SsangYong Rexton. Manual — part 20
DI01-34
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
Y220_01048
Accessories - Removal and Installation
PCV valve and oil separator
EGR valve pipe (LH, Center, RH)
Power steering pump
Cooling fan clutch
Auto tensioner
Alternator
Turbo charger
Fuel return hose
Cable and connector
Oil filter assembly
EGR valve
Start motor
Mounting bracket
Air conditioner compressor
DI01-35
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
• The engine accessories can be removed without any specific order. In general, remove the components from top
to bottom. However, be careful not to splash the lubricants to engine and body when disassembly. Especially,
avoid getting into other components.
Removal and Installation Order of Major Accessories
1. Vacuum Modulator
2. Engine Cables and Connectors
3. Fuel Hoses
3-1. EGR Valve Assembly
4. Oil Filter Assembly
4-1. Belt Tensioning Assembly
5. Power Steering Pump Assembly
6. Air Conditioner Compressor Assembly
7. PCV Valve Assembly
8. Turbo Charger
Oil Dipstick Tube
Alternator Assembly
+
* Camshaft Position Sensor
* Crankshaft Position Sensor
* Injector Fuel Line Connector
* Glow Plug Connector
* Fuel Return Hose
* High/Low Pressure Hoses in HP Pump
* Ground Cables
* Fuel Pressure Sensor Connector
* Booster Pressure Sensor Connector
* Knock Sensor Connector
* Coolant Temperature Sensor Connector
* HP Pump: Fuel Temperature Sensor (Green)
IMV (Brown)
DI01-36
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
1. Remove the fuel pipes.
A. Remove the fuel supply pipes between each
cylinder and common rail with a special tool.
Installation Notice
B. Remove the high fuel pressure pipe mounting bolts
with a special tool.
- High fuel pressure supply pipe at common rail
side
Installation Notice
Y220_01049
Y220_01050
Y220_01051
Y220_01052
Notice
1. Plug the openings of injector nozzle and common
rail with sealing caps after removed the fuel pipes.
Tightening torque
40 ± 4.0 Nm
2. Replace the pipes with new ones. Be careful not
to be mixed the fuel pipes because the pipe
appearance of #1 and #3 cylinders and #2 and #4
are same each other.
Tightening torque
40 ± 4 Nm
No. 1
No. 3
No. 2
No. 4
No. 5
DI01-37
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
Y220_01055
C. High fuel pressure supply pipe at HP pump side
Installation Notice
D. Unscrew the bracket mounting bolts and remove the
high fuel pressure supply pipes.
Note
Special tool: Fuel pipe remover and installer
Tightening torque
40 ± 4.0 Nm
Y220_01054
Y220_01053
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