 :
Switch of dia
parts is operated Buzzer,frequency: twice
gnosis is
IGN1:
“ ON ”
Buzzer,frequency: once
Power window: buzzer:
Three times
11 Switch parking brake Buzzer,frequency: once
12 Switch of seat belt Buzzer,frequency: once
13 Washer switch 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 Switchof variable volume Buzzer, frequency: once
16 IGN, starting plus ALT ’L’ Buzzer,frequency: once
17 related parts is Switch of defogger Buzzer,frequency: once
18 operating. Signal of speed sensor Buzzer,frequency: once

SSANGYONG Y200
9D-86 BODY ELECTRICAL

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

YAD9D3G0

2. After disconnecting the connector, remove switch

assembly.
3. Install the reverse order of removal

YAD9D3H0

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,

YAD9D3J0
• Switch of front fog lamp

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.

YAD9D3K0

SSANGYONG Y200
BODY ELECTRICAL 9D-87

Circuit of Digital Watch and Connector

YAD9D3L0

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.

YAD9D3M0

Diagram of Switch Circuit

YAD9D3N0

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.

YAD9D3P0

SSANGYONG Y200
SECTION 9E

BODY’S MEASURING DIMENSION

TABLE OF CONTENTS
Body’S Measuring Dimension ............................. 9E-2 Windshield And Rear Glass ................................. 9E-7
Under Body(Frame) ............................................. 9E-2 Tail Gate .............................................................. 9E-8
Frame .................................................................. 9E-3 Chart Of Gap ....................................................... 9E-9
Side Structure Complete ...................................... 9E-4 Under Coating ................................................... 9E-11
Engine Room ....................................................... 9E-6 Body Mounting .................................................. 9E-12
9E-2 BODY’S MEASURING DIMENSION

BODY’S MEASURING DEMENSION

UNDER BODY(FRAME)

YAD9E010

SSANGYONG Y200
BODY’S 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
9E-6 BODY’S MEASURING DIMENSION

ENGINE ROOM

YAD9E050

SSANGYONG Y200
BODY’S MEASURING DIMENSION 9E-7

WIND SHIELD AND REAR GLASS

YAD9E060

SSANGYONG Y200
9E-8 BODY’S MEASURING DIMENSION

TAIL GATE

YAD9E070

SSANGYONG Y200
BODY’S MEASURING DIMENSION 9E-9

CHART OF GAP

YAD9E080

Chart of measuring demension

Position Control of Measuring Demension Position Control of Measuring Demension

+1
A: 2.2 -0.5 F: 2.5
B: 40 G: 5.0 ± 0.5
C: 3.0 ± 0.5 H: 3.5
D: 4 +1
-0.5 I: 4.9 ± 0.5
4.5 → 4.2 Variable
+2
E: J: 5.7 -0

SSANGYONG Y200
9E-10 BODY’S MEASURING DIMENSION

YAD9E090

Chart of measuring demension

Position Control of Measuring Demension Position Control of Measuring Demension

+1
A: 4 -0.5 H: 4.5 +-01
B: 4.0 I: ↑
C: 4.5 → 4.2 Variable J: ↑
D: 2.2 +1
-0.5 K: ↑
E: 4.5 +1
-0 L: 2.2 +-01
F: 4.5 +1
-0 M: 5 ± 0.5
G: 6.5 ± 1 N: 3.5

SSANGYONG Y200
BODY’S MEASURING DIMENSION 9E-11

UNDER COATING

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; ;
;;;;;;;;;
;;;;;;;;; YAD9E100

SSANGYONG Y200
9E-12 BODY’S MEASURING DIMENSION

BODY MOUNTING
Mounting Point

YAD9E110

SSANGYONG Y200

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