SsangYong Rexton. Manual - part 81

DI07-40

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

2. Loosen the bracket bolts and disconnect the hose from

the drain plug.

3. Remove the fuel filter.

4. Install in the reverse order of removal.

5. Press the priming pump until it becomes rigid to deliver

the fuel to the transfer line of HP pump.

1. Disconnect the fuel supply and return hoses.

Removal and Installation

Y220_07084

Y220_07085

Notice

• Plug the openings of hoses and fuel filter with

sealing caps.

• Ensure that the hoses are connected to correct

positions.

DI07-41

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

Y220_07087

Priming Pump

If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or dam-
age to each component. Therefore, the hand priming pump is
installed to fill filter.

When the vehicle is under the conditions as below, press the
priming pump until it becomes rigid before starting the engine.

Conditions for using Priming Pump

- After run out of fuel

- After draining the water from fuel filter

- After replacing the fuel filter

Relations Between Pressure and Temperature In Fuel Transfer Line

Y220_07086

Notice

When the fuel filter is replaced, the fuel in the fuel tank should be transferred to the filter by using priming
pump. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine.

• The fuel transfer line is the line between fuel tank and HP pump inlet port. The pressure on this line affects the

lifetime of fuel filter.

• Temperature of fuel transfer line

- HP pump inlet temperature is less than 80°C.

- The temperature of fuel pump inlet is up to 80°C.

And, diesel fuel has lubrication effects due to its viscosity. Thus, the fuel is also used for pump lubrication.
However, this lubrication performance drops as the temperature rises. Accordingly, when the fuel temperature is
over 50°C, 100% of fuel is returned to fuel tank to cool down the temperature and then increase the lubrication
effects of fuel and prevent heat damage on each section of high fuel pressure line.

to fuel filter

from fuel tank

Pump inlet pressure

Fuel transfer

line

Pump

Ventury

Pump outlet pressure

Injector No.1 return pressure

Injector

Injector No.5 return pressure

High pressure common rail

DI07-42

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

High Pressure Accumulator (Common Rail)

Y220_07088

Description

The high pressure accumulator reserves the high pressure fuel. Simultaneously, the pressure changes due to the
delivery from HP pump and the fuel injection is diminished by rail volume. This high pressure accumulator is commonly
used in all cylinders. Even when a large amount of fuel leaks, the common rail maintains its internal pressure. This
ensures that the injection pressure can be maintained from when the injector opens.

Function

• Relieve the pressure pulsation

• Provide pressure information to ECU (fuel pressure sensor)

Specifications

• Material: Forged Steel

• Dimension: - Volume: 22 ± 1cc

- Length: Max. 397.7 mm

- Outer diameter: 25.3 mm

• Fuel pressure sensor Integrated type

- Sensor input voltage: 5 ± 0.1V

- Sensor output signal voltage: - 4.055 ± 0.125 V @ 1600 ± 15 bar

- 0.5 ± 0.04 V @ 0 bar

• Operating pressure range

- Normal condition: 0 ~ 1600 bar

- Max. Overpressure: 2100 bar

• Ambient temperature: - available within -40°C ~ 125°C

- Spontaneous max. temperature after engine stops: 140°C (acceptable against total 15 hours)

• Fluid temperature: -40 ~ 100°C under normal operating conditions

• Removal and installation: 10 times without any damage

DI07-43

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

<High pressure accumulator>

Y220_07089

High Fuel Pressure Pipe

• Function: Resistant to pressure changes, tightness against surroundings, supplying fuel through pump, rail and

injector with high pressure

• Material: Steel (Zn Plated)

• Common: Cylinder 1 & 3, 2 & 4, 5

• Internal pressure

- Internal operating pressure: 0 ~ 1600 bar during its lifetime

- Spontaneous max. pressure when restoring: 2100 bar (max. total period: 20 hours)

- Bursting pressure: over 2500 bar

• To keep cleanness and tightness, the high pressure pipe assembly should be used only once.

HP pipe

Injector

Fuel pressure sensor

HP pump

HP pipe

Notice

• Make sure to replace the removed high fuel pressure pipes.

• Tighten the fasteners with the specified tightening torque.

No. 1

No. 2

No. 3

No. 4

No. 5

High fuel pressure pipe