This document provides a 3-sentence summary of the Rexton service manual section on general information:
The section outlines key engine systems including intake, exhaust, lubrication, and cooling. It also describes engine controls and components. Cleanliness procedures are emphasized due to the precision of the direct injection fuel system. Vehicle identification numbers and specifications are included to aid technicians in service and repair.
The automotive industry in India produced over 22.9 million vehicles in fiscal year 2022, up from the previous year. Passenger vehicle production was around 3.7 million units in 2022. China led global vehicle production in 2021 with over 26 million units produced. India's automotive sector employed over 1.36 million people in 2018.
2012 Polaris Sportsman 500 HO Service Repair Manualjksmreremmd
This is the Highly Detailed factory service repair manual for the2012 POLARIS SPORTSMAN 500 HO, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2012 POLARIS SPORTSMAN 500 HO Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General
Maintenance
Engine
Fuel Systems
Body / Suspension
Clutch
Final Drive
Transmission
Brakes
Electrical
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2012 POLARIS SPORTSMAN 500 HO Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
8
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYSinventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
This document discusses three Honda products - the Activa scooter, Unicorn motorcycle, and CB 1000R motorcycle. It provides details on each product like launch year, key features, pricing strategy used, and promotional activities. For the Activa, it mentions the first scooter launched by Honda in India in 2001. For the Unicorn, it highlights the mono-suspension design. And for the CB 1000R, it focuses on the powerful engine and transmission system.
DESIGN AND ANALYSIS OF I.C. ENGINE PISTON AND PISTON-RING USING CATIA AND ANS...IAEME Publication
In this present work a piston and piston ring are designed for a single cylinder four stroke petrol engine using CATIA V5R20 software. Complete design is imported to ANSYS 14.5 software then analysis is performed. Three different materials have been selected for structural and thermal analysis of piston. For piston ring two different materials are selected and structural and thermal analysis is performed using ANSYS 14.5 software. Results are shown and a comparison is made to
find the most suited design.
Customer perception @ bijjaragi motors project report mba marketingBabasab Patil
This document provides an overview of the automobile industry in India and Bijjaragi Motors. It discusses the history of the automobile industry in India and covers major players like Tata Motors. It also analyzes factors driving growth in the Indian automobile market such as rising incomes. The document aims to understand customer perception and loyalty towards Bijjaragi Motors by conducting primary research through questionnaires.
This document discusses the key steps in developing a new vehicle from prototype to production including specifying technical specifications, planning production and storage, assembling the vehicle on a line using various machines, testing and inspection, scheduling workers and ensuring safety, managing sales and warehouses, and conducting administration and media activities to promote the new vehicle.
This document provides an overview of bogie assembly for locomotives. It describes that a bogie is a three-axle frame that supports the weight of the locomotive and runs on six wheels. The key components of a bogie include the bogie frame, axles, wheels, traction motors, suspension system, and brake rigging. It then discusses the types of bogies based on wheel arrangement and frame construction, as well as the important parts, suspension arrangement, and ride characteristics.
The automotive industry in India produced over 22.9 million vehicles in fiscal year 2022, up from the previous year. Passenger vehicle production was around 3.7 million units in 2022. China led global vehicle production in 2021 with over 26 million units produced. India's automotive sector employed over 1.36 million people in 2018.
2012 Polaris Sportsman 500 HO Service Repair Manualjksmreremmd
This is the Highly Detailed factory service repair manual for the2012 POLARIS SPORTSMAN 500 HO, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2012 POLARIS SPORTSMAN 500 HO Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General
Maintenance
Engine
Fuel Systems
Body / Suspension
Clutch
Final Drive
Transmission
Brakes
Electrical
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2012 POLARIS SPORTSMAN 500 HO Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
8
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYSinventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
This document discusses three Honda products - the Activa scooter, Unicorn motorcycle, and CB 1000R motorcycle. It provides details on each product like launch year, key features, pricing strategy used, and promotional activities. For the Activa, it mentions the first scooter launched by Honda in India in 2001. For the Unicorn, it highlights the mono-suspension design. And for the CB 1000R, it focuses on the powerful engine and transmission system.
DESIGN AND ANALYSIS OF I.C. ENGINE PISTON AND PISTON-RING USING CATIA AND ANS...IAEME Publication
In this present work a piston and piston ring are designed for a single cylinder four stroke petrol engine using CATIA V5R20 software. Complete design is imported to ANSYS 14.5 software then analysis is performed. Three different materials have been selected for structural and thermal analysis of piston. For piston ring two different materials are selected and structural and thermal analysis is performed using ANSYS 14.5 software. Results are shown and a comparison is made to
find the most suited design.
Customer perception @ bijjaragi motors project report mba marketingBabasab Patil
This document provides an overview of the automobile industry in India and Bijjaragi Motors. It discusses the history of the automobile industry in India and covers major players like Tata Motors. It also analyzes factors driving growth in the Indian automobile market such as rising incomes. The document aims to understand customer perception and loyalty towards Bijjaragi Motors by conducting primary research through questionnaires.
This document discusses the key steps in developing a new vehicle from prototype to production including specifying technical specifications, planning production and storage, assembling the vehicle on a line using various machines, testing and inspection, scheduling workers and ensuring safety, managing sales and warehouses, and conducting administration and media activities to promote the new vehicle.
This document provides an overview of bogie assembly for locomotives. It describes that a bogie is a three-axle frame that supports the weight of the locomotive and runs on six wheels. The key components of a bogie include the bogie frame, axles, wheels, traction motors, suspension system, and brake rigging. It then discusses the types of bogies based on wheel arrangement and frame construction, as well as the important parts, suspension arrangement, and ride characteristics.
The document discusses various automotive safety standards including AIS, FMVSS, and CMVR. It provides details on 6 standards under each category:
AIS standards cover areas like starting gradeability, lighting requirements, battery safety, speed limiting devices, type approval process, and truck body construction.
FMVSS standards include controls and displays, windshield wiping/washing, tire and rim selection, hydraulic/electric brakes, side impact protection, and rear impact guards.
CMVR rules discuss mandatory seatbelt usage, rules for foreign drivers, prohibiting dangerous vehicle positioning, and passenger door requirements.
A project report on customer satisfaction level for two wheeler vehicleBabasab Patil
The document discusses a study on customer satisfaction levels for two-wheeler vehicles made by TVS Motor Company in Belgaum, India. The study aims to understand customer satisfaction with TVS products and services through a survey of 100 customers and analysis of company data. The goals are to help TVS identify areas for improving customer experience and competitiveness.
The S85B50 engine is BMW's first 10-cylinder engine for series production vehicles, featuring a high-speed layout and bedplate structure to withstand vibrations up to 8,250 rpm. It utilizes optimized valve train components like box-type tappets and hydraulic lash adjusters for reduced weight and friction to enable extremely fast VANOS adjustment via high oil pressure and proportional valves. Individual throttle valves are also used to satisfy the engine's rapid response characteristics.
A comparative study of customer satisfaction towards performance of Hero, Baj...hasnain2
MBA marketing project report on
A comparative study of customer satisfaction towards performance of Hero, Bajaj, Honda and Tvs bikes(A Case of Malegaon City)
Design and assembly analysis of a gear train of a gear box reportAkhilesh Arkala
The document provides information about gear boxes and differentials used in vehicles. It discusses the components and purpose of differentials, which allow the outer wheel to turn faster than the inner wheel when a vehicle takes a turn. It then describes the typical components of a differential including the crown wheel and pinion, sun gears, and differential casing. The document notes that the aim of the project is to analyze the design and contact stresses on gear assemblies in a gear box operating at speeds of 2500 rpm and 5000 rpm, and to determine the best material for the gears through stress, displacement, and weight reduction analyses. The analyses will be conducted using Pro/Engineer and Cosmos software.
