GENERAL INFORMATION

1. SPECIFICATIONS.................................. 3
2. ENGINE LAYOUT................................... 4
3. MAJOR COMPONENTS......................... 5
4. LOCATIONS IN ENGINE
COMPARTMENT................................... 7

DURING SERVICE WORK

1. GUIDELINES FOR SERVICE WORK

SAFETY................................................. 11
2. TIGHTENING TORQUE BY BOLT
STRENGTH............................................ 16
3. TIGHTENING TORQUE.......................... 17
4. VARIANT CODING................................. 20

SPECIAL TOOL

1. SPECIAL TOOL..................................... 24
2. GENERAL DEDICATED EQUIPMENTS.. 29
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1. SPECIFICATIONS
Category Specifications Remarks
Engine designation D22DTR -
Engine type / Number of cylinders In-line 4 cylinders -
Displacement (cc) 2,157 -
Compression ratio 15.5 : 1 -
Max. power (PS) 181 ps/4,000 rpm -
Max. torque (Nm) 400 Nm/1,400 ~ 2,800 rpm -
Cylinder block Cast iron casting -
Fuel injection pressure (bar) 2,000 bar -
Oil pump type Fixed discharge type -
Engine oil capacity Approx. 6.0 L -
Coolant capacity Approx. 10.2L -
Fuel tank capacity Approx. 70 L -
Power steering fluid capacity Approx. 1.1 L -
2. ENGINE LAYOUT
Front view Rear view

Right view Left view

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3. MAJOR COMPONENTS
Front view

Vacuum pump

Cam position sensor

Oil filter & cooler assembly

Power steering pump pulley

Oil pressure switch

Water pump pulley

Idler pulley No. 2

Alternator

Idler pulley No. 1

Auto tensioner

A/C compressor

Isolation damper

Rear view

E-EGR valve

Fuel temperature sensor

Fuel HP pump assembly

IMV

Coolant outlet port assembly

Coolant temperature sensor

Crankshaft position sensor

Drive plate
Right view

Front exhaust gas temperature

sensor

Oil dipstick tube &

gauge assembly

E-VGT actuator

E-VGT turbocharger

Turbocharger Hollow bolt

Oil pan

Oil drain plug

Left view

Electric throttle body

Variable swirl valve

assembly

E-EGR valve

E-EGR solenoid valve

EGR cooler

Oil cooler assembly

Thermostat assembly
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4. LOCATIONS IN ENGINE COMPARTMENT

Coolant reservoir Brake fluid reservoir

Fuel filter

Engine oil dipstick

Engine oil filler cap

Battery

Engine oil filter

Power steering fluid reservoir

Washer fluid reservoir Air cleaner Fuse and relay box

- When checking the engine compartment, be careful not to touch the hot components such
as engine, radiator, exhaust manifold, LNT & DPF, and muffler immediately after the engine
has been stopped. Check the engine compartment after the engine has been cooled down
sufficiently.
- Regularly check the engine oil level and add Ssangyong genuine engine oil, if necessary.
- Clean the oil dipstick gauge with a clean cloth to prevent any foreign material from entering.

- Operating vehicle with insufficient amount of engine oil can cause severe damage to the engine.
1) Major Check Items and Service Interval
Daily Interval of regular inspection, adjustment and
Check item Remarks
check replacement
Engine oil level Check and
check and O - replenish as
replenishment necessary
Engine oil and filter EU Replace at every 20,000 km of driving or
replacement every year
Check frequently and fill up if necessary
- Gen Initial check: 7500 km, change every 15000 -
km or 12 months
Replace at every 15,000 km of driving or
every year
Check frequently and fill up if necessary

