SsangYong Stavic / SsangYong Rodius (2005 year). Service manual — part 67
DI0A-3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
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-100
(refer to “DI10 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 “DI10 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
DI0A-4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
6. Follow the job procedures. If you find a defective component, replace it with new one.
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-5
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
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-100, check if there are current faults and
erase the history faults.
Note
For details, refer to “DI10 Diagnosis table”.
Warning
Do not crank engine before having filled pump.
Priming pump
DI0A-7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
Front view
Rear view
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. Viscos clutch
8. Auto tensioner pulley
9. Auto tensioner
10. Poly-groove belt
11. Cam position sensor
12. Drive plate (M/T: DMF)
13. Oil filter
14. Vacuum pump
15. Crank position sensor
16. EGR valve
17. Power steering pump
18. EGR center pipe
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