This presentation is all about the latest innovation of the air -free tire concept by BRIDGESTONE, in the automobile sector. this will tell us how such tires actually works and has an edge over normal and tubeless tires.
Este documento presenta un catálogo de partes eléctricas de Bosch para el año 2018, incluyendo rectificadores de voltaje de diferentes fabricantes como Bosch, Denso, Hitachi para una variedad de automóviles de Hyundai, Kia, Mazda, Mitsubishi, Nissan, Subaru, Toyota y otros. Se proporcionan detalles como las características, dimensiones y aplicaciones de cada parte.
This document provides instructions for using a parts catalogue for a Hero MotoCorp motorcycle. It explains how to identify parts, read part numbers, find labor times, and order replacement parts. The document contains an index of engine and frame systems to locate parts efficiently in the catalogue. It also provides color codes, abbreviations, and other information to properly use the parts catalogue.
This document provides safety, operation, and maintenance instructions for Samuel Strapping Systems semi-automatic strapping machines models P-626 and P-726. It describes the major components of the machines and strapping head, instructions for installation, pre-assembly, threading strap through the machine, operating controls, the strapping cycle, maintenance, troubleshooting, electrical schematics, and includes a list of spare parts.
This document discusses the components and specifications of tires. It describes various tire parts like the tread, sidewall, beads, and materials like cords and elastomers. It provides information on tire ratings for load, speed, and service. Wheel alignment and conditions that affect tire wear like improper inflation pressure or misalignment are also covered. Retreading worn tires is discussed as a way to make commercial vehicle tires more economical.
Traction control systems help prevent wheel slippage and maintain traction under acceleration. The document discusses the history of traction control which originated from 4-wheel drive systems and antilock braking systems. It describes different types of traction control systems including limited slip differentials and how they work. Examples are given of traction control systems used in cars, motorcycles, and race vehicles to improve safety and performance by avoiding wheel slip during acceleration and turns.
comparartive study of customer preference towards automobile sector with refe...Arham Bothra
This document appears to be a student project report comparing customer preferences between Maruti Suzuki and Hyundai in the automobile sector in Bikaner, India. It includes a bonafide certificate, declaration, acknowledgements, abstract, table of contents and several chapters that will analyze collected primary data on consumer preferences between the two companies. The report was submitted by two students for their Master's program and was supervised by Mr. Shailendra Barath.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
mechanical project title-diploma and engineering 2018-2019Self-employed
all domain project available mini project Rs=4800 to 6000 main project Rs=8000 to 17000.
For new ideas and additional titles contact:
Newage Technologies & Solutions
2nd floor Suja complex, Near ANB jewelers Nattu Gounder Street, Kallakurichi-6060202
E-mail : ntsnewage@gmail.com Cell: 7373894403, 8122227872. whats-app:7373894403
Brand image of yamaha motors private india ltdManish Gujrati
This document provides background information on a project report about the brand image of Yamaha motorcycles and its competitors. It begins with an acknowledgment of the industry guide who mentored the project. It then includes a declaration by the student and an executive summary that outlines the purpose of studying customer interest in Yamaha products by surveying 345 respondents. The document continues with tables of contents and an introduction about the motorcycle industry and Yamaha's history.
This document provides specifications and repair information for a 4F27E transmission. It includes:
- Line pressure specifications for park, neutral, reverse, and drive gears.
- Gear ratios for the transmission.
- Instructions for checking oil pressure and diagnosing issues like slipping gears or lack of shifts.
- Details on parts like bands, pistons, valves, solenoids, and their functions within the transmission.
- Procedures for inspecting components and air checking clutches during disassembly and repair.
structural and modal analysis of an engine block by varying materialsIjripublishers Ijri
The largest part of the engine is cylinder block. The upper section of the cylinder block consists of cylinders and pistons. Crankcase is supported by the crankshaft and it is placed in the lower section. Aluminum cylinder blocks are lighter than the cast-iron cylinder blocks of the same size. Cylinder block, pistons, cylinder head, crankshaft and connecting rods are the major elements of the engine. IC engine cooling uses either a liquid or gas to remove the unnecessary heat from an internal combustion engine. For special purpose and small engines, air cooling makes for a lightweight and relatively simple system, if we use the materials with better waste heat dissipation it will help in achieving better efficiencies and long life of the engine.
http://www.ijriset.com/pdf/mech/VOLUME%203/IJRI-ME-03-033/IJRI-ME-03-033%20STRUCTURAL%20AND%20MODAL%20ANALYSIS%20OF%20AN%20ENGINE%20BLOCK%20BY%20VARYING%20MATERIALS.html#
http://www.ijriset.com/pdf/mech/VOLUME%203/IJRI-ME-03-033/IJRI-ME-03-033%20STRUCTURAL%20AND%20MODAL%20ANALYSIS%20OF%20AN%20ENGINE%20BLOCK%20BY%20VARYING%20MATERIALS.pdf
Customer satisfaction and service analysis @ tvs motors project report mbaBabasab Patil
The document discusses the history and operations of Manickbag TVS, a dealership of TVS Motors in Belgaum City. It provides background on TVS Motors, which was established in 1911 and is a major manufacturer of motorcycles and scooters in India. The project focuses on understanding customer satisfaction with and identifying areas for improvement in the post-sales services provided by Manickbag TVS through a survey of 100 customers and their feedback. The objectives are to analyze satisfaction levels, problems customers face, post-sales service performance, and opportunities for new improvements.
Formula 1 cars rely heavily on aerodynamics to produce downforce, using large front and rear wings. They are single-seater, open cockpit vehicles powered by 3.0-liter engines. Teams construct the cars themselves, which use advanced carbon fiber materials and finely tuned fuel blends. Aerodynamic features like the front wings, rear wing, barge boards, and specialized suspensions and wheels are crucial for performance and reducing drag. Major Formula 1 teams include Ferrari, McLaren, Williams, and Renault.
2001 Ssangyong Rexton Service Repair Manual.pdff8usuejdkdmm
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to the high precision of components. Possible issues from water in fuel are discussed along with remedies.
2002 Ssangyong Rexton Service Repair Manual.pdff8usuejdkdmm
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to its high-precision components. Possible issues from water in fuel are discussed along with remedies.
The document discusses various automotive safety standards including AIS, FMVSS, and CMVR. It provides details on 6 standards under each category:
AIS standards cover areas like starting gradeability, lighting requirements, battery safety, speed limiting devices, type approval process, and truck body construction.
FMVSS standards include controls and displays, windshield wiping/washing, tire and rim selection, hydraulic/electric brakes, side impact protection, and rear impact guards.
CMVR rules discuss mandatory seatbelt usage, rules for foreign drivers, prohibiting dangerous vehicle positioning, and passenger door requirements.
A project report on customer satisfaction level for two wheeler vehicleBabasab Patil
The document discusses a study on customer satisfaction levels for two-wheeler vehicles made by TVS Motor Company in Belgaum, India. The study aims to understand customer satisfaction with TVS products and services through a survey of 100 customers and analysis of company data. The goals are to help TVS identify areas for improving customer experience and competitiveness.
The S85B50 engine is BMW's first 10-cylinder engine for series production vehicles, featuring a high-speed layout and bedplate structure to withstand vibrations up to 8,250 rpm. It utilizes optimized valve train components like box-type tappets and hydraulic lash adjusters for reduced weight and friction to enable extremely fast VANOS adjustment via high oil pressure and proportional valves. Individual throttle valves are also used to satisfy the engine's rapid response characteristics.