Coolant level check Check and

and replenishment, replenish as
cooling system O - necessary
connection

Coolant replacement - Change at every 5 years or 200,000 km of driving. -

(Long life antifreeze)
Drive belt Check at every 20,000 km of driving
- -
Replace if necessary
Air cleaner element Initial clean : 5,000 km, Clean every 10,000 km
cleaning and - Replace every 30,000km -
replacement
Fuel filter EU Replace at every 40,000 km of driving
replacement and (separate water in fuel filter at every 20,000
water separation km of driving)
- -
Gen Replace at every 45,000 km of driving
(separate water in fuel filter at every 15,000
km of driving)
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The regular inspection interval should be shortened if the vehicle is used under following severe
conditions:

1. Vehicle is traveled a short distance repeatedly

2. Frequent operating in sandy and dusty areas
3. Idling vehicle too long
4. Operating in a place with heavy traffic
5. High frequency of driving in rough roads such as sand, gravel road, snowy road and unpaved
road
6. High frequency of driving in mountain roads, uphill/downhill, etc.
7. Used for patrol car, taxi, commercial vehicle, towing vehicle, etc.
8. Frequent driving at high speed (170 km/h)
9. Frequent stop-and-start driving
10.Driving on road with salt or corrosive substances or cold areas
11.Towing a trailer or off-road driving
12.Frequent driving under full load condition
2) Fluid Specifications And Capacity
Item Oil capacity Size

Engine oil Approx. 6.0 L Use Ssangyong genuine parts

(use oil for MB 229.51 SAE 5W30 or MB 229.52 SAE
5W30)
Coolant capacity Approx. 10.2 L Ssangyong genuine parts
Power steering fluid Approx. 1.1 L Ssangyong genuine parts (S-PSF3)

3) D22DT (EURO-VI) Engine Self-Cleaning

- The EURO-VI is a strict emission regulation ensures to minimize harmful substances to the
environment and human body in exhaust gas emissions. The D22DT EURO-VI engine is equipped
with a clean engine that complies with the EURO-VI regulation while realizing optimal power
performance.
- There are also other systems for minimizing harmful emissions. However, for reliability of the system,
the carbon and other foreign substances should be removed continuously from the mechanical
components such as the valve where the inlet air and recirculating exhaust gas flow through, in order
to enable precise control of the vehicle ECU.
- Removal of the carbon and other foreign substances and the process of finding the exact position
value (learning) are performed automatically by means of self-cleaning every time the engine stops.
The swirl valve, E-EGR valve, and turbocharger actuator perform self-cleaning.
- Since self-cleaning is repeated every time the engine stops, this causes a somewhat large operation
noise, but this is normal operation, not a sign of a malfunction.
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1. GUIDELINES FOR SERVICE WORK SAFETY

1) For Safety
To maintain and operate the vehicle under optimum state and carry out the service safely, following the
correct methods and procedures is required.
Accordingly, the purpose of this manual is to prevent differences in personal working methods, skills, tips
and service procedures; and to provide prompt/correct service procedures.

The "Note" and "Caution" stated in this manual has the follow meaning:

This indicates detailed description of supplementary information on work procedure or skill.

This indicates precautions on tool/device or part damages or personal injuries that can occur during
service activities.

However, the notes and cautions cannot be comprehensive measures, so always observe and pay
close attention to the situations based on common senses.
2) During Service Activities
(1) Before lifting up the vehicle with a vehicle lift, support and lift the vehicle on the correct lifting
points.

(2) When using a jack, park the vehicle on the level ground and place wheel chocks underneath the
tires. Position the jack under the frame and lift up the vehicle and then support with chassis stand
before servicing.

(3) Before performing the service, be sure to disconnect the battery negative (-) terminal to prevent
damages by bad wire and short circuit.

(4) If performing the service inside of the vehicle is required, use protection cover to prevent damage
and contamination to the seats and floor.

(5) Brake fluid and anti-freeze can damage the painted surfaces of body. So carefully handle them
while performing the service.

(6) Use recommended and specified tools to increase efficiency of service activities.

(7) Use only genuine parts recommended by Ssangyong.

