2012 SSANGYONG NEW REXTON fuel filter

Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 4
-
Vacuum pump
3 -
Timing gear case cover
3 -
7 -
1 -
3 -
Cylinder head cover
21 -
Oil gauge tube
1 -
Oil filter cap 1
-
Fuel rail
2 -
Injector clamp bolt
2 -
High pressure pipe
(between HP pump and
fuel rail)M17 1
-
High pressure pipe
(between fuel rail and
injector)M17 4
-
Crank position sensor
1 -
Main wiring
5 -
Intake duct M8x25 4
-
Power steering pump
3 -
Cylinder head front cover
5 -
Ladder frame
5 -
Oil pump
3 -

2210-01
1. SPECIFICATION
Description Specification
Fuel Diesel
Fuel filterType Fuel heater + priming pump + water
separator integrated type
Filter type Changeable filter element type
Water accumulating capacity 200 cc
Heater capacity 250W 13.5V
Injector System pressure 1800 bar
High pressure fuel
pumpType Eccentric cam/Plunger type
Operating type Gear driven type
Normal operating temperature
Operating pressure 1800 bar
Operating temperature
Low pressure fuel
pumpType Vane type
Gear ratio (pump/engine) 0.5 : 1
Pressure 6 bar
Fuel tankCapacity 75 L
Material Steel
Fuel sender Single sender type
Change interval EU every 40,000 km
GEN every 45,000 km
Water separation
intervalEU every 20,000 km
GEN every 15,000 km

2210-01
Priming pump cap
Follow the job procedures. If you find a defective component, replace it with new one. 5.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each
injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques
during installation. Over or under torques out of specified range may cause damages and leaks at
connections. Once installed, the pipes have been deformed according to the force during installation,
therefore they are not reusable. The copper washer on injector should be replaced with new one. The
injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point
may be deviated from correct position, and it may cause engine disorder.
Plug the removed components with clean and undamaged sealing caps and store it into the box to
keep the conditions when it was installed. 6.
To supply the fuel to transfer line of HP pump
press the priming pump until it becomes
hard. 7.
Priming pump
Fuel filter assembly
Check the installed components again and connect the negative battery cable. Start the engine and
check the operating status.
With Scan Tool, check if there are current faults and erase the history faults. 8.
9.

2210-01
3) DI Engine Fuel System Pressure Test
(1) Test device (Tool kit)
Device for high pressure
Device for low pressure
(2) Pre-check
Check-tighten fuel supply line
Check fuel level in fuel tank
Check air in fuel supply line (bubble in fuel supply line or fuel)
Check fuel supply line for leaks (low pressure and high pressure)
Check that specified fuel is used
Check fuel filter for contamination -
-
-
-
-
-

(3) DI Engine Fuel System Check Procedure
If several DTCs are output simultaneously, check the electric wiring for open or short circuit.
Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities. Carry
out the high pressure fuel system check.

(6) Low Pressure System Pressure Test
Inspection procedure
All wirings/connectors and fuel lines should be
connected and the engine should work
properly.
Prepare a special tool for low pressure test
and clean it thoroughly to prevent foreign
materials from entering. 1.
2.
Disconnect the key connector for fuel filter connection, and connect both connectors to the fuel filter
and hose. 3.
Start the engine and check visually for clogged low pressure fuel system, excessive air or air entry.
If the fuel flow is not sufficient or air is in the fuel, repair the leak area. 4.
5.

3. CAUTIONS FOR DI ENGINE
1) Cautions for DI Engine
This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation
from engine, warning lights, symptoms when engine malfunctioning, causes and actions.
DI Engine 1.
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically,
delivers high power and reduces less emission..
System Safety Mode 2.
When a severe failure has been occurred in a vehicle, the system safety mode is activated to protect the
system. It reduces the driving force, restricts the engine speed (rpm) and stops engine operation. Refer
to "Diagnosis" section in this manual.
Engine CHECK Warning Lamp 3.
The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or
major electronic systems of the engine are not working properly. As a result, the
Water Separator Warning Lamp 4.
When the water level inside water separator in fuel filter exceeds a certain level (approx.
45 cc), this warning light comes on and buzzer sounds.
Also, the driving force of the vehicle decreases (torque reduction). If these conditions
occur, immediately drain the water from fuel filter.

(2) Di engine and its expected problems and remedies can be caused by
water in fuel
System supplement against paraffin separation
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then
can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply
summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and
season. However, above phenomenon can be happened if stations have poor facilities or sell improper
fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal
preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging
due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by
injector returns through fuel filter to have an effect of built-in heater (see fuel system).
System supplement and remedy against water in fuel
As mentioned above, some gas stations supply fuel with excessive than specified water. In the
conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine
hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can
cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high
speed pumping and bacterization (under long period parking). To prevent problems can be caused by
excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water
that has relatively bigger specific gravity is accumulated on the bottom of the filter.
Water drain from water separator
If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel,
so the engine ECU turns on warning lamp on the meter cluster and buzzer if water level is higher than a
certain level.
Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer
checks in to change engine oil, be sure to perform water drain from fuel filter.
Water
separator
To separate the water from the fuel filter,
remove the fuel filter assembly first.