A comparative study of customer satisfaction towards performance of Hero, Baj...hasnain2
MBA marketing project report on
A comparative study of customer satisfaction towards performance of Hero, Bajaj, Honda and Tvs bikes(A Case of Malegaon City)
Design and assembly analysis of a gear train of a gear box reportAkhilesh Arkala
The document provides information about gear boxes and differentials used in vehicles. It discusses the components and purpose of differentials, which allow the outer wheel to turn faster than the inner wheel when a vehicle takes a turn. It then describes the typical components of a differential including the crown wheel and pinion, sun gears, and differential casing. The document notes that the aim of the project is to analyze the design and contact stresses on gear assemblies in a gear box operating at speeds of 2500 rpm and 5000 rpm, and to determine the best material for the gears through stress, displacement, and weight reduction analyses. The analyses will be conducted using Pro/Engineer and Cosmos software.
This presentation is all about the latest innovation of the air -free tire concept by BRIDGESTONE, in the automobile sector. this will tell us how such tires actually works and has an edge over normal and tubeless tires.
Este documento presenta un catálogo de partes eléctricas de Bosch para el año 2018, incluyendo rectificadores de voltaje de diferentes fabricantes como Bosch, Denso, Hitachi para una variedad de automóviles de Hyundai, Kia, Mazda, Mitsubishi, Nissan, Subaru, Toyota y otros. Se proporcionan detalles como las características, dimensiones y aplicaciones de cada parte.
This document provides instructions for using a parts catalogue for a Hero MotoCorp motorcycle. It explains how to identify parts, read part numbers, find labor times, and order replacement parts. The document contains an index of engine and frame systems to locate parts efficiently in the catalogue. It also provides color codes, abbreviations, and other information to properly use the parts catalogue.
This document provides safety, operation, and maintenance instructions for Samuel Strapping Systems semi-automatic strapping machines models P-626 and P-726. It describes the major components of the machines and strapping head, instructions for installation, pre-assembly, threading strap through the machine, operating controls, the strapping cycle, maintenance, troubleshooting, electrical schematics, and includes a list of spare parts.
This document discusses the components and specifications of tires. It describes various tire parts like the tread, sidewall, beads, and materials like cords and elastomers. It provides information on tire ratings for load, speed, and service. Wheel alignment and conditions that affect tire wear like improper inflation pressure or misalignment are also covered. Retreading worn tires is discussed as a way to make commercial vehicle tires more economical.
Traction control systems help prevent wheel slippage and maintain traction under acceleration. The document discusses the history of traction control which originated from 4-wheel drive systems and antilock braking systems. It describes different types of traction control systems including limited slip differentials and how they work. Examples are given of traction control systems used in cars, motorcycles, and race vehicles to improve safety and performance by avoiding wheel slip during acceleration and turns.
comparartive study of customer preference towards automobile sector with refe...Arham Bothra
This document appears to be a student project report comparing customer preferences between Maruti Suzuki and Hyundai in the automobile sector in Bikaner, India. It includes a bonafide certificate, declaration, acknowledgements, abstract, table of contents and several chapters that will analyze collected primary data on consumer preferences between the two companies. The report was submitted by two students for their Master's program and was supervised by Mr. Shailendra Barath.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
mechanical project title-diploma and engineering 2018-2019Self-employed
all domain project available mini project Rs=4800 to 6000 main project Rs=8000 to 17000.
For new ideas and additional titles contact:
Newage Technologies & Solutions
2nd floor Suja complex, Near ANB jewelers Nattu Gounder Street, Kallakurichi-6060202
E-mail : ntsnewage@gmail.com Cell: 7373894403, 8122227872. whats-app:7373894403
Brand image of yamaha motors private india ltdManish Gujrati
This document provides background information on a project report about the brand image of Yamaha motorcycles and its competitors. It begins with an acknowledgment of the industry guide who mentored the project. It then includes a declaration by the student and an executive summary that outlines the purpose of studying customer interest in Yamaha products by surveying 345 respondents. The document continues with tables of contents and an introduction about the motorcycle industry and Yamaha's history.
This document provides specifications and repair information for a 4F27E transmission. It includes:
- Line pressure specifications for park, neutral, reverse, and drive gears.
- Gear ratios for the transmission.
- Instructions for checking oil pressure and diagnosing issues like slipping gears or lack of shifts.
- Details on parts like bands, pistons, valves, solenoids, and their functions within the transmission.
- Procedures for inspecting components and air checking clutches during disassembly and repair.
structural and modal analysis of an engine block by varying materialsIjripublishers Ijri
The largest part of the engine is cylinder block. The upper section of the cylinder block consists of cylinders and pistons. Crankcase is supported by the crankshaft and it is placed in the lower section. Aluminum cylinder blocks are lighter than the cast-iron cylinder blocks of the same size. Cylinder block, pistons, cylinder head, crankshaft and connecting rods are the major elements of the engine. IC engine cooling uses either a liquid or gas to remove the unnecessary heat from an internal combustion engine. For special purpose and small engines, air cooling makes for a lightweight and relatively simple system, if we use the materials with better waste heat dissipation it will help in achieving better efficiencies and long life of the engine.
http://www.ijriset.com/pdf/mech/VOLUME%203/IJRI-ME-03-033/IJRI-ME-03-033%20STRUCTURAL%20AND%20MODAL%20ANALYSIS%20OF%20AN%20ENGINE%20BLOCK%20BY%20VARYING%20MATERIALS.html#
http://www.ijriset.com/pdf/mech/VOLUME%203/IJRI-ME-03-033/IJRI-ME-03-033%20STRUCTURAL%20AND%20MODAL%20ANALYSIS%20OF%20AN%20ENGINE%20BLOCK%20BY%20VARYING%20MATERIALS.pdf
Customer satisfaction and service analysis @ tvs motors project report mbaBabasab Patil
The document discusses the history and operations of Manickbag TVS, a dealership of TVS Motors in Belgaum City. It provides background on TVS Motors, which was established in 1911 and is a major manufacturer of motorcycles and scooters in India. The project focuses on understanding customer satisfaction with and identifying areas for improvement in the post-sales services provided by Manickbag TVS through a survey of 100 customers and their feedback. The objectives are to analyze satisfaction levels, problems customers face, post-sales service performance, and opportunities for new improvements.
Formula 1 cars rely heavily on aerodynamics to produce downforce, using large front and rear wings. They are single-seater, open cockpit vehicles powered by 3.0-liter engines. Teams construct the cars themselves, which use advanced carbon fiber materials and finely tuned fuel blends. Aerodynamic features like the front wings, rear wing, barge boards, and specialized suspensions and wheels are crucial for performance and reducing drag. Major Formula 1 teams include Ferrari, McLaren, Williams, and Renault.
2001 Ssangyong Rexton Service Repair Manual.pdff8usuejdkdmm
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to the high precision of components. Possible issues from water in fuel are discussed along with remedies.
2002 Ssangyong Rexton Service Repair Manual.pdff8usuejdkdmm
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to its high-precision components. Possible issues from water in fuel are discussed along with remedies.
2003 Ssangyong Rexton Service Repair Manual.pdff8usuejdkdmm
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to its high-precision components. Possible issues from water in fuel are discussed along with remedies.
2001 Ssangyong Rexton Service Repair Manual.pdfufjskekdm9dik
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to the high precision of components. Possible issues from water in fuel are discussed along with remedies.
2003 Ssangyong Rexton Service Repair Manual.pdfufjjksekmdmmd2w
This document provides information on the engine controls, intake system, lubrication system, cooling system, fuel system, general specifications, vehicle identification, and how to use the workshop manual for a DI diesel engine. It discusses the importance of cleanliness when working on the fuel system and provides service procedures. It also describes potential issues caused by water in the fuel and supplements to address water separation and paraffin buildup. Diagrams are included showing the engine structure and layout.
2002 Ssangyong Rexton Service Repair Manual.pdfufjskekdm9dik
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to the high precision of components. Possible issues from water in fuel are discussed along with remedies.