(8) Never reuse cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts.
Replace them with new ones.

(9) If they are reused, normal functions will not be expected.

(10) Always arrange disassembled parts in order of the disassembly and put them to one side.

(11) The hardness and design of the bolts and nuts vary depending on the installation location.
So be careful not to mix up the removed bolts and nuts and arrange them in good order.

(12) Clean the parts which will be inspected and assembled. Thoroughly clean the oil-related parts to
prevent the dirt or foreign materials on these parts from affecting the oil viscosity.

(13) Apply oil or grease on the driving and sliding surfaces before installing parts. Use sealers or
specified gaskets to prevent leaks, if necessary.

(14) Tighten every bolt and nut to the specified torque.

(15) When the service activities have been completed, thoroughly check if the service activities were
carried out properly or the problems were solved.
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3) Basic Inspection
(1) Horn
- Activate the horn and listen for the horn sound.
(2) Brake system
- Check if an abnormal sound occurs, working distance of the brake pedal has been increased and
braking is applied on one side only while depressing the brake pedal. In addition, if the brake warning
lamp continues to flash or illuminate, the brake system is defective. Check it
again.
- After rotating tires, check the connection of the brake pipe and hose, oil leakage, crack or
interference. Check also brake disc's surface and wear condition when replacing the tires.
- Check the parking brake cable and that it operates normally. (When you depress the brake pedal
frequently, check it more often.)
(3) Exhaust system
- Abnormal sounds and a burnt odor from the exhaust pipe mean leaks in or overheating of the
exhaust system. Have the system inspected and repaired immediately at the nearest repair
facility.
- Inspect the complete exhaust system including the underbody installed to the exhaust system and
the catalytic converter, if equipped. Inspect the body near the exhaust system. Look for broken,
damaged, missing, or out-of position parts as well as open seams, holes, loose connections, or other
conditions which could cause heat build-up in the floor panel or could let exhaust gases enter the
vehicle.
(4) Tires
- If shaking of seat or steering wheel and vehicle leaning to one side occur on the normal straight and
even road, it indicates tire pressure imbalance or faulty wheel balance. Check the tire pressure and
wheel alignment.
(5) Steering and suspension system
- Check the steering and suspension system for damage, looseness, damaged part, wear and lack of
lubrication. Check the power steering pipe and hose for connection, oil leakage, rupture and
interference and check the drive axle boot and seal for surface damage, tear or oil leakage. If
necessary, replace or repair the corresponding part.
(6) Engine oil
- Check the oil level and add or change the oil, if necessary. The best time to check the engine oil level
is when the engine is running at normal operating temperature.
(7) Coolant
- Check the coolant level and coolant conditions (contamination, foreign materials) in the coolant
reservoir tank. Inspect the coolant hose for damage or leaks. Add Ssangyong genuine coolant or
replace with Ssangyong genuine parts, if needed.
(8) Engine drive belt
- Check all drive belts of the engine for wear, cracks, looseness, tension. Re-tighten or replace the belt,
if needed.
4) Guidelines on Engine Service
Basic cautions and service guidelines which can be easily forgotten by technicians are described here.
Follow these instructions: (a) to prevent personal injuries and vehicle damages that can be caused by
mistakes during inspection/repair of the engine and components; and (b) to ensure optimized engine
performance and safety after completing service.
(1) Precautions
- Before work on engine and electrical equipment, be sure to disconnect the negative (-) battery
terminal.
- Before performing the service, be sure to clean the work areas.
- Always put the ignition switch to the OFF position, except when required. Otherwise, there
may be electrical equipment damages or personal injuries due to short-circuit or short-circuit
to ground.
- There should be no leaks in the fuel injection system (HP pump, fuel hose, high pressure pipe) of the
engine. To achieve this always protect the components of the fuel injection system from foreign
materials.
- While removing the engine, use the dedicated equipment, such as, jack for engine and transmission,
engine stand, engine crane, etc.
(2) Engine and accessories
Working with an engine requires high precision. Therefore, tighten the parts to the specified torque and
keep the removed parts clean when disassembling, removing, installing, and assembling.
Keeping the working areas clean and servicing with great care are essential for checking the engine and
parts of the vehicle.
- When removing the engine, the engine-related parts (bolts, gaskets, etc.) should be arranged in good
order.
- When disassembling/assembling the internal components of the engine, follow the
disassembly/assembly instructions in this manual and clean each component thoroughly and
apply engine oil before installation.
- While removing the engine, drain the engine oil, coolant, and fuel in the fuel system to prevent
leaks.
- When removing and installing parts, be sure to check that each connection to the engine does not
interfere with other parts.
(3) Electrical equipment
Take extra care when handling the electrical equipment. The engine is equipped with so many electrical
equipment. This complexity may cause short circuit and bad contacts which can lead to engine
performance reduction, incomplete combustion and other problems. Therefore, the technicians should
be familiar with the characteristics of the vehicle's electrical equipment.
- When working with the electrical equipment, be sure to disconnect the negative (-) battery terminal
and turn the ignition switch to off, except when required.
- When replacing the electrical equipment, use the same genuine parts and be sure to check if the
ground or connections are securely connected. Loose grounding or connections can lead to vehicle
fire or severe personal injuries.
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(4) Fuel and lubrication systems

