2001-2006 SsangYong Rexton Service & Repair Manual

CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 GENERAL INFORMATION 00 SECTION DI0A Table of Contents CLEANNESS ....................................... DI0A-3 STRUCTURE ...................................... DI0A-8 ENGINE CONTROLS ....................... DI0A-11 ECU related components .............. DI0A-11 Engine and sensors ..................... DI0A-12 Electrical components and pre heating system ...................... DI0A-13 INTAKE SYSTEM ............................. DI0A-14 Intake air flow chart ...................... DI0A-15 INTAKE SYSTEM ............................. DI0A-16 Exhaust air flow chart ................... DI0A-17 LUBRICATION SYSTEM .................. DI0A-18 COOLING SYSTEM ......................... DI0A-19 Coolant flow chart ........................ DI0A-20 FUEL SYSTEM ................................. DI0A-21 Fuel supply system ...................... DI0A-22 GENERAL SPECIFICATIONS ........... DI0A-23 Vehicle specifications ................... DI0A-23 Maintenance ................................ DI0A-26 VEHICLE IDENTIFICATION .............. DI0A-28 HOW TO USE AND MAINTAIN WORKSHOP MANUAL ........................................... DI0A-30 Consists of workshop manual ...... DI0A-30 Manual description ...................... DI0A-30 Guidelines for service work safety ........................................... DI0A-31 Lifting points ................................. DI0A-36 Tightening torque of standard bolts .............................................. DI0A-37

DI0A-3 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 µm of preciseness. The pressure regulation and injector operation are done by electric source from engine ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine. You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side figure shows the clearance between internal operating elements. Cleanness of DI Engine Fuel System and Service Procedures The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise. CLEANNESS Y220_0A035 Hair Nozzle hole Valve actuator lift: 0.028 mm Diameter: 0.40 mm Operating clearance: 0.002 mm Diameter: 2.0 mm

DI0A-4 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 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-i (refer to “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 “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-5 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 6. Follow the job procedures. If you find a defective component, replace it with new one. Y220_0A039 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-6 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 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-i, check if there are current faults and erase the history faults. Note For details, refer to “DI10 Diagnosis teable”. Y220_0A040 Y220_0A041 Y220_0A042 Priming pump Warning Do not crank engine before having filled pump.

DI0A-7 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL As mentioned above, some gas stations supply fuel with excessive than specified water. In the conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high speed pumping and bacterization (under long period parking). To prevent problems can be caused by excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water that has relatively bigger specific gravity is accumulated on the bottom of the filter. SYSTEM SUPPLEMENT AGAINST PARAFFIN SEPARATION. In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and season. However, above phenomenon can be happened if stations have poor facilities or sell improper fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal preciseness of HP pump and injector. Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by injector returns through fuel filter to have an effect of built-in heater (see fuel system). DI Engine and Its Expected Problems and Remedies Can be Caused by Water in Fuel Y220_0A041 If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel, so the engine ECU turns on warning light ( ) on the meter cluster and buzzer if water level is higher than a certain level. Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.)

DI0A-8 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 Front view Rear view Y220_0A001 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. Cooling fan pulley & viscos clutch 8. Aut tensioner pulley 9. Auto tensioner 10. Poly-groove belt 11. Cam position sensor 12. Drive plate (M/T: DMF) 13. Oil filter housing 14. Vacuum pump 15. Crank position sensor 16. EGR valve 17. Power steering pump 18. EGR center pipe

DI0A-9 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 Top view Y220_0A002 19. Cylinder head cover 20. Intake manifold 21. Water outlet port 22. Common rail 23. Fuel pressure sensor 24. Fuel pipe 25. Injector 26. Fuel return line 27. Oil filler cap 28. Glow plug 29. Booster pressure sensor 30. Oil separator 31. Oil dipstic 32. EGR center pipe

DI0A-10 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 Right side view Left side view Y220_0A003 33. Cylinder head 34. Cylinder block 35. Oil pan 36. Drain plug 37. Turbocharger 38. EGR - RH pipe 39. Oil separator 40. Oil dipstic 41. HP pump 42. Turbocharger vacuum modulator 43. EGR valve vacuum modulator 44. EGR valve 45. Exhaust manifold

DI0A-11 CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERAL INFORMATION DI ENG SM - 2004.4 HFM sensor/intake air temperature sensor Pre heating time relay Main relay ECU/barometric sensor Cam position sensor Fuel filter (water detection sensor) Accelerator pedal sensor ECU RELATED COMPONENTS ENGINE CONTROLS Y220_0A004

2001-2006 SsangYong Rexton Service & Repair Manual

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