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