2003 Ssangyong Rexton Service Repair Manual.pdfufjskekdm9dik
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to the high precision of components. Possible issues from water in fuel are discussed along with remedies.
This document provides information on the structure, systems, specifications, and maintenance of DI diesel engines. It includes sections on engine controls, intake and exhaust systems, lubrication, cooling, fuel supply, vehicle identification, and safety guidelines for working on the engine. Diagrams show engine components and system flows. Precautions for cleanliness when working on the fuel system are outlined due to the high precision of components. Possible issues from water in fuel are discussed along with remedies.
John Deere 740G 548G Grapple Skidder Technical Repair Manual.pdfFernelis Garcia
General Information
Safety Information
General Specifications
Torque Values,Fuels and Lubricants,Wheels,Transmission,Transmission, Engine, Cooling System, External Exhaust System,Electrical System,
Batteries, Support and Cables,Powered Wheels and Fastenings,Axles and Suspension System,Removal and Installation,Service Brakes,Active Elements,Hydraulic System,Park Brake.
Removal and Installation, Control Linkage, Gears, Shafts, Bearings, and Power Shift Clutch,Hydraulic System (Hydrostatic Transmission)
Engine,Engine Auxiliary Systems,Cold Weather Starting Aids,Cooling System,Speed Controls
Intake System,External Exhaust System,External Fuel Supply System,Dampener Drive,Elements
Splitter Drive (Pump Drive Gearbox),Removal and Installation,Gears, Shafts and Bearings
Steering System,Hydraulic System
John Deere 740G 548G Grapple Skidder Technical Repair Manual.pdf
John Deere 648G 748G Grapple Skidder Technical Repair Manual.pdfFernelis Garcia
John Deere 648G 748G Grapple Skidder Technical Repair Manual.pdf
General Information
Safety Information
General Specifications
Torque Values,Fuels and Lubricants,Wheels,Transmission,Transmission, Engine, Cooling System, External Exhaust System,Electrical System,
Batteries, Support and Cables,Powered Wheels and Fastenings,Axles and Suspension System,Removal and Installation,Service Brakes,Active Elements,Hydraulic System,Park Brake.
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2. SECTION INDEX
SERVICE VOLUME 1 OF 2
MANUAL(vol. 1 of 2) GENERAL INFORMATION DI0A
REXTON ENGINE ASSEMBLY DI01
ENGINE HOUSING DI02
INTAKE SYSTEM DI03
FOREWORD
This manual includes procedure for maintenance, EXHAUST SYSTEM DI04
adjustment, service operation and removal and
installation of components.
All information, illustrations and specifications LUBRICATION SYSTEM DI05
contained in this manual are based on the latest
product information available at the time of manual
approval.
The right is reserved to make changes at any time COOLING SYSTEM DI06
without notice.
FUEL SYSTEM DI07
ENGINE CONTROL SYSTEM DI08
ELECTRIC DEVICES AND
SENSORS DI09
SSANGYONG MOTOR CO., LTD.
DIAGNOSIS DI10
PYUNGTAEK, KOREA
3. DI ENGINE
CONTENTS
GENERAL INFORMATION .................... DI0A
ENGINE ASSEMBLY ............................. DI01
ENGINE HOUSING ................................ DI02
INTAKE SYSTEM................................... DI03
EXHAUST SYSTEM............................... DI04
LUBRICATION SYSTEM ....................... DI05
COOLING SYSTEM ............................... DI06
FUEL SYSTEM ...................................... DI07
ENGINE CONTROL SYSTEM ............... DI08
ELECTRIC DEVICES AND SENSORS . DI09
DIAGNOSIS ........................................... DI10
5. DI0A-1
SECTION DI0A
00
GENERAL INFORMATION
Table of Contents
CLEANNESS ....................................... DI0A-3 FUEL SYSTEM ................................. DI0A-21
STRUCTURE ...................................... DI0A-8 Fuel supply system ...................... DI0A-22
GENERAL SPECIFICATIONS ........... DI0A-23
ENGINE CONTROLS ....................... DI0A-11
Vehicle specifications ................... DI0A-23
ECU related components .............. DI0A-11
Maintenance ................................ DI0A-26
Engine and sensors ..................... DI0A-12
Electrical components and VEHICLE IDENTIFICATION .............. DI0A-28
pre heating system ...................... DI0A-13
HOW TO USE AND MAINTAIN WORKSHOP
INTAKE SYSTEM ............................. DI0A-14 MANUAL ........................................... DI0A-30
Intake air flow chart ...................... DI0A-15 Consists of workshop manual ...... DI0A-30
INTAKE SYSTEM ............................. DI0A-16 Manual description ...................... DI0A-30
Guidelines for service work
Exhaust air flow chart ................... DI0A-17
safety ........................................... DI0A-31
LUBRICATION SYSTEM .................. DI0A-18 Lifting points ................................. DI0A-36
COOLING SYSTEM ......................... DI0A-19 Tightening torque of standard
bolts .............................................. DI0A-37
Coolant flow chart ........................ DI0A-20
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
6.
7. DI0A-3
CLEANNESS
Cleanness of DI Engine Fuel System and Service Procedures
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure
reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 µm of
preciseness. The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the
HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over
250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side
figure shows the clearance between internal operating elements.
Valve actuator lift: 0.028 mm
Hair
Diameter: 0.40 mm
Operating
clearance:
Nozzle hole 0.002 mm
Diameter:
2.0 mm
Y220_0A035
The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign
material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of
system problems and claims may arise.
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
8. DI0A-4
Job procedures
1. Always keep the workshop and lift clean (especially, from dust).
2. Always keep the tools clean (from oil or foreign materials).
3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system. Wash
your hands and do not wear working gloves.
4. Follow the below procedures before starting service works for fuel system.
Carefully listen the symptoms and problems from customer.
Visually check the leaks and vehicle appearance on the wiring harnesses
and connectors in engine compartment.
Perform the diagnosis proceee with Scan-i
(refer to “DIAGNOSIS” section in this manual).
Locate the fault. If the cause is from fuel system (from priming pump to
injector, including return line), follow the step 1 through step 3 above.
5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps
to perform the diagnosis for DI engine fuel system in “DIAGNOSIS” section in this manual. At this point,
thoroughly clean the related area in engine compartment.
Notice
Clean the engine compartment before starting service works.
Tool kit for high pressure line Took kit for low pressure line Removal tool box and cap kits
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
9. DI0A-5
6. Follow the job procedures. If you find a defective component, replace it with new one.
Disconnect the negative battery cable.
For safety reasons: check pressure is low before opening the HP systems (pipes)
Use special tools and torque wrench to perform the correct works.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail
and each injector should be replaced with new ones. The pipes should be tightened to
specified tightening torques during installation. Over or under torques out of specified
range may cause damages and leaks at connections. Once installed, the pipes have been
deformed according to the force during installtion, therefore they are not reusable.
The copper washer on injector should be replaced with new one. The injector holder bolt
should be tightened to specified tightening torque as well. If not, the injection point may be
deviated from correct position, and it may cause engine disorder.
Plug the disconnected parts with sealing caps, and remove the caps immediately
before replacing the components.
Fuel pressure sensor
High pressure pump Common rail
IMV valve
Transfer pump and high Injection
pressure pump pipe
Fuel temperature sensor
Water separator
Water detection sensor
Priming
pump
Fuel filter
Injector
Cap position
Supply line
Return line
Fuel tank
Y220_0A039
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
10. DI0A-6
7. Plug the removed components with clean and
undamaged sealing caps and store it into the box to
keep the conditions when it was installed.
8. Clear the high pressure offset value by Scan-100 after
replacing the high pressure pump.
