SsangYong Rodius / Stavic 2004–2007 Service & Repair Manual Set

Use the system procedures alongside the corresponding circuits and connector references when tracing faults between sensors, control units, and actuators. Match the engine, transmission, and section revision to the vehicle’s configuration.

D27DT coverage limit: The complete-engine removal and separate engine-overhaul sections listed in the diesel contents are missing from this PDF. Internal component repairs are included in the Engine Housing chapter. The separate wiring-diagram publication covers LHD vehicles.

PDF Search, Bookmarks, and Diagram Detail

Text navigation and wiring labels: Body text is searchable, and embedded bookmarks provide navigation through the main sections and many individual procedures. Some diagram labels are embedded as graphics and cannot be located with text search. Small pin numbers and wire codes require zooming.

One printable 1,923-page PDF is supplied in a ZIP download. The total includes ten memo pages, one blank page, and five duplicated technical pages, along with the section dividers and contents pages.

Engine, Drivetrain, and Vehicle-System Repairs

The following is a selected content overview. Additional topics include A/V-system component removal and exterior-lamp aiming.

• M162 gasoline engine: Step-by-step engine-removal and cylinder-head procedures, compression and leakage diagnosis, cooling-system tests, and MSE 3.63D engine controls.

• D27DT diesel engine: Cylinder-head, camshaft, crankshaft, piston, and timing-drive service, plus common-rail diagnosis, injector C2I coding, and MDP learning.

• Transmission and TOD: Automatic-transmission teardown and adjustment, TSM54/52 inspection and shim selection, clutch bleeding, and transfer-case repair and coding.

• Chassis and brakes: Steering-pressure checks, suspension and front/rear axle service, wheel alignment, propeller-shaft inspection, brake repairs, and ABS/ESP diagnosis.

• Heating and A/C: FATC self-diagnosis, sensor and actuator service, rear A/C components, circuit diagrams, and fuel-fired and PTC heater service.

• Body and restraints: Airbag/SDM diagnosis, seat and belt removal, door and glass mechanisms, sunroof and instrument-panel service, body jack points, dimensions, and panel gaps.

• Vehicle electronics: Instrument-cluster and RK STICS diagnosis, rain-sensing wipers, parking aid, component locators, wiring diagrams, and connector identification.

This material is best suited to professional technicians and experienced mechanics with proper shop and diagnostic equipment, especially for unit disassembly, pressure testing, and control-unit coding.

M162 Internal Repair and Engine Controls

Internal engine work extends to valves, camshafts, the chain tensioner and guide rails, crankshaft seals, connecting rods, pistons and rings, the oil pump, oil galleries, and crankcase. Machining and inspection data address cylinder bores and crankcase/cylinder-head mating surfaces.

The timing-chain replacement section warns that uncontrolled chain movement during crankshaft rotation can tangle and damage the chain.

Engine-control coverage includes ignition, injectors, the fuel rail and regulator, and electronic throttle safety functions. Oxygen and knock sensors, camshaft actuation, immobilizer operation, cooling-fan control, and ECM diagnosis are also addressed.

Listed engine tools include compression pressure tester A9912 0012B (001 589 76 21 00), timing-chain assembly tool A9913 0010B (000 589 58 43 00), and fuel-pressure gauge A9922 0012A (103 589 00 21 00).

D27DT Fuel Diagnosis and Component Repair

The diesel chapters include cylinder-head and valve work, crankshaft bearing selection, piston and ring inspection, and timing-chain installation. High-pressure and vacuum pump service, turbocharger/EGR diagnosis, cooling and lubrication repairs, and preheating circuits extend the component coverage.

SCAN-100 diagnosis: Procedures cover trouble-code reading, live sensor data, actuator checks, and ECU identification. Fuel-system diagnosis supports fault isolation before parts replacement through transfer-line checks, rail-pressure testing, static and dynamic injector back-leak tests, and high-pressure pump testing.

The C2I material connects correct injector coding after injector or ECU replacement with engine power and combustion quality. MDP learning addresses precise control of small pilot-injection quantities as injectors age.

ECU replacement procedures also address variant data, multi-calibration, and immobilizer coding. Rail-pressure reset instructions accompany fuel-system component replacement.

Automatic, Manual, and Transfer-Case Service

The 722.6-family automatic-transmission material includes torque-converter operation, planetary power flow, electronic controls, and hydraulic circuits. Internal procedures cover the electro-hydraulic shift plate, clutch and brake assemblies, teardown, reassembly, measurement, and adjustment.

Application identification distinguishes D27DT 2WD/4WD and E3.2 gasoline 4WD installations. TCU diagnosis and SCN coding are included, and converter handle W 126 589 01 62 00 is identified for removal and installation work.

TSM54/52 sectional views distinguish 2WD and 4WD units. The instructions call for shim adjustment after replacement of a housing, counter gear, input shaft, or output shaft.

TOD documentation adds speed-sensor and shift-motor service, TCCU fault diagnosis, and control-unit coding matched to the vehicle configuration.

Steering, ABS/ESP, and LHD Circuit References

The power-steering pipe-installation caution links reversed high- and low-pressure pipes with abnormal steering-wheel vibration and system damage.

ABS/ESP coverage extends to electrical and hydraulic circuits, scan-tool forced operation, and ESP sensor initialization. The ESP bleeding procedure specifies a compressor-fed fluid-supply device.

The LHD wiring section supplies connector, ground, splice-pack, and engine-room fuse-box locations. Circuit examples include Starting & Charging, D27DT EU IV ECU, GSL G32 ECU, 5-speed TCU, TOD, and FATC. Connector identification and pin-position views support circuit tracing.

Exploded assembly views, component section views, and diagnostic charts accompany the repair material. Component-specific torque tables, fluid data, pressure-test values, electrical specifications, wear limits, clearances, and adjustment data are provided with the related chapters.

Heavy vehicle lifting, high-pressure diesel fuel, hydraulic brake and steering work, air-conditioning refrigerant, rotating engine parts, and airbag service require the specified safety precautions and suitable workshop equipment.

Compression-Test Data Preview

For the M162, the compression-test table gives a normal pressure range of 10–14 bar at an engine temperature of 80°C (176°F), with a maximum difference of 1.5 bar between cylinders.

For the D27DT at 80°C, the corresponding data lists 32 bar as normal and 18 bar as the minimum. The maximum permitted difference between cylinders is 3 bar.