The engine oil and fuel can cause corrosion damage to the painted surface of the body and rubber
products (e.g. hoses). If these fluids contact with the engine, foreign materials or dust in the air may be
attracted and cause further damage to the fuel system.
- Working with the system related to fluids, such as fuel and oil, should be done in a well-vented and no
smoking area.
- The gaskets and seals of the fuel and lubrication systems should be replaced with new ones. The bolts
and nuts should be tightened to the specified torque.
- After removing or installing, be sure to check the connections for leaks.

1. If fine dust or foreign materials enters the fuel system of DI engine, it may lead to critical fault
between injectors at the fuel system HP pump. Always fit the cap and pay attention not to contact
the contaminants with the parts when removing the parts related to fuel.
(See cleanliness when working on fuel system of DI engine)
2. When working on the fuel line from the priming pump to the injector (including return line), always
fit the cap onto the removed part and make sure that and the connecting channel and removed
parts do not contact with the foreign materials or dust.
3. Always replace the high pressure fuel supply pipe from the HP pump to the fuel rail and the high
pressure fuel pipe from the fuel rail to each injector with new ones.
2. TIGHTENING TORQUE BY BOLT STRENGTH

1) Metric bolt strength is stamped on the head of each bolt. The strength of bolt can be classified as 4T,
7T, 8.8T, 10.9T, 11T and 12.9T in general.
2) Observe the standard tightening torque during bolt tightening. You can determine the proper
tightening torque within 15 % of standard value, if necessary. Try not to over permitted maximum
tightening torque, if not required to do so.
3) Determine the proper tightening torque separately, if tightening with washer or packing is
required.
4) When the bolts are needed to be tightened to the below materials, follow the tightening torque
specified below.
- Aluminum alloy: Tighten to 80 % of above torque table.
- Plastics: Tighten to 20 % of above torque table.
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3. TIGHTENING TORQUE
Part name Tool dimensions Bolt Specified torque Remarks
quantity (Nm)

Main bearing cap 12-point, 13 mm 10 Not reusable

Connecting rod cap E12 8 50 to 80 Nm

Crankshaft rear seal 10mm 6 -

Oil pump 13mm 3 -

Flywheel T55 8 Not reusable

Crankshaft pulley 27mm 1 660 to 720 Nm

Not reusable
20 20 mm long
2 35 mm long
10mm
Oil pan 2 85 mm long
2 120 mm long
13mm 2 40 mm long
HP pump gear mounting 19mm 1 -
nut
HP pump mounting bolt Hexagon, 6 mm 3 -