Y220_0A040
9. To supply the fuel to transfer line of HP pump press
the priming pump until it becomes hard.
Warning
Do not crank engine before having filled pump.
Priming pump
Y220_0A041
10. Check the installed components again and connect
the negative battery cable. Start the engine and check
the operating status.
11. With Scan-i, check if there are current faults and erase
the history faults.
Note
For details, refer to “DI10 Diagnosis teable”.
Y220_0A042
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
11. DI0A-7
DI Engine and Its Expected Problems and Remedies Can be Caused
by Water in Fuel
SYSTEM SUPPLEMENT AGAINST PARAFFIN SEPARATION.
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on
the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply summer fuel and winter
fuel by differentiating mixing ratio of kerosene and other elements by region and season. However, above phenomenon
can be happened if stations have poor facilities or sell improper fuel for the season.
In case of DI engine, purity of fuel is very important factor to keep internal preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging due to
paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by injector returns
through fuel filter to have an effect of built-in heater (see fuel system).
SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL
As mentioned above, some gas stations supply fuel with
excessive than specified water. In the conventional IDI
engine, excessive water in the fuel only causes dropping
engine power or engine hunting. However, fuel system in
the DI engine consists of precise components so water in
the fuel can cause malfunctions of HP pump due to poor
lubrication of pump caused by poor coating film during high
speed pumping and bacterization (under long period parking).
To prevent problems can be caused by excessive water in
fuel, water separator is installed inside of fuel filter. When
fuel is passing filter, water that has relatively bigger specific
gravity is accumulated on the bottom of the filter.
Y220_0A041
If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel, so the
engine ECU turns on warning light ( ) on the meter cluster and buzzer if water level is higher than a certain level.
Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to
change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.)
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
12. DI0A-8
STRUCTURE
Front view
Rear view
Y220_0A001
1. TVD (Torsional Vibration Damper) 7. Cooling fan pulley & viscos clutch 13. Oil filter housing
2. Air conditioner compressor 8. Aut tensioner pulley 14. Vacuum pump
3. Power steering pump pulley 9. Auto tensioner 15. Crank position sensor
4. Idle pulley 10. Poly-groove belt 16. EGR valve
5. Water pump pulley 11. Cam position sensor 17. Power steering pump
6. Alternator 12. Drive plate (M/T: DMF) 18. EGR center pipe
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
13. DI0A-9
Top view
Y220_0A002
19. Cylinder head cover 24. Fuel pipe 29. Booster pressure sensor
20. Intake manifold 25. Injector 30. Oil separator
21. Water outlet port 26. Fuel return line 31. Oil dipstic
22. Common rail 27. Oil filler cap 32. EGR center pipe
23. Fuel pressure sensor 28. Glow plug
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
14. DI0A-10
Left side view
Right side view
Y220_0A003
33. Cylinder head 38. EGR - RH pipe 42. Turbocharger vacuum modulator
34. Cylinder block 39. Oil separator 43. EGR valve vacuum modulator
35. Oil pan 40. Oil dipstic 44. EGR valve
36. Drain plug 41. HP pump 45. Exhaust manifold
37. Turbocharger
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
15. DI0A-11
ENGINE CONTROLS
ECU RELATED COMPONENTS
Fuel filter
ECU/barometric sensor Cam position sensor (water detection sensor) Accelerator pedal sensor
HFM sensor/intake air Pre heating time relay Main relay
temperature sensor
Y220_0A004
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
16. DI0A-12
ENGINE AND SENSORS
Crankshaft position
Injector Common rail
sensor
Glow plug Fuel pressure sensor
Camshaft position Booster pressure sensor
sensor
HP pump Coolant temperature Knock sensor (2)
sensor
Y220_0A005
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
17. DI0A-13
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM
Glow plug Pre heating time relay
Fuse box Battery
Starter motor Alternator
Y220_0A006
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
18. DI0A-14
INTAKE SYSTEM
Air cleaner assembly HFM sensor Intake duct hose Intake manifold
Intake outlet hose Turbocharger Intercooler Inlet hose
Y220_0A007
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
19. DI0A-15
INTAKE AIR FLOW CHART
Intake valve (in combustion chamber)
Intake manifold
Air cleaner side
Turbo-
charger Engine
(compressor)
HFM sensor
Intake hose (outlet) Intercooler Intake hose (inner)
Y220_0A008
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
20. DI0A-16
INTAKE SYSTEM
Muffler Exhaust manifold EGR valve
Turbocharger Catalytic converter EGR pipe Vacuum modulator
Y220_0A009
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
21. DI0A-17
EXHAUST AIR FLOW CHART
Catalytic converter Exhaust pipe Muffler
Ambient
air
Exhaust gas
Turbocharger
(turbine side)
EGR vacuum
modulator
To turbocharger
booster
Turbocharger
booster vacuum
modulator
Turbocharger booster EGR valve
Exhaust manifold
EGR pipe
Y220_0A010
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
22. DI0A-18
LUBRICATION SYSTEM
Cylinder head cover Oil dipstic PCV valve Engine oil filter
housing
Engine oil pump Oil pan Engine oil cooler Engine oil pressure
switch
Y220_0A011
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
23. DI0A-19
COOLING SYSTEM
Coolant reservoir Water pump
Radiator assembly Cooling fan and fan
clutch
Y220_0A013
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
24. DI0A-20
COOLANT FLOW CHART
Heater
Oil cooler
Coolant reservoir Intake manifold
Thermostat
Coolant outlet port
Water pump
Inner hose Outlet hose
Cooling fan
Radiator
Y220_0A014
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
25. DI0A-21
FUEL SYSTEM
Fuel return hose Fuel pressure pipe Common rail Fuel filter
Injector HP pump Priming pump
Y220_0A015
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
26. DI0A-22
FUEL SUPPLY SYSTEM
Fuel pressure sensor
High pressure pump Common rail
IMV valve
Low and high High
pressure
pressure pump
pipe
Fuel temperature
sensor
Water separator
Label
Fuel filter Prining pump (C21)
Water detection
sensor
Injector
Sensors
HFM sensor
Cam position sensor
Crank position sensor
Fuel tank ECU
Knock sensor etc.
Components:
Supply line
- High pressure fuel pump - Fuel rails - Fuel pressure sensor Return line
- Fuel injectors - Electroc control unit (ECU) - Various sensors and actuators ECU communication line
Y220_0A016
According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor deter-
mines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is gener-
ated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensa-
tion signal to respond to injection starting, pilot injection set values, various operations and variables.
