SsangYong Rexton. Service manual - part 417

SSANGYONG  Y200

1F1-86  M162 ENGINE CONTROLS

YAA1F180

KAA1F430

KAA1F440

KAA1F130

14. Turn the roll over valves counterclockwise at an

angle of 90 degrees.

15. Turn the lock ring counterclockwise.

16. Remove and discard the gasket.

17. Installation should follow the removal procedure

in the reverse order.

4. Disconnect the vacuum hose.

5. Disconnect the circlip and remove the fuel

pressure regulator.

6. Apply the oil to O-ring lightly and then replace it.

7. Perform a leak test of the fuel pressure regulator

with the engine off and the ignition on.

8. Installation should follow the removal procedure

in the reverse order.

Caution: The fuel system is under pressure. To avoid
fuel spillage and the risk of personal injury or fire,
it is necessary to relieve the fuel system pressure
before disconnecting the fuel lines.

3. Relieve the fuel pressure in fuel supply system

by pressing the service valve.

FUEL PRESSURE REGULATOR

Removal and Installation Procedure

1. Disconnect the negative battery cable.

2. Remove the fuel pressure test connector.

Installation Notice

Tightening Torque

25 N•m (18 lb-ft)

M162 ENGINE CONTROLS  1F1-87

SSANGYONG  Y200

KAA1F440

KAA1F060

KAA1F070

KAA1F080

11. Remove the two left and two right bolts and one

center bolt of the fuel rail assembly from the intake
manifold.

Installation Notice

FUEL RAIL AND INJECTORS

Removal and Installation Procedure

Caution: The fuel system is under pressure. To
avoidfuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pressure
before disconnecting the fuel lines.

1. Discharge the fuel pressure from the fuel pressure

test connector.

2. Disconnect the negative battery cable.

3. Disconnect the vacuum hose from the fuel pressure

regulator.

4. Remove the cable guide.

5. Disconnect the Hot Film Air Mass (HFM) sensor

connector.

6. Remove the intake air duct mounting bolts.

Installation Notice

Tightening Torque

9 N•m (80 lb-ft)

7. Remove the intake air duct clamps.

8. Remove the intake air duct.

9. Remove the fuel return and supply line.

Notice: For removal, cover around parts with cloths
not to be stained by fuel. In case of checking the
injector only, do not remove the fuel return and
supply line.

Installation Notice

Tightening Torque

23 N•m (17 lb-ft)

10. Remove the six injector connectors.

Tightening Torque

25 N•m (18 lb-ft)

SSANGYONG  Y200

1F1-88  M162 ENGINE CONTROLS

KAA1F090

YAA1F150

ENGINE COOLANT
TEMPERATURE  SENSOR

Removal and Installation Procedure

1. Relieve the coolant system pressure.

2. Disconnect the negative battery cable.

3. Disconnect the engine coolant temperature sensor

connector.

Notice:  Take care when handling the engine
coolant temperature sensor. Damage to the sensor
will affect the proper operation of the fuel injection
system.

4. Remove the engine coolant temperature sensor

from the pump hosing.

Installation Notice

Notice: Before removal, the fuel rail assembly may be
cleaned with as pray type cleaner, following package
instructions. Do not immerse the fuel rails in liquid
cleaning solvent. Use care in removing the fuel rail
assembly to prevent damage to the electrical
connectors and injector spray tips. Prevent dirt and
other contaminants from entering open lines and
passages. Fittings should be capped and holes
plugged during service.

Important: If an injector becomes separated from the
rail and remains in the cylinder head, replace the injector
O-ring seals and the retaining clip.

12. Remove the injectors and the fuel rail carefully.

13. Remove the fuel injector retainer clips.

14. Remove the fuel injectors by pulling them down

and out.

15. Discard the fuel injector O-rings.

16. Lubricate the new fuel injector O-rings with engine

oil. Install the new O-rings on the fuel injectors.

17. Perform a leak check of the fuel rail and fuel

injectors.

18. Installation should follow the removal procedure

in the reverse order.

Tightening Torque

30 N•m (22 lb-ft)

5. Installation should follow the removal procedure

in the reverse order.

M162 ENGINE CONTROLS  1F1-89

SSANGYONG  Y200

KAA1F010

KAA1F230

KAA1F240

7. Disconnect the throttle body electrical connector.

8. Remove the throttle body bolts.

Installation Notice

THROTTLE BODY (INTEGRATED
WITH  THE ACTUATOR)

Removal and Installation Procedure

1. Disconnect the negative battery cable.

2. Disconnect the mass air flow sensor connector.

3. Disconnect the mass air flow sensor from the air

filter housing.

4. Remove the intake air duct mounting bolts.

Installation Notice

Tightening Torque

9 N•m (80 lb-ft)

5. Remove the air inlet housing clamps.

6. Remove the inlet air housing.

10. Remove the throttle body and discard the gasket.

Important:  Use care in cleaning old gasket
material. Sharp tools may damage sealing
surfaces.

11. Installation should follow the removal procedure

in the reverse order.

Tightening Torque

12 N•m (106 lb-ft)

9. Remove the vacuum hose.