SsangYong Stavic / SsangYong Rodius (2005 year). Service manual - part 72

DI0A-24

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GENERAL INFORMATION

DI ENG SM - 2004.9

Guidelines on Engine Service

To prevent personal injuries and vehicle damages that can
be caused by mistakes during engine and unit inspection/
repair and to secure optimum engine performance and
safety after service works, basic cautions and service work
guidelines that can be easily forgotten during engine ser-
vice works are described in.

Cautions before service works

• Before work on engine and each electrical equipment,

be sure to disconnect battery negative (-) terminal.

• Before service works, be sure to prepare the works by

cleaning and aligning work areas.

• Always position the ignition switch to OFF if not

required. If not, there can be electrical equipment
damages or personal injuries due to short-circuit or
ground by mistake.

• There should be no leak from fuel injection system

(HP pump, fuel hose, high pressure pipe) of the D27DT
engine. So they should be protected from foreign
materials.

• While removing the engine, do not position the jack

and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine.

Engine and accessories

Engine has a lot of precise portions so tightening torque
should be correct during disassembly/assembly and re-
moval/installation and service work should be done in clean
ways during disassembly/assembly.

Maintaining working area clean and cautious service ad-
ministration is essential element of service works while
working on the engine and each section of the vehicle. So
the mechanics should well aware of it.

• While removing the engine, related parts (bolts,

gaskets, etc.) should be aligned as a group.

• While disassembling/assembling internal components

of the engine, well aware of disassembly/assembly
section in this manual and clean each component with
engine oil and then coat with oil before installation.

• While removing engine, drain engine oil, coolant and

fuel in fuel system to prevent leakage.

• During service work of removal/installation, be sure to

check each connected portions to engine not to make
interference.

Electrical equipment

Electrical equipment should be handled more carefully.
Currently, the engine is equipped with a lot of electrical
equipments so there can be engine performance drops,
incomplete combustion and other abnormals due to short
and poor contact. Mechanics should well aware of vehicle’s
electrical equipment.

• If have to work on the electrical equipment, be sure to

disconnect battery negative (-) terminal and position
the ignition switch to off if not required.

• When replacing electrical equipment, use the same

genuine part and be sure to check whether ground or
connecting portions are correctly connected during
installation. If ground or connecting portion is loosened,
there can be vehicle fire or personal injury.

Fuel and lubrication system

Painted surface of the body can be damaged or rubber
products (hoes) can be corroded if engine oil and fuel are
spilled over. If spilled over engine, foreign materials in air
can be accumulated on the engine damaging fuel system.

• If work on the fluid system such as fuel and oil, working

area should be well ventilated and mechanic should
not smoke.

• Gasket or seal on the fuel/lubrication system should

be replaced with new and bolts and nuts should be
tightened as specified.

• After removal/installation works, be sure to check

whether there is leak on the connecting section.

If fine dust or foreign material enters into DI engine’s
fuel system, there can be serious damages between
HP pump and injectors. So, be sure to cover removed
fuel system components with cap and protect removed
parts not to be contaminated with dirt. (Refer to clean-
ness in this manual while working on DI engine fuel
system)

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GENERAL INFORMATION

DI ENG SM - 2004.9

1. Before lifting up the vehicle with lift, correctly support the

lifting points and lift up.

2. When using a jack, park the vehicle on the level ground

and block front and rear wheels. Position the jack under
the frame and lift up the vehicle and then support with
chassis stand before service work.

3. Before service work, be sure to disconnect battery

negative (-) terminal to prevent damages by bad wire and
short.

4. If service from interior of the vehicle, use protection cover

to prevent damage and contamination of seat and floor.

5. Brake fluid and anti-freeze can damage painted surface

of body. So carefully handle them during service work.

During Service Work - Inspection

6. Use recommended and specified tools to increase

efficiency of service work.

7. Use only genuine spare parts.

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8. Never reuse cotter pin, gasket, O-ring, oil seal, lock

washer and self-locking nut. Replace them with new.

If reused, normal functions cannot be maintained.

9. Align the disassembled parts in clean according to

disassembling order and group for easy assembling.

10. According to installing positions, the bolts and nuts have

different hardness and design. So be careful not to mix
removed bolts and nuts each other and align them
according installing positions.

11. To inspect and assemble, clean the parts.

12. Securely clean the parts that related with oil not to be

affected by viscosity of oil.

13. Coat oil or grease on the driving and sliding surfaces

before installing parts.

14. Use sealer or gasket to prevent leakage if necessary.

15. Damaged or not, never reuse removed gasket. Replace

with new and cautious on installing directions.

16. Tighten every bolt and nut with specified torque.

17. When service work is completed, check finally whether

the work is performed properly or the problem is solved.

18. If work on the fuel line between priming pump and injector

(including return line), be sure to cover the removed parts
with cap and be careful not to expose the connecting
passage and removed parts to external foreign materials
or dust. (Refer to cleanness.)

19. If remove high pressure fuel supply pipe between HP pump

and fuel rail and high pressure fuel pipe between fuel rail
and each injector, be sure to replace them with new.

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GENERAL INFORMATION

DI ENG SM - 2004.9

5. Carefully install the wires not to be damaged during

installation/removal of parts due to interference.

6.  Be careful not to throw or drop each sensor or relay.

7. Securely connect each connector until hear a “click”

sound.

Notice

Be careful not to modify or alter electrical system and
electrical device. Or there can be vehicle fire or serious
damage.

1. Be sure to disconnect battery negative (-) terminal during

every service work. Before disconnecting battery negative
(-) terminal, turn off ignition key.

2. Replace with specified capacity of fuse if there is bad,

blown or short circuited fuse. If use electrical wire or steel
wire other than fuse, there can be damages on the various
electrical systems. If replaced with over-capacity fuse,
there can be damages on the related electrical device
and fire.

3. Every wire on the vehicle should be fastened securely

not to be loosened with fixing clip.

4. If wires go through edges, protect them with tape or other

materials not to be damaged.

During Service Work for Electric
Devices