SsangYong Rexton. Manual - part 16

DI01-18

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

If the measured value of the compression pressure test is not
within the specifications, perform the cylinder pressure leak-
age test.

Permissible Pressure Leakage

Notice

• Perform the pressure in order: 1 - 2 - 3 - 4 - 5

• Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the

combustion chamber)

Y220_01009

Test temperature

At whole engine

At valve and cylinder head gasket

At piston ring

at normal operating temperature (80°C)

Max. 25 %

Max. 10 %

Max. 20 %

CYLINDER PRESSURE LEAKAGE TEST

DI01-19

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

TIGHTENING TORQUE

Oil nozzle

Main bearing cap

Connecting rod cap

Rear cover

Oil pump

Oil baffle plate assembly

T.G.C.C

Flywheel

Crankshaft hub

Oil pan

High pressure pump assembly

High pressure pump sprocket assembly

High pressure pump bracket

Cylinder head assembly

Camshaft cap

Stud bolt

Camshaft sprocket (Intake)

Camshaft sprocket (Exhaust)

Chain tensioner

Coolant temperature sensor

M6 x 22

M11 x 62

M9 x 52

M6 x 20

M8 x 35SOC

M6 x 20

M6 x 16

M6 x 40

M6 x 60

M6 x 70

M8 x 80SOC

M10 x 30

M18 x 50

M6 x 20

M6 x 35

M6 x 38

M6 x 40

M8 x 40

M14 x 1.5-8-1

M7 x 16

M8 x 25

M8 x 50

M12 x 177

M12 x 158

M8 x 60

M8

M11 x 52

M22

M14

10 ± 1

55 ± 5

90° ± 10°

40 ± 5

90° ± 10°

10 ± 1

25 ± 2.5

10 ± 1

10 ± 1

10 ± 1

10 ± 1

10 ± 1

25 ± 2.5

45 ± 5

90° ± 10°

325 ± 33

90° ± 10°

10 ± 1

10 ± 1

10 ± 1

25 ± 2.5

25 ± 2.5

65 ± 5

20 ± 2 x 90° + 10°

25 ± 2.5

Step1: 20 Nm ± 2 Nm

Step2: 85 Nm ± 5 Nm

Step3: 3 x 90° + 10°

25 ± 2.5

15 ± 1.5

25 ± 2.5

90° ± 10°

65 ± 5

22 ± 2.2

Size

Name

Tightening Torque

NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

5

12

5

6

3

10

1

6

3

2

1

8

1

24

3

3

4

4

1

3

2

2

11

1

24

10

1

1

1

1

Quantity

DI01-20

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Auto tensioner

Water pump assembly

Water pump pulley

Hot water inlet pipe assembly

Alternator bracket

Alternator

Air conditioner compressor assembly

Air conditioner compressor bracket

assembly

Air conditioner compressor sub

bracket assembly

Intake manifold

Bracket

Knock sensor

Camshaft position sensor

Booster pressure sensor

Exhauster manifold

Turbo charger assembly

Turbo charger adaptor piece

Nut

Combination bolt

T/C oil supply pipe

T/C oil return pipe

EGR valve assembly

EGR-LH pipe bolt

EGR combination bolt

EGR-RH pipe nut

Glow plug cable nut

Vacuum pump

Cooling fan bracket assembly

Cylinder head cover

M8 x 45(LOWER)

M12 x 90

M6 x 50

M6 x 12

M6 x 12

M8 x 32

M10 x 90

M8 x 95

M8 x 25

M8 x 60

M6 x 14

M8 x 16

M8 x 45

M8 x 130

M6 x 16

M8 x 28

M8 x 16

M6 x 16

M8

M8

M8

M8 x 22

M6 x 16

 (Cylinder block side)

M16 (T/C side)

M6 x 16 (T/C side)

M6 x 16

 (Cylinder block side)

M8 x 22

M6 x 16

M8 x 22

M6 x 16

M8 x 16

M8

M5

M6 x 20

M6 x 25

M6 x 65

M6 x 85

M6 x 35

Size

Name

NO.

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

32 ± 3

82 ± 6

10 ± 1

10 ± 1

10 ± 1

25 ± 2.5

46 ± 4.6

46 ± 4.6

25 ± 2.5

25 ± 2.5

10 ± 1.0

25 ± 2.5

25 ± 2.5

25 ± 2.5

10 ± 1.0

20 ± 2.6

12 ± 1.7

10 ± 1.0

40 ± 4

25 ± 2.5

32 ± 3.2

25 ± 2.5

25 ± 2.5

25 ± 2.5

20 ± 2.0

10 ± 1.0

10 ± 1.0

25 ± 2.5

10 ± 1.0

35 ± 2.0

10 ± 1.0

25 ± 2.5

35 ± 2.0

15 ± 3

10 ± 1.0

10 ± 1.0

10 ± 1.0

10 ± 1.0

23 ± 2.3

Tightening Torque

1

1

7

4

2

4

2

4

1

3

1

1

6

6

1

2

1

2

10

4

1

1

1

1

1

2

2

2

2

2

4

4

2

5

3

5

1

3

21

Quantity

DI01-21

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Vacuum modulator

WDT combination bolt

Oil dipstick tube

Oil filter assembly

Fuel rail assembly

Injector clamp washer

Fuel pipe clip (H-C)

Fuel pipe clip (C-I)

Crankshaft position sensor

Crankshaft position sensor

Fuel pressure sensor

Wiring

Intake manifold bracket

Power steering pump

Piston protrusion

Clearance between connecting rod

and pin boss

End play of crankshaft

Name

NO.

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

NEW: 0.100 ~ 0.245 mm // USED: 0.300 mm

10 ± 1.0

10 ± 1.0

10 ± 1.0

25 ± 2.5

25 ± 2.5

25 ± 2.5

25 ± 2.5

10 ± 1.0

180 + 20°

10 ± 1.0

10 ± 1.0

0.8 ± 0.4

0.7 ~ 1.5

10 ± 1.0

25 ± 2.5

25 ± 2.5

25 ± 2.5

25 ± 2.5

0.765 ~ 1.055

0.05 ~ 0.31

Tightening Torque

4

3

1

1

2

1

3

5

1

5

1

1

5

2

2

2

2

5

5

Quantity

M6 x 16SOC

M6 x 16

M6 x 16

M8 x 35SOC

M8 x 50SOC

M8 x 55SOC

M8 x 35SOC

M6 x 60

M6 x 19

M6 x 16

M5 x 17

GAP

M6 x 16

M8 x 16

M8 x 40

M8 x 100

NUT

Size