SsangYong Rexton. Manual - part 2

DI0A-1

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GENERAL INFORMATION

DI ENG SM - 2004.4

GENERAL INFORMATION

 00

SECTION DI0A

Table of Contents

CLEANNESS ....................................... DI0A-3

STRUCTURE ...................................... DI0A-8

ENGINE CONTROLS ....................... DI0A-11

ECU related components .............. DI0A-11

Engine and sensors ..................... DI0A-12

Electrical components and
pre heating system ...................... DI0A-13

INTAKE SYSTEM ............................. DI0A-14

Intake air flow chart ...................... DI0A-15

INTAKE SYSTEM ............................. DI0A-16

Exhaust air flow chart ................... DI0A-17

LUBRICATION SYSTEM .................. DI0A-18

COOLING SYSTEM ......................... DI0A-19

Coolant flow chart ........................ DI0A-20

FUEL SYSTEM ................................. DI0A-21

Fuel supply system ...................... DI0A-22

GENERAL SPECIFICATIONS ........... DI0A-23

Vehicle specifications ................... DI0A-23

Maintenance ................................ DI0A-26

VEHICLE IDENTIFICATION .............. DI0A-28

HOW TO USE AND MAINTAIN WORKSHOP
MANUAL ........................................... DI0A-30

Consists of workshop manual ...... DI0A-30

Manual description ...................... DI0A-30

Guidelines for service work
safety ........................................... DI0A-31

Lifting points ................................. DI0A-36

Tightening torque of standard
bolts .............................................. DI0A-37

DI0A-3

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GENERAL INFORMATION

DI ENG SM - 2004.4

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.

Cleanness of DI Engine Fuel System and Service Procedures

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.

CLEANNESS

Y220_0A035

Hair

Nozzle hole

Valve actuator lift: 0.028 mm

Diameter: 0.40 mm

Operating
clearance:
0.002 mm

Diameter:

2.0 mm

DI0A-4

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GENERAL INFORMATION

DI ENG SM - 2004.4

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.

Job procedures

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