Cylinder head M14 10 Not reusable

10mm 16 -
Camshaft cap
13mm 4 -
Exhaust stud bolt - 10 -
Exhaust camshaft
13mm 3 -
sprocket
Coolant temperature
24mm 1 -
sensor
13mm 1 -
Belt auto tensioner
17mm 1 -
Water pump Hexagon, 5 mm 7 -
 Part name Tool dimensions Bolt Specified torque Remarks
quantity (Nm)
Hot water inlet pipe 10mm 2 -
(Bottom)
15mm 1 -
Alternator
17mm 1 -
A/C compressor 13mm 4 -
A/C bracket 10mm 4 -
13mm 2 35 mm long
Intake manifold
13mm 6 110 mm long
5 40 mm long
Oil filter & cooler 13mm 1 120 mm long
2 140 mm long
Oil pressure switch 24mm 1 -
Cam position sensor 10mm 1 10~14Nm -
T-MAP sensor 10mm 1 -
Exhaust manifold 12mm 10 -
Turbocharger 13mm 3 -
T/C support bracket 13mm 1 -
bolt (Turbo side)
T/C support bracket 13mm 1 -
bolt (Block side)
T/C oil supply pipe bolt 24mm 1 -
(Block Side)
T/C oil return pipe(Block Hexagon, 5 mm 2 -
Side)
T/C oil supply & return
pipe(Turo Side) Hexagon, 5 mm 2 -
supply
EGR valve 13mm 3 -
EGR pipe bolt 10mm 2 -
(Intake side)
EGR pipe bolt 13mm 2 -
(EGR cooler side)
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Part name Tool dimensions Bolt Specified torque Remarks

quantity (Nm)
No. 1, 2 idle T50 1 -
bearing
Glow plug M10 4 -
Vacuum pump 10mm 3 -
8 40 mm long
Timing gear case cover 10mm 1 45 mm long
2 50 mm long
Cylinder head cover 10mm 17 -
Oil gauge tube 10mm 1 -
Oil filter cap - 1 -
Fuel rail Hexagon, 6 mm 2 -
Injector clamp bolt E10 2 Not reusable
High-pressure pipe
(high pressure pump to 17mm 1 Not reusable
fuel rail assembly)
High-pressure pipe
(Fuel rail assembly to 17mm 4 Not reusable
injector)
Crankshaft position
Hexagon, 3 mm 1 -
sensor
Main wiring 10mm 5 -
Intake duct 13mm 4 -
Ladder frame 13mm 6 -
Cylinder head front 10mm 5 -
cover
4. VARIANT CODING
1) Engine Variant Coding

Items Option Description Remarks

Additional Heater NO Select "YES" since Additional -
Heater is a standard feature
YES Select
Glow-plug AQGS(CAN) Use GCU which communicates with Auto Select
ECU via CAN bus. Select "AQGS
(CAN)"
Gearbox 6 speed manual Select
6 speed auto Select
specifications
(AISIN)
A/C NO Select
on specifications
YES Select
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Items Option Description Remarks

Immobilizer NO Select "YES" since immobilizer is a -
standard feature
YES Select
Vehicle speed CAN Select "CAN" since it transmits vehicle Auto Select
sensor speed signal via CAN communication

FAN PWM Select "PWM" since PWM cooling fan Auto Select
is a standard feature
Cruise Control NO -
a standard feature
YES Select
G-sensor NO -
standard feature
YES Select
SKM Key NO Select "NO" or "YES" depending on Select
specifications
YES Select
EEM NO Select "NO" since EEM not equipped Select
YES -
ISG NO Select "NO" since ISG not equipped Select
YES -
Variable Oil Pump NO Select "NO" since variable oil pump Select
not equipped
YES -
(2) Chassis variant coding

Items Option Description Remarks

Korea/Export Korea -
General Export depending on specifications General
EU Export Europe
Brake NO -
ESP is a standard feature
ABS General

