SsangYong Rexton. Manual - part 46

DI03-18

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

INTAKE SYSTEM

DI ENG SM - 2004.4

Intake Manifold - Removal/Installation

Preceding Work: Disconnection of negative battery cable

1. Lift up the vehicle and remove the skid plate.

Y220_03033

Y220_03034

Y220_03035

Y220_03036

Notice

• Replace the pipes (2, 3) at both sides of EGR cooler

(1) and gaskets with new ones.

• Make sure that the convex surface of gasket is facing

to the pressurized direction.

2. Open the coolant reservoir cap and remove loosen the

drain cock to drain the coolant.

3. Remove the air inlet hose (1) from intake manifold.

4. Loosen the clamp and remove the coolant inlet hose (2).

5. Remove the coolant inlet port housing.

6. Remove the vacuum hose from EGR valve.

7. Remove the EGR valve mounting bolts and gasket.

Remove the EGR exhaust pipe (primary) mounting bolts
and gasket.

DI03-19

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

INTAKE SYSTEM

DI ENG SM - 2004.4

8. Remove the brackets and connectors from top section of

the engine.

- Vacuum hose bracket in turbo charger

- Booster pressure sensor

- Main wiring bracket

- Ground cable bracket

- Fuel pressure sensor connector

9. Unscrew the bolts and remove the vacuum modulator

bracket.

Tightening torque

9.0 Nm

10. Remove the HP pump fuel supply line bolts.

11. Remove the HP pump fuel supply line mounting bracket.

12. Remove the HP pump fuel return line at fuel filter.

13. Remove the injector return line at HP pump.

Y220_03037

Y220_03038

Y220_03039

Notice

• Be careful not to damage the pipes to HP pump.

• Plug the fuel return port of the HP pump with a

sealing cap.

Notice

• Plug the openings of pipes and ports with sealing

caps to keep the cleanness of the fuel system.

• Replace the pipes with new one once removed.

DI03-20

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

INTAKE SYSTEM

DI ENG SM - 2004.4

14. Remove the intake manifold mounting bolts.

15. Lift up the vehicle and remove the propeller shaft joint

bolts.

16. Unscrew the bolt in oil filter and remove the intake

manifold and gasket.

17. Install in the reverse order of removal.

Y220_03040

Y220_03041

Tightening torque

25 ± 2.5 Nm

Notice

1. Check the length of the bolts before installation.

M8 x 45: 6EA

M8 x 130: 6EA

Notice

• Replace the gasket with new one.

• Make sure that the residual coolant in intake

manifold gets into the inside of inlet port.

Notice

• Replace the gasket with new one.

• If replaced only gasket without any other service

operation, completely remove the coolant and other
contaminants from the engine before installation.

EXHAUST SYSTEM

SECTION 

DI04