SsangYong Rexton. Manual - part 21

DI01-38

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Turbo charger

booster vacuum

modulator

EGR vacuum booster

vacuum modulator

To EGR valve

From vacuum pump

To turbo charger

booster

Y220_01057

2. Disconnect the vacuum hoses and module cables from the vacuum modulator.

Y220_01056

A. Remove the vacuum modulator bracket.

(Upper: 10 M x 2, Lower: 10M x 2)

Installation Notice

Upper bolt

Lower bolt

25 ± 2.5 Nm

25 ± 2.5 Nm

Notice

Put the installation marks on the modulator hoses and connectors.

DI01-39

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01058

3. Disconnect the wiring harnesses and connectors from the engine.

Fuel return hose

Injector fuel line

connector

Glow plug connector

Camshaft position

sensor

Crankshaft position

sensor

Oil pressure switch

HP pump connector

Knock sensor connector

Coolant temperature

sensor connector

Booster pressure sensor

connector

Fuel pressure sensor

connector

Fuel temperature
Sensor

IMV

DI01-40

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

A. Remove the cable assembly from the engine.

Important

1. If possible, remove the cables after removing the

fuel pipes. It make the operation easier and protect
the cables and connectors.

2. Remove the cable screws and ground cable, and

then remove the engine cable assembly.

4. Disconnect the high and low fuel pressure hoses from

the HP pump.

Notice

•

Be careful not to damage the HP pump connecting
pipe (venturi) while removing the fuel hose from
the HP pump.

Notice

•

Be careful not to damage the hose connections.

•

Plug the openings in HP pump immediately after
disconnecting the hoses.

Y220_01059

Y220_01060

Y220_01061

DI01-41

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

5. Remove the EGR valve and EGR valve pipe.

A. Disconnect the vacuum hose from the EGR valve.

B. Unscrew the EGR valve bolts and EGR #1 pipe

connecting bolts and remove the EGR valve and steel
gasket.

Installation Notice

C. Remove the EGR valve #1 pipe.

Installation Notice

D. Unscrew the EGR valve #3 pipe (2) mounting bolts

and remove the pipe from the exhaust manifold.

Installation Notice

Notice

The EGR #2 pipe should be replaced with new one.

EGR valve bolt

EGR valve and

center pipe bolt

25 ± 2.5 Nm

25 ± 2.5 Nm

Center pipe bolt

Center pipe and #1 pipe

bolt and nut

35 ± 3.5 Nm

35 ± 3.5 Nm

Tightening torque

35 ± 3.5 Nm

Notice

1. The EGR #3 pipe should be replaced with new

one.

2. Make sure that the convex surface of new steel

gasket is facing to the bolts.

6. Remove the oil filter assembly.

A. Remove the oil cooler hose.

Y220_01062

Y220_01063

2

Y220_01064

Y220_01065