2012 SSANGYONG RODIUS fuel pressure

01-4
2. MAJOR COMPONENTS
Front view ▶
Vacuum pump
Camshaft position sensor
Oil filter assembly
Power steering pump pulley
Oil pressure switch
Water pump pulley
Idler pulley No. 22
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
Crankshaft position sensorIMV valve
Isolation damper

01-10
(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. 1.
2.

01-14
Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Idler pulley/tensioner
pulley1 45±4.5Nm -
Glow plug M5 4 20±2Nm -
Vacuum pumpM8×25 3 10±1Nm -
Timing gear case coverM6×40 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head coverM6×35 21 10±1Nm -
Oil dipstick gauge coverM6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel railM8×25 2 25±2.5Nm -
Injector clamp boltM6×44 2 9±1.0Nm
130˚±10˚ -
High pressure pipe
(between high pressure
pump and fuel rail
assembly)M17 1 30±3Nm -
High pressure pipe
(between fuel rail
assembly and injector)M17 4 30±3Nm -
Crankshaft position sensorM5×14 1 8±0.4Nm -
Main wiringM6×16 5 10±1Nm -
Intake ductM8×25 3 25±2.5Nm -
Power steering pumpM8×100 3 25±2.5Nm -
Cylinder head front coverM6×10 5 10±1Nm -
Ladder frameM8×16 5 30±3Nm -

02-6
Cylinder head coverM6×352110±1Nm-
Oil gauge tubeM6×16110±1Nm-
Oil filter cap 125±2.5Nm-
Fuel railM8×25225±2.5Nm-
Injector clamp boltM6×4429±1.0Nm
130˚±10˚-
High pressure pipe
(between HP pump and
fuel rail)M17 130±3Nm-
High pressure pipe
(between fuel rail and
injector)M17 430±3Nm-
Crank position sensorM5×1418±0.4Nm-
Main wiringM6×16510±1Nm-
Intake ductM8×25325±2.5Nm-
Power steering pumpM8×100325±2.5Nm-
Cylinder head front
coverM6×10510±1Nm-
Ladder frame M8x16 530±3Nm-
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 420±2Nm-
Vacuum pumpM8×25310±1Nm-
Timing gear case coverM6×40710±1Nm-
M6×45110±1Nm-
M6×50310±1Nm-

02-70000-00
3. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value ▶
Compression ratio16.5 : 1
Test conditionat normal operating temperature (80˚C)
Compression pressur
eStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston
ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating
status.
Measurement ▶
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47004f005f005700b6006a00500055>
Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Remove the air cleaner duct and glow plugs. -
-
-
Place the diagram sheet to compression
pressure tester and install it into the plug
hole. 1. Before cranking the engine, make sure that the test wiring, tools and persons are keeping
away from moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
-
-

02-270000-00
3) Valve Assembly (Installed in Cylinder Head)
(1) Features
Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash
Optimized adjustment of valve clearance reduces the valve noise.
Roller type finger follower reduces the friction loss.
Vertical installation.
Simple and compact design reduces the moving operation (improving valve following and fuel
consumption at high speed) 1.
2.
3.
4.
5.
(2) Arrangement
Hydraulic lash adjuster
Upper valve spring retainer
Lower valve spring retainer
Valve spring
Exhaust valveIntake valve
Finger follower

03-32210-01
1. SPECIFICATIONS
Description Specification
Fuel Diesel
Fuel filter Type Fuel heater + priming pump + water
separator integrated type
Filter type Changeable filter element 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
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-40 ~ 125˚C
Operating pressure 1800 bar
Operating temperature-30 ~ 120˚C
Low pressure fuel
pumpType Vane type
Gear ratio (pump/engine) 0.5 : 1
Pressure 6 bar
Fuel tank Capacity 80 L
Material Steel
Fuel sender Single sender type

03-4
Took kit for low pressure lineTool kit for high pressure line
2. MAINTENANCE AND INSPECTION
1) Maintenance Procedures for DI Engine Fuel System
Always keep the workshop and lift clean (especially, from dust).
Always keep the tools clean (from oil or foreign materials).
Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel
system. Wash your hands and do not wear working gloves. 1.
2.
3.
Follow the below procedures before starting service works for fuel system.
If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and
sealing caps to perform the diagnosis for DI engine fuel system in this manual. At this point,
thoroughly clean the related area in engine compartment. 4.
Clean the engine compartment before starting service works.