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
27. DI0A-23
GENERAL SPECIFICATIONS
VEHICLE SPECIFICATIONS
Vehicle Dimension (mm)
Y220_0A017
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
28. DI0A-24
Specifications
Systems Items Diesel Remark
General Overall length (mm) 4,720 (4,785) ( ): optional
Overall width (mm) 1,870 item
Overall height (mm) 1,760 (1,830)
Gross vehicle weight (kg) AT: 2450 (2510), MT: 2405 (2465)
Curb weight (kg) AT: 1995 (2055), MT: 1950 (2010)
Min. turning radius (m) 5.6
Ground clearance (mm) 200
Fuel Diesel
Fuel tank capacity 80
Engine Model D27DT
No. of cyl./Compression ratio 5/18:1
Total displacement 2,696 cc
Camshaft arrangement DOHC
Max. power 170 ps/4,000 rpm
Max. torque 34.7 kg•m/1,800 rpm
Injection timing ATDC 4° ± 1°(at idle)
Idle speed 760 ± 50 rpm
Cooling system Water-cooled/forced circulation
Coolant capacity Approx. 11.5
Lubrication Gear pump, forced circulation
Max. oil capacity 9.3
Turbo charger and cooling type Turbo charger, air-cooled
Manual Type Remote control, floor change type
transmission 1st IDI Engine 4.007 DI Engine 4.315
2nd 2.367 2.475
rd
3 1.473 1.536
th
4 1.000 1.000
5th 0.872 0.807
Rev. 3.700 3.591
Automatic Model Electronic
transmission Type Floor change type
1st 2.742 3.595 2.742
2nd 1.508 2.186 1.508
rd
3 1.000 1.405 1.000
th
4 0.708 1.000 0.708
5th - 0.831 -
Rev. 1st 2.429 3.162 2.429
nd
Rev. 2 - 1.926 -
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
29. DI0A-25
Specifications (Cont’d)
Systems Items Diesel Remark
Transfercase Model Part-time ( ): optional item
Type Planetary gear type
Gear ratio High 1.000 : 1
Low 2.483 : 1
Clutch Type Hydraulic [A/T: Torque converter]
Disc type Dry single diaphragm type
[A/T: 3 elements 1 stage 2 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 Inner Disc
Outer Drum (Disc)
Parking brake Cable type (internal expansion)
Suspension 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
Starter capacity (V-kW) Diesel : 12 - 2.2, Gasoline : 12 - 1.8
Alternator capacity (V-A) IDI 12 - 75 (12 - 90)
DI 12 - 140 (12 - 115)
Gasoline 12 - 115
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
30. DI0A-26
MAINTENANCE
Major Components and Service Interval
* Use only Ssangyong Genuine Parts.
Components Daily Weekly Service Interval Remarks
Engine Gasoline O - Initial change: 10,000 km More frequent maintenance is required if
the vehicle is operated under severe
oil and engine Replace at every 15,000 km condition.
oil filter O - Severe conditions?
DI diesel Initial change: 5,000 km
- Frequent low-speed operation as in
engine Replace at every 10,000 km or 12 months stop-and-go traffic
- When most trips are less than 6 km (in
IDI diesel O - winter, less than 16 km)
engine - Driving in sandy, dusty, and salty road
- Driving in mountainous areas
- Extensive idling or high load operation
such as towing a trailer
Coolant O - Replace at every 60,000 km or 3 years
Brake pipe and hose - - Initial inspection: 1,000 km
Inspect at every 20,000 km, replace if necessary
Brake pad, shoe and - - Inspect at every 10,000 km, check or adjust if necessary
disc
Air Gasoline - O Clean at every 15,000 km, If vehicle is operated under dusty or sandy
area, frequently clean and inspect the air
cleaner engine Replace at every 60,000 km cleaner system. If necessary, replace the air
element - O cleaner element.
DI diesel Initial clean: 5,000 km,
engine Clean at every 10,000 km, replace if
IDI diesel - O necessary,
engine Replace at every 30,000 km
Fuel filter Gasoline - - Replace at every 60,000 km
engine
DI diesel - - Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)
engine
IDI diesel - - Replace at every 40,000 km
engine
Auto- 4-speed - - Inspect at every 30,000 km or 1 year, More frequent maintenance is required if the
matic replace if necessary (replace at every vehicle is operated under severe condition.
transmis- 5-speed - - - Driving in unpaved road
60,000 km if the vehicle is operated - Towing a trailer
sion oil
under severe conditions)
Manual transmission - - Inspect at every 10,000 km,
oil Replace at every 60,000 km
Transfer case oil - - Inspect at every 10,000 km,
Replace at every 60,000 km (but, frequently chexk the leaks)
Axle oil - - Replace at every 30,000 km
Air conditioner air - - Replace at every 10,000 km More frequent maintenance is required if the
vehicle is operated under severe condition.
filter - Driving in sandy, dusty, and unpaved road
- Excessive operation of air conditioner or
heater
Spark plug (gasoline - - Replace at every 60,000 km
engine)
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
31. DI0A-27
Lubrication Chart
Lubricant Capacity Classification
Quality API : CG grade or above,
IDI Engine 6.0 ~ 8.0 L
class** ACEA : B2, B3 or B4
Diesel
MB sheet : 229.1/3 (preferable)
DI Engine 6.8 ~ 8.3 L
Viscosity MB sheet No. 224.1
Engine oil
Quality API : SJ grade or above,
G23D 5.5 ~ 7.5 L
class** ACEA : A2 or A3
Gasoline
MB sheet : 229.1/3 (preferable)
G32D/G28D 7.0 ~ 9.0 L
Viscosity MB sheet No. 224.1
IDI Engine 10.5 ~ 11.0 L
MB sheet 325.0
Engine coolant DI Engine 11.0 ~ 12.0 L
(Antifreeze and soft water mixed) G23D 10.0 ~ 10.5 L BASF GLYSANTIN G05-11,
G32D/G28D 11.3 ~ 11.5 L HOECHST GENANTIN SUPER 8023/14
ATF DEXRON® II, III,
Manual transmission oil 4WD: 3.6 L, 2WD: 3.4 L
ATF S-2, S-3, S-4, TOTAL FLUID ATX
Brake/Clutch fluid (Level must be
maintained between MAX & MIN Properly SAE J 1703, DOT 3 or DOT 4
level)
Power steering fluid 1.1 L ATF DEXRON® II, III
4-speed: 9.5 L CASTROL TQ 95
Automatic transmission fluid
5-speed: 8.0 L SHELL or FUCHS ATF 3353
Transfer case fluid IDI Engine Part time 1.2 ~ 1.4 L
ATF DEXRON® II, III,
Part time 1.4 ~ 1.5 L
DI Engine
Full time(TOD) 1.4 ~ 1.5 L
ATF S-4, TOTAL FLUID ATX
Gasoline Full time(TOD) 1.4 ~ 1.5 L
Front 1.4 ~ 1.5 L
Axle fluid SAE 80W/90, API GL-5
Rear 2.2 L
Wheel bearing grease Properly SHELL Retinax “A” grade
Propeller shaft grease - Front/Rear Properly ALVANIA EP#2
* Please contact Ssangyong Dealer for approved alternative fluid.
** In only case not available MB 229.1 or 229.3, API or ACEA oil may be accepted, however it would rather recommend
to shorten the change interval around 30%.
IDI: Indirect Injection
DI: Direct Injection
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
32. DI0A-28
VEHICLE IDENTIFICATION
1. Vehicle identification Number
Vehicle identification number (VIN) is is on the right front
axle upper frame.
[KPTPOA19S1P 122357]
K .. Nation (K: Korea)
P .. Maker Identification (P: Ssangyong Motor Company)
T .. Vehicle Type (T: Passenger car - 4WD)
P .. Line Models (P: Rexton)
O . Body Type (O: 5-door)
A .. Trim Level (A: Standard, B: Deluxe,
Y220_0A018
C: Super deluxe)
1 .. Restraint System (0: No seatbelts, 1: 3-point
seatbelts, 2: 2-point seatbelt)
9 .. Engine Type (9: 3199cc, In-line 6 cylinders, Gasoline E32)
(D: 2874cc, Il-line 5 cylinders, Diesel)
S .. Check Digit (S: All area except North America)
1 .. Model Year (1: 2001, 2: 2002, 3: 2003)
P .. Plant Code (P: Pyungtaek plant)
122357 (Production serial number)
2. Certification Label
The certification label is affixed on the bottom of driver’s side
B-pillar.
Y220_0A019
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
33. DI0A-29
3. Engine Serial Number
The engine serial number is stamped on the lower area of
cylinder block in exhaust manifold side.
Y220_0A020
4. Manual Transmission Number
The transmission label is affixed on the upper area of clutch
housing.
5. Automatic Transmission Number
The transmisson label is affixed on the right area of transmis-
sion housing.
Y220_0A021
6. Transfer Case Number
The transfer case label is affixed on the transfer case housing.
