ENGINE SERVICE MANUAL PYUNGTAEK, KOREA SECTION INDEX SERVICE MANUAL(vol. 1 of 2) VOLUME 1 OF 2 GENERAL INFORMATION
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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