fuel pump SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

3) F35 ~ F404) F41 ~ F49, FUEL PUMP RELAY(GSL)

(1) CONNECTOR INFORMATION
(2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION STOP LAMP, FUEL PUMP, IMMOBILIZER 3)

01-4
2. MAJOR COMPONENTS
Front view ▶
Vacuum pump
Oil filter assembly
Camshaft position sensor
Power steering pump pulley
Water pump pulley
Alternator pulley
Idler pulley No. 2
A/C compressor pulley
Auto tensioner
Idler pulley No. 1
Isolation damper
Rear view ▶
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Oil pressure switch

01-90000-00
(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. -
-

02-6
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 4 20±2Nm -
Vacuum pumpM8×25 3 10±1Nm -
Timing gear case coverM12×55 3 85±8.5Nm -
M6×25 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head coverM6×35 21 10±1Nm -
Oil gauge tubeM6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel railM8×35SOC 2 25±2.5Nm -
Injector clamp boltM6×60 2 10±1Nm,
120˚+10˚ -
High pressure pipe
(between HP pump and
fuel rail)M17 1 30±3Nm -
High pressure pipe
(between fuel rail and
injector)M17 4 30±3Nm -
Crank position sensorM5×14 1 8±0.4Nm -
Main wiringM6×16 5 10±1Nm -
Intake duct M8x25 4 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 -
Oil pumpM8×35 3 25±2.5Nm
-

02-12
Electrical equipment ▶
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 each 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 make cause a fire and personal
injury. -
-Fuel and lubrication system ▶
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. -
-
-
-
If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
in HP pump and injectors. Thus, be sure to plug the inlets of removed fuel line 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)

03-32210-01
1. SPECIFICATION
Description Specification
Fuel Diesel
Fuel filterType Fuel heater + priming pump + water
separator integrated type
Filter type Changeable filter element type
Change interval every 50,000 km
Water separation interval 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 tankCapacity 75 L
Material Steel
Fuel sender Single sender type

03-4
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.
Tool kit for high pressure lineTook kit for low pressure line

03-52210-01
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
Priming pump cap
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.

03-8
(4) Loss of pump pressure/flow
Loss of HP pump pressure/flow ▶
Faulty fuel supply line, or damaged or worn pump causes the lack of flow pressure and flow
volume
Example: ▶
Air in fuel supply line
Excessive load on fuel supply line (←400 mBar)
Burned out and mechanical worn pump
High temperature of fuel supply (> 85℃) -
-
-
-