SsangYong Rexton. Service manual — part 21
DI01-38
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
Turbo charger
booster vacuum
modulator
EGR vacuum booster
vacuum modulator
To EGR valve
From vacuum pump
To turbo charger
booster
Y220_01057
2. Disconnect the vacuum hoses and module cables from the vacuum modulator.
Y220_01056
A. Remove the vacuum modulator bracket.
(Upper: 10 M x 2, Lower: 10M x 2)
Installation Notice
Upper bolt
Lower bolt
25 ± 2.5 Nm
25 ± 2.5 Nm
Notice
Put the installation marks on the modulator hoses and connectors.
DI01-39
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
Y220_01058
3. Disconnect the wiring harnesses and connectors from the engine.
Fuel return hose
Injector fuel line
connector
Glow plug connector
Camshaft position
sensor
Crankshaft position
sensor
Oil pressure switch
HP pump connector
Knock sensor connector
Coolant temperature
sensor connector
Booster pressure sensor
connector
Fuel pressure sensor
connector
Fuel temperature
Sensor
IMV
DI01-40
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
A. Remove the cable assembly from the engine.
Important
1. If possible, remove the cables after removing the
fuel pipes. It make the operation easier and protect
the cables and connectors.
2. Remove the cable screws and ground cable, and
then remove the engine cable assembly.
4. Disconnect the high and low fuel pressure hoses from
the HP pump.
Notice
•
Be careful not to damage the HP pump connecting
pipe (venturi) while removing the fuel hose from
the HP pump.
Notice
•
Be careful not to damage the hose connections.
•
Plug the openings in HP pump immediately after
disconnecting the hoses.
Y220_01059
Y220_01060
Y220_01061
DI01-41
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
5. Remove the EGR valve and EGR valve pipe.
A. Disconnect the vacuum hose from the EGR valve.
B. Unscrew the EGR valve bolts and EGR #1 pipe
connecting bolts and remove the EGR valve and steel
gasket.
Installation Notice
C. Remove the EGR valve #1 pipe.
Installation Notice
D. Unscrew the EGR valve #3 pipe (2) mounting bolts
and remove the pipe from the exhaust manifold.
Installation Notice
Notice
The EGR #2 pipe should be replaced with new one.
EGR valve bolt
EGR valve and
center pipe bolt
25 ± 2.5 Nm
25 ± 2.5 Nm
Center pipe bolt
Center pipe and #1 pipe
bolt and nut
35 ± 3.5 Nm
35 ± 3.5 Nm
Tightening torque
35 ± 3.5 Nm
Notice
1. The EGR #3 pipe should be replaced with new
one.
2. Make sure that the convex surface of new steel
gasket is facing to the bolts.
6. Remove the oil filter assembly.
A. Remove the oil cooler hose.
Y220_01062
Y220_01063
2
Y220_01064
Y220_01065
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