SsangYong Rexton. Manual - part 20

DI01-34

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01048

Accessories - Removal and Installation

PCV valve and oil separator

EGR valve pipe (LH, Center, RH)

Power steering pump

Cooling fan clutch

Auto tensioner

Alternator

Turbo charger

Fuel return hose

Cable and connector

Oil filter assembly

EGR valve

Start motor

Mounting bracket

Air conditioner compressor

DI01-35

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

• The engine accessories can be removed without any specific order. In general, remove the components from top

to bottom. However, be careful not to splash the lubricants to engine and body when disassembly. Especially,
avoid getting into other components.

Removal and Installation Order of Major Accessories

1. Vacuum Modulator

2. Engine Cables and Connectors

3. Fuel Hoses

3-1. EGR Valve Assembly

4. Oil Filter Assembly

4-1. Belt Tensioning Assembly

5. Power Steering Pump Assembly

6. Air Conditioner Compressor Assembly

7. PCV Valve Assembly

8. Turbo Charger

Oil Dipstick Tube

Alternator Assembly

+

* Camshaft Position Sensor

* Crankshaft Position Sensor

* Injector Fuel Line Connector

* Glow Plug Connector

* Fuel Return Hose

* High/Low Pressure Hoses in HP Pump

* Ground Cables

* Fuel Pressure Sensor Connector

* Booster Pressure Sensor Connector

* Knock Sensor Connector

* Coolant Temperature Sensor Connector

* HP Pump: Fuel Temperature Sensor (Green)

IMV (Brown)

DI01-36

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

1. Remove the fuel pipes.

A. Remove the fuel supply pipes between each

cylinder and common rail with a special tool.

Installation Notice

B. Remove the high fuel pressure pipe mounting bolts

with a special tool.

- High fuel pressure supply pipe at common rail

side

Installation Notice

Y220_01049

Y220_01050

Y220_01051

Y220_01052

Notice

1. Plug the openings of injector nozzle and common

rail with sealing caps after removed the fuel pipes.

Tightening torque

40 ± 4.0 Nm

2. Replace the pipes with new ones. Be careful not

to be mixed the fuel pipes because the pipe
appearance of #1 and #3 cylinders and #2 and #4
are same each other.

Tightening torque

40 ± 4 Nm

No. 1

No. 3

No. 2

No. 4

No. 5

DI01-37

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01055

C. High fuel pressure supply pipe at HP pump side

Installation Notice

D. Unscrew the bracket mounting bolts and remove the

high fuel pressure supply pipes.

Note

Special tool: Fuel pipe remover and installer

Tightening torque

40 ± 4.0 Nm

Y220_01054

Y220_01053