Y220_0A022
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
34. DI0A-30
HOW TO USE AND MAINTAIN WORKSHOP MANUAL
CONSISTS OF WORKSHOP
MANUAL Consists of Small Group
1. Group: The manual is divided in large group like 1. Contents: In small group, included subjects and
engine, transmission, axle and others and this group detailed subjects are described in.
is also divided in small group by vehicle state. 2. General: In the general, summary of the small group
2. Small group: Each small group consists of general, (assembly), function and operational principle,
vehicle service, unit repair and special tool usage. specifications, structure and components, diagnosis
and circuit diagram are described in.
MANUAL DESCRIPTION 3. Vehicle service: Service works on the vehicle like
• The contents of the manual consist of operational replacement of parts and inspection repairs are
principle of system, specifications, diagnosis, removal/ described in the order of repair works with actual
installation on vehicle, inspections, disassembly/ photos and illustrations. Also cautions in service
assembly of removed assembly, special tool usage. works, references and inspection methods after
Not providing simple removal/installation information completion of service are described in.
but focused on to describe much more functions, roles 4. Disassembly and assembly of unit assembly:
and principles of system. Detailed service works like disassembly, inspection,
• Every automotive term like part name on the manual adjustment and assembly on removed component
is the same in parts catalog, technical bulletin and (assembly) are described in with systematic contents
drawings to avoid confusion among them. and photo illustration.
Vehicle model
Abbreviation of small
group and page
Bolded: Notice, Installation Notice,
Note
Describes information on the manual Describes small group name, model
like modification, application date, and publication date
applicable V.I.N
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
35. DI0A-31
GUIDELINES FOR SERVICE WORK SAFETY
General Cautions on Inspection/Service
Notice
During service works, be sure to observe below general
items for your safety.
• For service works, be sure to disconnect battery
negative (-) terminal if not starting and inspection.
• While inspecting vehicle and replacing various
consumable parts, be sure to take caution not to
damage vehicle and injure people.
• Engine and transmission may be hot enough to
burn you. So inspect related locations when they
cooled down enough.
Y220_0A024
• If engine is running, keep your clothing, tools, hair
To maintain and operate the vehicle under optimum state and hands away from moving parts.
by performing safe service works, the service works should • Even when the ignition key is turned off and
be done by following correct methods and procedures. positioned to LOCK, electrical fan can be operated
Accordingly, the purpose of this manual is to prevent dif- while working on near around electrical fan or
ferences that can be caused by personal working method, radiator grille if air conditioner or coolant
skill, ways and service procedures and to allow prompt/ temperature rises.
correct service works. • Every oil can cause skin trouble. Immediately wash
out with soap if contacted.
Note, Notice
• Painted surface of the body can be damaged if
While using this manual, there are a lot of Note or Notice
spilled over with oil or anti-freeze.
having below meaning.
• Never go under vehicle if supported only with jack.
Note • Never near the battery and fuel related system to
Note means detailed description of supplementary flames that can cause fire like cigarette.
information on work procedure or skill. • Never disconnect or connect battery terminal or other
electrical equipment if ignition key is turned on.
Notice
• While connecting the battery terminals, be cautious
Notice means precautions on tool/device or part of polarities (+, –) not to be confused.
damages or personal injuries that can occur during • There are high voltage and currency on the battery
service works. and vehicle wires. So there can be fire if short-
circuited.
However, above references and cautions cannot be inclu-
• Do not park while running the engine in an
sive measures, so should have habits of taking concerns
enclosed area like garage. There can be toxication
and cautions based on common senses.
with CO, so make sufficient ventilation.
• The electrical fan works electrically. So the fan can
be operated unexpectedly during working causing
injuries if the ignition key is not in LOCK position.
Be sure to check whether ignition key is in LOCK
position before work.
• Be careful not to touch hot components like
catalytic converter, muffler and exhaust pipe when
the engine is running or just stopped. They may
burn you badly.
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
36. DI0A-32
Guidelines on Engine Service Fuel and lubrication system
Painted surface of the body can be damaged or rubber
To prevent personal injuries and vehicle damages that can
products (hoes) can be corroded if engine oil and fuel are
be caused by mistakes during engine and unit inspection/
spilled over. If spilled over engine, foreign materials in air
repair and to secure optimum engine performance and
can be accumulated on the engine damaging fuel system.
safety after service works, basic cautions and service work
guidelines that can be easily forgotten during engine ser- • If work on the fluid system such as fuel and oil, working
vice works are described in. area should be well ventilated and mechanic should
not smoke.
Cautions before service works • Gasket or seal on the fuel/lubrication system should
• Before work on engine and each electrical equipment, be replaced with new and bolts and nuts should be
be sure to disconnect battery negative (-) terminal. tightened as specified.
• Before service works, be sure to prepare the works by • After removal/installation works, be sure to check
cleaning and aligning work areas. whether there is leak on the connecting section.
• Always position the ignition switch to OFF if not
required. If not, there can be electrical equipment If fine dust or foreign material enters into DI engine’s
damages or personal injuries due to short-circuit or fuel system, there can be serious damages between
ground by mistake. HP pump and injectors. So, be sure to cover removed
• There should be no leak from fuel injection system fuel system components with cap and protect removed
(HP pump, fuel hose, high pressure pipe) of the D27DT parts not to be contaminated with dirt. (Refer to clean-
engine. So they should be protected from foreign ness in this manual while working on DI engine fuel
materials. system)
• While removing the engine, do not position the jack
and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine. Electrical equipment
Engine and accessories Electrical equipment should be handled more carefully.
Engine has a lot of precise portions so tightening torque Currently, the engine is equipped with a lot of electrical
should be correct during disassembly/assembly and re- equipments so there can be engine performance drops,
moval/installation and service work should be done in clean incomplete combustion and other abnormals due to short
ways during disassembly/assembly. and poor contact. Mechanics should well aware of vehicle’s
electrical equipment.
Maintaining working area clean and cautious service ad-
ministration is essential element of service works while • If have to work on the electrical equipment, be sure to
working on the engine and each section of the vehicle. So disconnect battery negative (-) terminal and position
the mechanics should well aware of it. the ignition switch to off if not required.
• While removing the engine, related parts (bolts, • When replacing electrical equipment, use the same
gaskets, etc.) should be aligned as a group. genuine part and be sure to check whether ground or
connecting portions are correctly connected during
• While disassembling/assembling internal components
installation. If ground or connecting portion is loosened,
of the engine, well aware of disassembly/assembly
there can be vehicle fire or personal injury.
section in this manual and clean each component with
engine oil and then coat with oil before installation.
• While removing engine, drain engine oil, coolant and
fuel in fuel system to prevent leakage.
• During service work of removal/installation, be sure to
check each connected portions to engine not to make
interference.
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
37. DI0A-33
During Service Work - Inspection
1. Before lifting up the vehicle with lift, correctly support the
lifting points and lift up.
2. When using a jack, park the vehicle on the level ground
and block front and rear wheels. Position the jack under
the frame and lift up the vehicle and then support with
chassis stand before service work.
Y220_0A025
3. Before service work, be sure to disconnect battery
negative (-) terminal to prevent damages by bad wire and
short.
Y220_0A026
4. If service from interior of the vehicle, use protection cover
to prevent damage and contamination of seat and floor.
5. Brake fluid and anti-freeze can damage painted surface
of body. So carefully handle them during service work.
Y220_0A027
6. Use recommended and specified tools to increase
efficiency of service work.
7. Use only genuine spare parts.
Y220_0A028
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
38. DI0A-34
8. Never reuse cotter pin, gasket, O-ring, oil seal, lock
washer and self-locking nut. Replace them with new.
If reused, normal functions cannot be maintained.
9. Align the disassembled parts in clean according to
disassembling order and group for easy assembling.
