Ssangyong Rexton Service Manual ENGINE

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ENGINE SERVICE MANUAL

PYUNGTAEK, KOREA

SECTION INDEX

SERVICE MANUAL(vol. 1 of 2)

VOLUME 1 OF 2 GENERAL INFORMATION

DI0A

ENGINE ASSEMBLY

DI01

ENGINE HOUSING

DI02

INTAKE SYSTEM

DI03

This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components.

EXHAUST SYSTEM

DI04

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval.

LUBRICATION SYSTEM

DI05

COOLING SYSTEM

DI06

FUEL SYSTEM

DI07

ENGINE CONTROL SYSTEM

DI08

ELECTRIC DEVICES AND SENSORS

DI09

DIAGNOSIS

DI10

REXTON FOREWORD

The right is reserved to make changes at any time without notice.

SSANGYONG MOTOR CO., LTD. PYUNGTAEK, KOREA

DI ENGINE CONTENTS GENERAL INFORMATION .................... DI0A ENGINE ASSEMBLY ............................. DI01 ENGINE HOUSING ................................ DI02 INTAKE SYSTEM................................... DI03 EXHAUST SYSTEM............................... DI04 LUBRICATION SYSTEM ....................... DI05 COOLING SYSTEM ............................... DI06 FUEL SYSTEM ...................................... DI07 ENGINE CONTROL SYSTEM ............... DI08 ELECTRIC DEVICES AND SENSORS . DI09 DIAGNOSIS ........................................... DI10

SECTION

DI0A

GENERAL INFORMATION

DI0A-1

SECTION 00 DI0A

GENERAL INFORMATION

Table of Contents CLEANNESS ....................................... DI0A-3

FUEL SYSTEM ................................. DI0A-21

STRUCTURE ...................................... DI0A-8

Fuel supply system ...................... DI0A-22

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

GENERAL INFORMATION DI ENG SM - 2004.4

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

CHANGED BY EFFECTIVE DATE AFFECTED VIN

DI0A-3

CLEANNESS Cleanness of DI Engine Fuel System and Service Procedures 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 pre