SsangYong Rexton. Manual — part 77
DI07-24
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
Removal
Preceding Works
- Disconnection of negative battery cable
- Removal of engine cover
The trouble diagnosis should be performed before removing the HP pump. Refer to “Diagnosis” section.
1. Remove the bolts on the fan shroud. Disconnect the air
intake duct from intake manifold and the coolant outlet
port connecting hose.
2. Remove the fan belt while pressing down the auto
tensioner adjusting bolt.
3. Unscrew the center bolt and remove the cooling fan clutch
while holding the pulley with counter holder (special tool).
Y220_07036
Y220_07037
Y220_07038
Notice
Plug the coolant port not to get the coolant into the
engine. Add the coolant as required when installing.
4. Remove the fan shroud and fan clutch simultaneously.
Tightening torque
45 ± 4.5 Nm
DI07-25
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
Y220_07039
Y220_07040
Y220_07041
Y220_07042
8. Unscrew the bolts and remove the cooling fan bracket
(timing chain cover side).
7. Unscrew the bolts and remove the idle pulley.
5. Unscrew the bolts and remove the belt pulley while
holding the belt pulley with a special tool.
6. Unscrew the upper and lower bolts and remove the auto
tensioner.
Notice
To prevent oil leaks, store the removed auto tensioner
in upright position.
Tightening torque
10 ± 1.0 Nm
Tightening torque
10 ± 1.0 Nm
Tightening torque
10 ± 1.0 Nm
Tightening torque
Upper bolt
Lower bolt
Nm
82 ± 6.0 Nm
32 ± 3.0 Nm
DI07-26
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
10. Align the TDC mark on the crankshaft pulley to the guide
pin and rotate the pulley 720° counterclockwise. Check
the mark on the camshaft again.
9. Remove the engine oil filler cap and adjust the mark on
camshaft to TDC position.
11. Disconnect the vacuum line of EGR vacuum modulator
(1), the vacuum line of turbo charger vacuum modulator
(2) vacuum line and connectors.
12. Unscrew the bolts and remove the intake manifold
mounting bracket.
- Upper bolts: 13M/ 2EA
Lower boltes: 5M/ 2EA (Hexagon bolt)
Y220_07043
Y220_07044
Y220_07045
Y220_07046
Notice
Be careful not to be mixed the lines when installing.
Tightening torque
23 ± 2.3 Nm
DI07-27
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.4
13. Disconnect the connector behind HP pump, fuel pipes
and hose lines.
1) Fuel temperature sensor connector (green)
2) IMV connector
3) Fuel return hose (be careful not to break the HP
pump connecting port)
4) Venturi hose
14. Remove the coolant temperature sensor and the knock
sensor.
Y220_07047
Y220_07048
Y220_07049
Y220_07050
15. Unscrew the bolts and remove the high fuel pressure
pipes at HP pump and common rail. Plug the openings
with sealing caps.
16. Remove the HP pump mounting bracket at engine.
Notice
Replace the fuel pipes with new ones.
Notice
Plug each opening with sealing cap.
Tightening torque
40 Nm
Tightening torque
23 ± 2.3 Nm
Tightening torque
Knock sensor
Temperature sensor
Nm
22 Nm
20 Nm
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