2012 SSANGYONG NEW REXTON fuel pump

0000-00
Knock sensor (one) and
water temperature sensor
Fuel rail sensor (common
rail)
1. LOCATION OF MAJOR SENSORS ON ENGINE
Major sensors and devices
InjectorGlow plugCommon rail
Camshaft position sensorBoost pressure sensor
Crankshaft position
sensor
HP pumpCommon rail
Injector
Turbocharger vacuum
modulator

0000-00
Accelerator pedal moduleFuse
Relay
Engine main relay 4
PPS (integrated
two pedal position
sensors)
Pre-glow and immobilizer
Engine main relay 4
IMV
Priming pumpFuel filter

InjectorFuel filter and priming pump
8. LAYOUT OF FUEL SYSTEM
Components
IMV connector
Pressure sensor
in fuel rail
High pressure
fuel pipe
Fuel pipe
Common rail IMV connector
HP pump
Priming pumpFuel filter
Connector
Returned fuel
from HP pumpFuel filter
Fuel tank
HP pump
Fuel tank
Fuel return port
Low pressure fuel supply portVenturi
Fuel return portFuel temperature
sensor
IMV valve
IMV connectorHigh pressure fuel
supply port
(with orifice)

0000-00
(4) Lubrication system
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used
engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact happens,
rinse affected areas immediately with plenty of water. Do not wash it with gasoline or solvent. If
irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in accordance
with local environmental regulations. -
-
-
(5) Tightening the fastener
Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
-
3) Fuel and Oil System
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. -
-
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.

0000-00
HP PumpFuel Line
Injector (7-way Injection and C3I Coding)Fuel filter Priming Pump
Common Rail
2. COMPONENTS OF FUEL SYSTEM
Fuel nozzle
holes (7)
Injector
Fuel pipe
High pressure fuel pip Fuel rail pressure sensor
Fuel filter
Connector
Priming
pump
Fuel from
HP pumpFuel filter
HP pumpFuel tank
Fuel tank
Common rail
Fuel return
port
Low pressure
fuel supply port
Venturi
High pressure
fuel supply port
(orifice included)
Fuel
temperature
sensor
IMV valve
Fuel return
port
IMV
connector

2. MAJOR COMPONENTS
Front view
Vacuum pump
Camshaft position sensor
Oil filter assembly
Power steering pump pulley
Oil pressure switch
Idler pulley No. 2
Water pump pulley
Alternator pulley
Auto tensioner
Idler pulley No. 1
A/C compressor pulley
Rear view
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Isolation damper

(3) Cautions before service
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used
engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact happens,
rinse affected areas immediately with plenty of water. Do not wash it with gasoline or solvent. If
irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in accordance
with local environmental regulations. -
-
-
(5) Tightening the fastener
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. Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.
(4) Lubrication system
3) Fuel and Oil System
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. -
-Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
-

Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Idler pulley/tensioner
pulley1
-
Glow plug M5 4
-
Vacuum pump
3 -
Timing gear case cover
7 -
1 -
3 -
Cylinder head cover
21 -
Oil dipstick gauge cover
1 -
Oil filter cap 1
-
Fuel rail
2 -
Injector clamp bolt
2 -
High pressure pipe
(between high pressure
pump and fuel rail
assembly)M17 1
-
High pressure pipe
(between fuel rail
assembly and injector)M17 4
-
Crankshaft position
sensor
1 -
Main wiring
5 -
Intake duct
3 -
Power steering pump
3 -
Cylinder head front cover
5 -