Guidelines On Engine Service; Cautions Before Service Works; Engine And Accessories; Fuel And Lubrication System - SSANGYONG 2004 Rexton 2.7XDi Workshop Manual

DI0A-32

Guidelines on Engine Service

To prevent personal injuries and vehicle damages that can
be caused by mistakes during engine and unit inspection/
repair and to secure optimum engine performance and
safety after service works, basic cautions and service work
guidelines that can be easily forgotten during engine ser-
vice works are described in.

Cautions before service works

• Before work on engine and each electrical equipment,
be sure to disconnect battery negative (-) terminal.
• Before service works, be sure to prepare the works by
cleaning and aligning work areas.
• Always position the ignition switch to OFF if not
required. If not, there can be electrical equipment
damages or personal injuries due to short-circuit or
ground by mistake.
• There should be no leak from fuel injection system
(HP pump, fuel hose, high pressure pipe) of the D27DT
engine. So they should be protected from foreign
materials.
• While removing the engine, do not position the jack
and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine.

Engine and accessories

Engine has a lot of precise portions so tightening torque
should be correct during disassembly/assembly and re-
moval/installation and service work should be done in clean
ways during disassembly/assembly.
Maintaining working area clean and cautious service ad-
ministration is essential element of service works while
working on the engine and each section of the vehicle. So
the mechanics should well aware of it.
• While removing the engine, related parts (bolts,
gaskets, etc.) should be aligned as a group.
• While disassembling/assembling internal components
of the engine, well aware of disassembly/assembly
section in this manual and clean each component with
engine oil and then coat with oil before installation.
• While removing engine, drain engine oil, coolant and
fuel in fuel system to prevent leakage.
• During service work of removal/installation, be sure to
check each connected portions to engine not to make
interference.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

Fuel and lubrication system

Painted surface of the body can be damaged or rubber
products (hoes) can be corroded if engine oil and fuel are
spilled over. If spilled over engine, foreign materials in air
can be accumulated on the engine damaging fuel system.
• If work on the fluid system such as fuel and oil, working
area should be well ventilated and mechanic should
not smoke.
• Gasket or seal on the fuel/lubrication system should
be replaced with new 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.
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 clean-
ness in this manual while working on DI engine fuel
system)
Electrical equipment
Electrical equipment should be handled more carefully.
Currently, the engine is equipped with a lot of electrical
equipments so there can be engine performance drops,
incomplete combustion and other abnormals due to short
and poor contact. Mechanics should well aware of vehicle's
electrical equipment.
• If have to work on the electrical equipment, be sure to
disconnect battery negative (-) terminal and position
the ignition switch to off if not required.
• When replacing electrical equipment, use the same
genuine part and be sure to check whether ground or
connecting portions are correctly connected during
installation. If ground or connecting portion is loosened,
there can be vehicle fire or personal injury.
GENERAL INFORMATION
DI ENG SM - 2004.4