SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 67

DI0A-3

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.9

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

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

3. 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.

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

Job procedures

Carefully listen the symptoms and problems from customer.

Visually check the leaks and vehicle appearance on the wiring harnesses

and connectors in engine compartment.

Perform the diagnosis proceee with SCAN-100

(refer to “DI10 DIAGNOSIS” section in this manual).

Locate the fault. If the cause is from fuel system (from priming pump to

injector, including return line), follow the step 1 through step 3 above.

5. 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 “DI10 DIAGNOSIS” section in this manual. At this point,
thoroughly clean the related area in engine compartment.

Notice

Clean the engine compartment before starting service works.

Tool kit for high pressure line

Took kit for low pressure line

Removal tool box and cap kits

DI0A-4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.9

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

Fuel pressure sensor

Common rail

Injection
pipe

Injector

High pressure pump

IMV valve

Transfer pump and high

pressure pump

Fuel temperature sensor

Fuel tank

Fuel filter

Priming
pump

Water separator

Water detection sensor

Disconnect the negative battery cable.

Plug the disconnected parts with sealing caps, and remove the caps immediately

before replacing the components.

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 to
specified 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 installtion, 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.

Supply line

Return line

Cap position

Use special tools and torque wrench to perform the correct works.

For safety reasons: check pressure is low before opening the HP systems (pipes)

DI0A-5

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.9

7. Plug the removed components with clean and

undamaged sealing caps and store it into the box to
keep the conditions when it was installed.

8. Clear the high pressure offset value by SCAN-100 after

replacing the high pressure pump.

9. To supply the fuel to transfer line of HP pump press

the priming pump until it becomes hard.

10. Check the installed components again and connect

the negative battery cable. Start the engine and check
the operating status.

11. With SCAN-100, check if there are current faults and

erase the history faults.

Note

For details, refer to “DI10 Diagnosis table”.

Warning

Do not crank engine before having filled pump.

Priming pump

DI0A-7

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.9

Front view

Rear view

STRUCTURE

1. TVD (Torsional Vibration Damper)

2. Air conditioner compressor

3. Power steering pump pulley

4. Idle pulley

5. Water pump pulley

6. Alternator

7. Viscos clutch

8. Auto tensioner pulley

9. Auto tensioner

10. Poly-groove belt

11. Cam position sensor

12. Drive plate (M/T: DMF)

13. Oil filter

14. Vacuum pump

15. Crank position sensor

16. EGR valve

17. Power steering pump

18. EGR center pipe