SsangYong Rexton. Service manual — part 445
SSANGYONG Y200
1F2-106 M161 ENGINE CONTROLS
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
661 589 00 46 00
Fuel Tank Cap Wrench
103 589 00 21 00
Fuel Pressure Gauge
YAA1F890
KAA1F490
SECTION 1F3
DIESEL ENGINE CONTROLS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Description and Operation . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . .. 1F3-2
Governor . . . . . . . . . . . . . . ... 1F3-4
Absolute Metering Manifold Pressure
Compensator (ALDA) . . . . . . . . . . 1F3-10
Pneumatic Idle Speed Increase (PLA) . . . ... 1F3-11
Pneumatic Shut-Off Device (PNAB) . . . . ... 1F3-12
Exhaust Gas Recirculation (EGR) Valve . . . . 1F3-13
Component Locator . . . . . . . . . . . 1F3-15
Fuel Injection Pump . . . . . . . . . . .. 1F3-15
Vacuum Pump (Sectional View) . . . . . . . 1F3-16
Diagnostic Information And Procedure . . ... 1F3-17
Vacuum Control System Test . . . . . . . 1F3-17
Vacuum Shut-Off Leak Test . . . . . . . ... 1F3-21
Idle Speed Adjustment . . . . . . . . . . 1F3-23
Fuel Pump Test . . . . . . . . . . . . . 1F3-25
Injection Nozzle Test . . . . . . . . . . 1F3-28
Checking and Adjusting Start Of Delivery . . .. 1F3-31
Repair Instructions . . . . . . . . . . . 1F3-41
On-Vehicle Service . . . . . . . . . . ... 1F3-41
Vacuum Pump . . . . . . . . . . . . .. 1F3-41
Vacuum Unit Replacement . . . . . . . . 1F3-43
Fuel Pump . . . . . . . . . . . . . . 1F3-44
Injection Nozzles . . . . . . . . . . . .. 1F3-46
Injection Nozzle Repair . . . . . . . . . . 1F3-48
Injection Timing Device Assembly . . . . . 1F3-51
Injection Timing Device . . . . . . . . . . 1F3-56
Fuel Injection Pump . . . . . . . . . . .. 1F3-58
Fuel Tank . . . . . . . . . . . . . . .. 1F3-64
Specifications . . . . . . . . . . . . ... 1F3-66
General Specifications . . . . . . . . . .. 1F3-66
Fastener Tightening Specifications . . . . . 1F3-67
Schematic and Routing Diagrams . . . . ... 1F3-68
EGR System . . . . . . . . . . . . ... 1F3-68
Special Tools and Equipment . . . . . . .. 1F3-69
Special Tools Table . . . . . . . . . . ... 1F3-69
SSANGYONG Y200
1F3-2 DIESEL ENGINE CONTROLS
DESCRIPTION AND OPERATION
FUEL SYSTEM
Fuel Injection System
1 Fuel Injection Pump
2 Fuel Feed Pump
3 Overflow Valve
4 Injection Nozzle
5 Pre-filter
6 Fuel Return Hoses
7 Injection Line
8 Fuel Tank
9 Fuel Filter
10 Choke Orifice
YAD1FAA0
DIESEL ENGINE CONTROLS 1F3-3
SSANGYONG Y200
YAD1FAB0
Fuel Injection Pump Coding
PES 5M 55C 320 RS 167
P Injection Pump
E Self - Driven
S End Flange Mounting
5 Number of Cylinders (5EA)
M Pump Size (Flange Stroke)
M - 7 mm
A - 8 mm
M, W - 8 mm, 10 mm
P - 10 mm, 11 mm, 12 mm
Z - 12 mm
O - 15 mm
55 Element Diameter
C Modification Letter
320 Assembly Number
R Direction of Rotation (clockwise)
S167 Special Version
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