ESP specifications Europe/General

TPMS application NO General

TPMS is a standard feature
YES Europe/General
Depending on specifications
Transfer case 2WD Select
depending on specifications
P/Time 4WD Select
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Items Option Description Remarks

Transmission type M/T Select "M/T" or "A/T" depending on Select
specifications
A/T Select
Sedan Sedan(RV) Select "Sedan (RV)" Auto Select
/Limousine
Vehicle Code Musso Auto Select
(Platform) (Rexton sports) since vehicle type is Musso(Rexton
sports)
Vehicle Code D22DT Select "D22DT" since engine type is Auto Select
(Engine) D22DTR
ECU coding status ECU coded Select "ECU coded" since coding is Auto Select
completed
1. SPECIAL TOOL
PN & Name Special Tool Use
Part No.: T99110010A

Name:
Flywheel fixture

Usage:
Tool which holds flywheel or
drive plate so that engine can
not rotate when removing
crankshaft pulley, etc.

Part No.: Y99220182B

Name:
Remover - removing valve stem
seal

Usage:
Used to protect the rubber
valve guide from damage when
removing/installing it.

Part No.: Y99220142B

Name:
Installer - installing valve stem
seal

Usage:
Used to install valve stem seal
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PN & Name Special Tool Use

Part No.: Y99220082B
W99110230A

Name:
Valve spring complete

Usage:
Used to remove and install the
valve spring by compressing it.

Y99220082B W99110230A
Part No.: Y99220122B

Name:
Dial gauge - measuring piston
protrusion

Usage:
Used to measure piston
protrusion to determine cylinder
head gasket type.

Part No.: Y99220172B

Name:
Piston install guide tool

Usage:
Used to insert the piston in the
cylinder block.
 PN & Name Special Tool Use
Part No.: W99110120A

Name:
Insert guide - crankshaft rear oil
seal

Usage:
Used to protect retainer from
damage and seat rear
crankshaft oil seat correctly.

Part No.: T99180010A

Name:
EURO-V injector remover

Usage:
Used to remove injector
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Components of injector remover

No Part name Quantity Shape

1 Injector remover set 1set

2 Main bar 1EA

3 Cross bar 2EA

4 Main bolt holder 1EA

5 Ball bearing 1EA

No

6 Main nut - A 1EA

7 Main bolt - A 1EA

No Part name Quantity Shape

8 Injector holder - A 1EA

9 Injector holder - B 1EA

10 Injector holder cover 1EA

11 Bar holder assembly 2set

12 Support mounting bolt 4EA

13 Main support 4EA

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2. GENERAL DEDICATED EQUIPMENTS

PN & Name General tool Usage
Name:
Engine stand (1 tonne or more)

Usage:
Used to secure the removed
engine or engine with transaxle.
Use an equipment which is
designed to carry load of 1
tonne or more.

Name:
Engine crane (1 tonne or more)

Usage:
Used to move the removed
engine module with transaxle to
a working area or an engine
stand. Use an equipment which
is designed to carry load of 1
tonne or more.

Name:
Oil pan gasket remover

Usage:
Used to separate oil pan while
minimizing damage when
removing it.

Name:
Torque angle gauge

Usage:
Used to angle tighten correctly
after torque tightening.
 PN & Name General tool Usage
Name:
High pressure pump gear & nut
changer

Usage:
Used to fit/remove high
pressure pump sprocket

Part No.: Y99220092B

Name:
Adapter and gauge for
measuring compression
pressure

Usage:
Used to measure compression
pressure by inserting glow plug
hole
Part No.: A99000500A 3-way valve

Name:
Coolant vacuum filler

Usage:
Used to bleed coolant line and
fill coolant if coolant is drained
from water pump housing, for
example when working on Auxiliary tank
Reservoir tank
cylinder head or water pump adapter
Coolant filler tank