SsangYong Rexton. Service manual — part 81
DI07-40
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
2. Loosen the bracket bolts and disconnect the hose from
the drain plug.
3. Remove the fuel filter.
4. Install in the reverse order of removal.
5. Press the priming pump until it becomes rigid to deliver
the fuel to the transfer line of HP pump.
1. Disconnect the fuel supply and return hoses.
Removal and Installation
Y220_07084
Y220_07085
Notice
• Plug the openings of hoses and fuel filter with
sealing caps.
• Ensure that the hoses are connected to correct
positions.
DI07-41
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
Y220_07087
Priming Pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or dam-
age to each component. Therefore, the hand priming pump is
installed to fill filter.
When the vehicle is under the conditions as below, press the
priming pump until it becomes rigid before starting the engine.
Conditions for using Priming Pump
- After run out of fuel
- After draining the water from fuel filter
- After replacing the fuel filter
Relations Between Pressure and Temperature In Fuel Transfer Line
Y220_07086
Notice
When the fuel filter is replaced, the fuel in the fuel tank should be transferred to the filter by using priming
pump. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine.
• The fuel transfer line is the line between fuel tank and HP pump inlet port. The pressure on this line affects the
lifetime of fuel filter.
• Temperature of fuel transfer line
- HP pump inlet temperature is less than 80°C.
- The temperature of fuel pump inlet is up to 80°C.
And, diesel fuel has lubrication effects due to its viscosity. Thus, the fuel is also used for pump lubrication.
However, this lubrication performance drops as the temperature rises. Accordingly, when the fuel temperature is
over 50°C, 100% of fuel is returned to fuel tank to cool down the temperature and then increase the lubrication
effects of fuel and prevent heat damage on each section of high fuel pressure line.
to fuel filter
from fuel tank
Pump inlet pressure
Fuel transfer
line
Pump
Ventury
Pump outlet pressure
Injector No.1 return pressure
Injector
Injector No.5 return pressure
High pressure common rail
DI07-42
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
High Pressure Accumulator (Common Rail)
Y220_07088
Description
The high pressure accumulator reserves the high pressure fuel. Simultaneously, the pressure changes due to the
delivery from HP pump and the fuel injection is diminished by rail volume. This high pressure accumulator is commonly
used in all cylinders. Even when a large amount of fuel leaks, the common rail maintains its internal pressure. This
ensures that the injection pressure can be maintained from when the injector opens.
Function
• Relieve the pressure pulsation
• Provide pressure information to ECU (fuel pressure sensor)
Specifications
• Material: Forged Steel
• Dimension: - Volume: 22 ± 1cc
- Length: Max. 397.7 mm
- Outer diameter: 25.3 mm
• Fuel pressure sensor Integrated type
- Sensor input voltage: 5 ± 0.1V
- Sensor output signal voltage: - 4.055 ± 0.125 V @ 1600 ± 15 bar
- 0.5 ± 0.04 V @ 0 bar
• Operating pressure range
- Normal condition: 0 ~ 1600 bar
- Max. Overpressure: 2100 bar
• Ambient temperature: - available within -40°C ~ 125°C
- Spontaneous max. temperature after engine stops: 140°C (acceptable against total 15 hours)
• Fluid temperature: -40 ~ 100°C under normal operating conditions
• Removal and installation: 10 times without any damage
DI07-43
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
<High pressure accumulator>
Y220_07089
High Fuel Pressure Pipe
• Function: Resistant to pressure changes, tightness against surroundings, supplying fuel through pump, rail and
injector with high pressure
• Material: Steel (Zn Plated)
• Common: Cylinder 1 & 3, 2 & 4, 5
• Internal pressure
- Internal operating pressure: 0 ~ 1600 bar during its lifetime
- Spontaneous max. pressure when restoring: 2100 bar (max. total period: 20 hours)
- Bursting pressure: over 2500 bar
• To keep cleanness and tightness, the high pressure pipe assembly should be used only once.
HP pipe
Injector
Fuel pressure sensor
HP pump
HP pipe
Notice
• Make sure to replace the removed high fuel pressure pipes.
• Tighten the fasteners with the specified tightening torque.
No. 1
No. 2
No. 3
No. 4
No. 5
High fuel pressure pipe
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