10. According to installing positions, the bolts and nuts have
different hardness and design. So be careful not to mix
removed bolts and nuts each other and align them
according installing positions.
11. To inspect and assemble, clean the parts.
12. Securely clean the parts that related with oil not to be
Y220_0A029 affected by viscosity of oil.
13. Coat oil or grease on the driving and sliding surfaces
before installing parts.
14. Use sealer or gasket to prevent leakage if necessary.
15. Damaged or not, never reuse removed gasket. Replace
with new and cautious on installing directions.
16. Tighten every bolt and nut with specified torque.
17. When service work is completed, check finally whether
the work is performed properly or the problem is solved.
18. If work on the fuel line between priming pump and injector
(including return line), be sure to cover the removed parts
with cap and be careful not to expose the connecting
Y220_0A030
passage and removed parts to external foreign materials
or dust. (Refer to cleanness.)
19. If remove high pressure fuel supply pipe between HP pump
and fuel rail and high pressure fuel pipe between fuel rail
and each injector, be sure to replace them with new.
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
39. DI0A-35
During Service Work for Electric
Devices
Notice
Be careful not to modify or alter electrical system and
electrical device. Or there can be vehicle fire or serious
damage.
1. Be sure to disconnect battery negative (-) terminal during
every service work. Before disconnecting battery negative
(-) terminal, turn off ignition key. Y220_0A031
2. Replace with specified capacity of fuse if there is bad,
blown or short circuited fuse. If use electrical wire or steel
wire other than fuse, there can be damages on the various
electrical systems. If replaced with over-capacity fuse,
there can be damages on the related electrical device
and fire.
3. Every wire on the vehicle should be fastened securely
not to be loosened with fixing clip.
4. If wires go through edges, protect them with tape or other
materials not to be damaged.
5. Carefully install the wires not to be damaged during
installation/removal of parts due to interference.
6. Be careful not to throw or drop each sensor or relay.
7. Securely connect each connector until hear a “click”
sound.
Y220_0A032
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
40. DI0A-36
LIFTING POINTS
Lifting Positions
1. 4-post lift
As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move during
working.
Notice
During lifting, be sure to check whether vehicle is empty.
• Board-on lift connection device installed in front of vehicle should be positioned in front of sill locating
under the front door.
• Install lift connecting device on the edge of front and rear of board-on lift.
Warning
• Be sure to use attachment during lifting to prevent the lift from contacting with body floor.
• While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear. When
fixing the lift floor, be careful not to contact with brake tube and fuel lines.
2. Safety jack and safety stand
If lift up the vehicle with safety jack and stand, should be more
careful during works.
Warning
• Never be under the vehicle if supported with only jack.
If have to be under the vehicle, be sure to use safety
block.
• Use wheel block in front and rear of every wheel.
Y220_0A033
CHANGED BY GENERAL INFORMATION
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
41. DI0A-37
TIGHTENING TORQUE OF STANDARD BOLTS
Tightening Torque By Bolt Specification
Tightening Torque (kg.cm)
Bolt
Pitch Standard Tightening Torque Max. Allowable Tightening Torque
Diameter
4T 7T 9T 4T 7T 9T
M3 0.5 5 9 13 7 12 17
M4 0.7 12 20 30 16 27 40
M5 0.8 24 40 57 32 53 77
M6 1.0 41 68 99 55 91 130
M8 1.25 88 160 230 130 210 310
M10 1.25 190 330 470 260 430 620
1.5 190 310 450 250 420 600
M12 1.25 350 580 840 460 770 1,100
1.75 330 550 790 440 730 1,000
M14 1.5 550 910 1,300 730 1,200 1,900
M16 1.5 830 1,100 2,000 1,100 1,900 2,700
M18 1.5 1,200 2,000 2,900 1,600 2,700 3,800
M20 1.5 1,700 2,800 4,000 2,200 3,700 5,300
M22 1.5 2,300 3,800 5,400 3,000 5,000 7,200
M24 1.5 2,900 4,900 7,000 3,900 6,500 9,400
2.0 2,800 4,700 6,800 3,800 6,300 9,100
Y220_0A034
1. Metric bolt strength is embossed on the head of each 3. Determine extra proper tightening torque if tightens
bolt. The strength of bolt can be classified as 4T, 7T, with washer or packing.
8.8T, 10.9T, 11T and 12.9T in general. 4. If tightens bolts on the below materials, be sure to
2. Observe standard tightening torque during bolt determine the proper torque.
tightening works and can adjust torque to be proper • Aluminum alloy: Tighten to 80 % of above torque
within 15 % if necessary. Try not to over max. table.
allowable tightening torque if not required to do so.
• Plastics: Tighten to 20 % of above torque table.
GENERAL INFORMATION CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
44. DI01-1
SECTION DI01
00
ENGINE ASSEMBLY
Table of Contents
STRUCTURE AND FUNCTION DESCRIPTIONS ........ DI01-3
D27DT engine ........................................................ DI01-3
Engine performance curve ..................................... DI01-8
General diagnosis ................................................. DI01-10
DIAGNOSTIC INFORMATION AND PROCEDURE .. DI01-15
Oil leak diagnosis .................................................. DI01-15
Compression pressure test .................................. DI01-16
Cylinder pressure leakage test ............................ DI01-18
Tightening torque .................................................. DI01-19
REMOVAL AND INSTALLATION .............................. DI01-22
Engine mounting ................................................... DI01-22
DISASSEMBLY AND REASSEMBLY ........................ DI01-32
Components and special tools ............................. DI01-32
ENGINE ASSEMBLY CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
45.
46. DI01-3
STRUCTURE AND FUNCTION DESCRIPTIONS
D27DT ENGINE
Major Components in Engine and Engine Compartment
The advanced electronically controlled D27DT engine that has high pressure fuel system has been introduced to this
vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
Y220_01001
1. Coolant reservoir 6. Fuse box 11. EGR valve
2. FFH device 7. Battery 12. Air cleaner assembly
3. Brake fluid reservoir 8. Fuel filter 13. Turbo charger
4. Washer fluid reservoir 9. Power steering pump 14. Oil dipstick
5. Common rail 10. Priming pump
ENGINE ASSEMBLY CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
47. DI01-4
Engine Structure
Front View
Rear View
Y220_01002
1. TVD (Torsional Vibration Damper) 7. Viscos fan clutch 13. Oil filter
2. Air conditioner compressor 8. Auto tensioner pulley 14. Vacuum pump
3. Power steering pump pulley 9. Auto tensioner 15. Crank position sensor
4. Idle pulley 10. Poly-grooved belt 16. EGR valve
5. Coolant pump pulley 11. Cam position sensor 17. Power steering pump
6. Alternator 12. Drive plate (MT: DMF) 18. EGR to center pipe
CHANGED BY ENGINE ASSEMBLY
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
48. DI01-5
Top View
Y220_01003
19. Cylinder head cover 24. Fuel pipe 29. Booster pressure sensor
20. Intake manifold 25. Injector 30. PCV valve and oil separator
21. Water outlet port 26. Fuel return line 31. Oil dipstick
22. Common rail 27. Oil filler cap 32. EGR-LH pipe
23. Fuel pressure sensor 28. Glow plug
ENGINE ASSEMBLY CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
49. DI01-6
Left Side View
Right Side View
Y220_01004
33. Cylinder head 38. EGR-RH pipe 42. Turbo charger booster vacuum
34. Cylinder block 39. PCV valve and oil separator modulator
35. Oil pan 40. Oil dipstick 43. EGR valve vacuum modulator
36. Drain plug 41. High pressure pump 44. EGR valve
37. Turbo charger 45. Exhaust manifold
CHANGED BY ENGINE ASSEMBLY
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN