2012 SSANGYONG NEW REXTON Service Manual

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Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
If work on the fluid system such as fuel and oil, working area should be well ventilated and
smoking should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones 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. -
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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
cleanness in this manual while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line),
always plug the openings with caps to prevent foreign materials or dust from entering to the
openings and connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector) should
be replaced with new ones when removed. 1.
2.
3.
Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. There could be poor engine performance,
incomplete combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and electrical equipment, be sure to disconnect battery negative (-)
terminal.
When replacing the electric device, use only genuine part and check the conditions of
connections and grounds. Loosened connection or ground makes cause a fire and personal
injury. -
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6. STANDARD BOLTS SPECIFICATIONS
Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be
classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.
Observe standard tightening torque during bolt tightening works and can adjust torque to be
proper within 15 % if necessary. Try not to over max. allowable tightening torque if not
required to do so.
Determine extra proper tightening torque if tightens with washer or packing.
If tightens bolts on the below materials, be sure to determine the proper torque.
- Aluminum alloy: Tighten to 80 % of above torque table.
- Plastics: Tighten to 20 % of above torque table. 1.
2.
3.
4.

1. ENGINE COMPARTMENT
The major changes due to the newly adopted engine compared to D27DT engine are as follows:

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Engine Compartment Layout
Engine assembly
Engine oil dipstick
Vacuum pump
Oil filter and cooler
Fuel filter and priming pump
Brake booster
Brake oil tank
AQGS unit
Washer fluid filler cap
Engine compartment fuse box
PTC relay box
Battery
Vacuum modulator (for VGT turbo charger) 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.FFH Assembly (Only for vehicle with FFH)
Power steering oil tank
Engine oil filler cap
Fan shroud
E-EGR Valve
High-capacity PCV oil separator
HFM sensor (6.0)
VGT turbo charger
Air cleaner housing
2Coolant surge tank
ABS/ESP HECU (Including TPMS function:
optional)
Exhaust gas FRT Temp. sensor (T3) 14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

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Major Sensors and Components

2. SYSTEMS IN ENGINE COMPARTMENT
1) Engine Accessories Related to ECU