2004–2007 SsangYong Rodius Service Manual (P/N M162 GSL ENG SM)

• 1,923-page PDF - M162 gasoline engine: 262 pages; D27DT diesel engine and diagnosis: 536 pages; chassis, drivetrain, electrical, HVAC, and body: 1,053 pages; LHD electrical wiring diagrams: 72 pages.
• Covers M162.990 3.2L DOHC six-cylinder gasoline-engine repair, including compression and leakage diagnosis, engine removal, cylinder-head service, camshaft timing, timing-chain replacement, crankshaft sealing, valve train, pistons, connecting rods, lubrication, cooling, and MSE 3.63D controls.
• Documents D27DT 2.7L XDi five-cylinder diesel removal and overhaul, cylinder head, camshafts, timing drive, high-pressure and vacuum pumps, turbocharger/EGR, common-rail fuel service, SCAN-100 fault diagnosis, injector C2I coding, MDP learning, and pressure-leakage testing.
• Provides internal service for the DC 5-speed automatic transmission in W5A330/W5A580 and 2WD/4WD configurations, plus TSM54/52 manual-transmission disassembly, shim adjustment, clutch bleeding, TOD transfer-case repair and coding, propeller shafts, and front/rear axles.
• Extends beyond the powertrain to steering, brakes, ABS/ESP, suspension and alignment, FATC air conditioning, fuel-fired and PTC heaters, instrument cluster, STICS/RK, rain-sensing wipers, parking aid, airbags, seats, doors, body dimensions, and panel-gap data.
• Supplies component locators, exploded assembly and section views, hydraulic and electrical circuits, diagnostic charts, torque tables, fluid data, wear and clearance limits, pressure-test values, adjustment specifications, and identified factory special tools.

Rodius/Stavic Coverage and Section Revisions

This factory workshop-manual set covers the SsangYong Stavic/Rodius systems represented by 2004.09 and 2005.07 section revisions. The gasoline pages carry the identifier M162 GSL ENG SM - 2005.7, while the diesel material is marked DI ENG SM - 2004.9. The identification chapter decodes LHD and RHD model designators, engine codes, model-year characters from 2004 through 2008, and production serial numbers. These identifiers should be matched to the vehicle rather than read as blanket coverage for every configuration.

The transmission pages explain DC automatic-transmission part, serial, and variant markings. Separate 2005-and-later chapters are provided for electrical-system layout, the meter cluster, and interior switches. Because the material moves from maintenance into unit overhaul, pressure testing, scan-tool diagnosis, control-unit coding, and restraint-system service, it is best suited to professional technicians and experienced mechanics with proper shop and diagnostic equipment.

M162 and D27DT Engine Repair

The M162 section is much broader than a set of engine specifications. It covers on-vehicle repair and internal work on the cylinder head, camshafts, valves, timing chain, chain tensioner and guide rails, crankshaft seals, connecting rods, piston rings, oil pump, oil galleries, and crankcase. Machining and inspection data address cylinder bores and crankcase/cylinder-head mating surfaces. Engine-control coverage reaches ignition, injectors, the fuel rail and regulator, electronic throttle safety functions, oxygen and knock sensors, camshaft actuation, immobilizer, cooling-fan control, and ECM diagnosis.

The D27DT material adds engine removal and overhaul, high-pressure common-rail fuel-system work, turbocharger and EGR service, cooling and lubrication repairs, preheating circuits, and a large fault-diagnosis section. SCAN-100 procedures cover trouble-code reading, live sensor data, actuator checks, ECU identification, injector correction coding, and guided fuel-system tests. The C2I and MDP chapters matter after injector or ECU replacement because the manual connects correct coding and learning to engine power, combustion quality, and small-quantity injection control.

Representative factory tools are identified by both tool name and number. Engine examples 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). The automatic-transmission section specifies converter handle W 126 589 01 62 00.

722.6, TSM54/52, TOD, Chassis, and Electrical

Automatic-transmission coverage identifies D27DT 2WD/4WD and E3.2 4WD applications. It follows the 722.6-family unit through power flow, electronic controls, hydraulic circuits, torque converter, shift plate, clutch and brake assemblies, removal, teardown, reassembly, measurement, and adjustment. The TSM54/52 chapter includes 2WD and 4WD sectional views, diagnosis, removal, complete disassembly/reassembly, inspection, and shim selection. TOD material adds transfer-case internal repair, speed-sensor and shift-motor service, TCCU fault diagnosis, and control-unit coding.

Chassis chapters cover power-steering pressure checks and bleeding, front and rear suspension, wheel alignment, propeller-shaft inspection, foundation brakes, parking brake, and ABS/ESP electrical and hydraulic diagnosis. Body and cabin sections address airbag/SDM faults, seat and belt removal, door and glass mechanisms, sunroof, instrument panel, body jack points, structural dimensions, and panel gaps. HVAC material includes FATC self-diagnosis, circuit diagrams, sensor and actuator service, rear air-conditioning components, the fuel-fired heater, and PTC heating.

The separate wiring section is marked LHD. It provides connector, ground, splice-pack, and engine-room fuse-box locations along with circuits for starting/charging, D27DT EU IV ECU, GSL G32 ECU, the 5-speed TCU, TOD, and FATC. Connector identification and pin-position views support circuit tracing without turning the description into a wiring-index dump.

Manual-Specific Repair Cautions and Factory Data

The manual flags several model-specific repair traps. During M162 valve-train work, the loose timing chain must be controlled while the crankshaft is turned; otherwise the chain can tangle and be damaged. In the power-steering section, reversing the high- and low-pressure pipes is linked to abnormal steering-wheel vibration and system damage.

Component-specific torque tables, fluid specifications, pressure tests, electrical values, wear limits, clearances, and adjustment data are placed with the related repair 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.