SsangYong Rexton. Service manual - part 80

DI07-36

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

17. Install the coolant pump pulley.

18. Install the fan clutch with a special tool.

19. Install the oil dipstick tube and bracket.

20. Install the exhaust EGR pipe and bracket.

21. Engage the turbo charger and PCV separator connecting

lines.

22. Engage the air cleaner hose and tighten the clamp.

23. Connect the HFM sensor connector.

24. Install the EGR center pipe.

Y220_07077

Y220_07078

Y220_07079

Tightening torque

10 ± 1.0 Nm

Tightening torque

10 ± 1.0 Nm

Tightening torque

10 ± 1.0 Nm

Tightening torque

10 ± 1.0 Nm

Tightening torque

25 ± 2.5 Nm

Notice

Make sure that the convex
surface of new steel gasket
is facing the direction as
shown in the figure.

25. Connect the HP pump connectors and engage the hose lines.

- Fuel temperature sensor connectors and IMV connector

- Venturi hose and fuel return hose

26. Install the coolant temperature sensor and the knock sensor.

27. When replaced the HP pump, initialize the fuel pressure

by using Scan-i. Refer to “Trouble Diagnosis” section in
this manual.

Notice

If the initialization of fuel pressure has not been
performed, the engine ECU controls new HP pump
with the stored offset value. This may cause the
poor engine output.

Gasket

Installing
direction

DI07-37

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

32. Place the fan shroud in its location and install the cooling

fan by using an open end wrench.

Tightening torque

10 ± 1.0 Nm

33. Install the fan shroud.

34. Add the coolant.

35. Check all the connections for tightness and pump the

priming pump to deliver the fuel to the transfer line of HP
pump.

36. Start the engine and check if abnormality is present.

37. Run leak detection cycle to get rid of air in the system

using scan 100.

29. Connect the hose to coolant outlet port and tighten the

clamp.

30. Install the air intake duct.

31. Install the fan belt while pressing the auto tensioner

adjusting bolt.

27. Install the vacuum modulator to the intake manifold

bracket.

28. Connect the vacuum modulator connecting lines and

connector.

(1) Vacuum modulator for turbo charger control

(2) Vacuum modulator for EGR valve control

Y220_07080

Y220_07081

Notice

Ensure that the vacuum hoses are connected to
correct positions.

DI07-38

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

Y220_07082

Fuel Filter

Function

Foreign materials in fuel can damage the pump components, transfer valve and injectors. Therefore, the high pressure
direct injection engine must use fuel filter. Otherwise, the operation performance will drop dramatically. And, diesel fuel
may contain water due to condensation by temperature changes and this condensation water can damage the system
by corroding the injection system. Thus, the common rail engine should have function that can drain water periodically.

Fuel filter

Filter volume: 500 ± 25 cm

3

Filtering efficiency

• Particles larger than 3

µm > 98 %

• Particles larger than 5

µm > 99.8 %

• Particles larger than 15

µm > 100 %

Drain plug

Water Sensor

Capacity: 120 cm

3

Warning light ON level: 75 cm

3

to HP pump

from HP pump

to  fuel  tank

from fuel tank

DI07-39

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

FUEL SYSTEM

DI ENG SM - 2004.4

Change Interval: 30,000 km

Water separation and storage function

• Function: It separates the condensation water from diesel fuel to prevent the water from getting into FIE system, and

results in protection of FIE system. (manual drain)

• Water storage capacity: 120 cc

• Water sensor:  light if over 39 cc

• Water drain interval: When changing engine oil or every 

20,000 km

Water sensor

It is integrated in the filter and sends signal to ECU when water level reaches at a specified value (over 39 cc) in the filter
to let the driver drain the water.

Fuel De-Waxing – Improving starting performance in cold weather

Due to characteristics of diesel fuel, some of fuel components solidify during cold winter under below a specific tempera-
ture (-15°C). When those symptoms happen, engine may stall; however, some of the fuel (temperature rises due to high
compression) in the HP pump in D27DT engine return to the filter to warm up fuel when temperature is below 50°C by
improving cold start performance during cold winter.