SsangYong Rexton. Manual - part 3

DI0A-5

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EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

6. Follow the job procedures. If you find a defective component, replace it with new one.

Y220_0A039

Fuel pressure sensor

Common rail

Injection
pipe

Injector

High pressure pump

IMV valve

Transfer pump and high

pressure pump

Fuel temperature sensor

Fuel tank

Fuel filter

Priming
pump

Water separator

Water detection sensor

Disconnect the negative battery cable.

Plug the disconnected parts with sealing caps, and remove the caps immediately

before replacing the components.

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.

Supply line

Return line

Cap position

Use special tools and torque wrench to perform the correct works.

For safety reasons: check pressure is low before opening the HP systems (pipes)

DI0A-6

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AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

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.

9. To supply the fuel to transfer line of HP pump press

the priming pump until it becomes hard.

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_0A040

Y220_0A041

Y220_0A042

Priming pump

Warning

Do not crank engine before having filled pump.

DI0A-7

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

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.

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).

DI Engine and Its Expected Problems and Remedies Can be Caused
by Water in Fuel

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.)

DI0A-8

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EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

Front view

Rear view

Y220_0A001

STRUCTURE

1. TVD (Torsional Vibration Damper)

2. Air conditioner compressor

3. Power steering pump pulley

4. Idle pulley

5. Water pump pulley

6. Alternator

7. Cooling fan pulley & viscos clutch

8. Aut tensioner pulley

9. Auto tensioner

10. Poly-groove belt

11. Cam position sensor

12. Drive plate (M/T: DMF)

13. Oil filter housing

14. Vacuum pump

15. Crank position sensor

16. EGR valve

17. Power steering pump

18. EGR center pipe