SsangYong Actyon Sports II. Manual - part 21

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2. MAINTENANCE AND INSPECTION

1) Maintenance Procedures for DI Engine Fuel System

Always keep the workshop and lift clean (especially, from dust).

Always keep the tools clean (from oil or foreign materials).

Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system. 

Wash your hands and do not wear working gloves.

1.

2.

3.

Follow the below procedures before starting service works for fuel system.

If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing 

caps to perform the diagnosis for DI engine fuel system in this manual. At this point, thoroughly clean 

the related area in engine compartment.

4.

Clean the engine compartment before starting service works.

Tool kit for high pressure line

Took kit for low pressure line

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Follow the job procedures. If you find a defective component, replace it with new one.

5.

Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each 

injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques 

during installation. Over or under torques out of specified range may cause damages and leaks at 

connections. Once installed, the pipes have been deformed according to the force during installation, 

therefore they are not reusable. The copper washer on injector should be replaced with new one. The 

injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point 

may be deviated from correct position, and it may cause engine disorder.

Plug the removed components with clean and undamaged sealing caps and store it into the box to 

keep the conditions when it was installed.

6.

To supply the fuel to transfer line of HP pump 

press the priming pump until it becomes 

hard.

7.

Priming pump

Priming pump cap

Fuel filter assembly

Check the installed components again and connect the negative battery cable. Start the engine and 

check the operating status.

With Scan Tool, check if there are current faults and erase the history faults.

8.

9.

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2) Diagnostic Test for Engine Fuel System

(1) Overview

If a DTC is displayed on the diagnostic device, check the low pressure- and high pressure fuel systems 

before removing the components.

To run the system properly, the electric system must be intact but for the DI engine, the fuel pressure 

should be measured also when there is a malfunction even after the diagnostic test with a diagnostic 

device.

(2) Hydraulic system

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(3) Excessive backleak of injector

Excessive injector backleak

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Occurs when the injector control valve is not sealed due to the entry of the foreign materials.

Example:

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Entry of foreign materials

Burned out and worn HP pump

Mechanical damage inside the injector

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