fuel filter SSANGYONG RODIUS 2012 Service Manual

02-30000-00
2232-01 Fuel Filter Assembly
- Changed fuel filter
2112-02 PWM Cooling Fan
- To increase the cooling performance,
PWM cooling fan has been introduced.
Newly Installed Equipment
Water detection
sensor
Priming pump
Front RHFront LH
Electric fan
Front RHFront LH
PWM electric fan
1990-01 Engine Mounting Insulator
- Changed design according to installation
of new engine
2330-01 Intercooler
- To increase the cooling performance,
made the cooling capacity bigger and
changed the design.

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

01-70000-00
1) Service Interval
DescriptionDaily
inspectionWeekly
inspectionService interval
Engine oil & oil
filterInspection - EU Change every 20,000 km or 12
months (The service interval should
be shortened under severe
conditions)
General Change every 15,000 km or 12
months (The service interval should
be shortened under severe
conditions)
Coolant Inspection - Change every 200,000 km or 5 years
Air cleaner
element- Inspection Diesel EU Change every 20,000 km
(The service interval should
be shortened under severe
conditions)
General Change every 15,000 km
(The service interval should
be shortened under severe
conditions)
Gasoline Clean every 15,000 km, replace every
60,000 km (The service interval should
be shortened under severe
conditions)
Fuel filter - - EU Change every 40,000 km (Draining
water from fuel filter: whenever
replacing the engine oil)
General Change every 45,000 km (Draining
water from fuel filter: whenever
replacing the engine oil)

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-

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

03-52210-01
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.
Fuel filter assembly
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.
To supply the fuel to transfer line of HP
pump press the priming pump until it
becomes hard. 7.
Priming pump
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.
Priming pump cap

03-92210-01
Device for high pressure
Device for low pressure
3) DI Engine Fuel System Pressure Test
(1) Test device (Tool kit)
(2) Pre-check
Check-tighten fuel supply line
Check fuel level in fuel tank
Check air in fuel supply line (bubble in fuel supply line or fuel)
Check fuel supply line for leaks (low pressure and high pressure)
Check that specified fuel is used
Check fuel filter for contamination -
-
-
-
-
-

03-10
(3) DI Engine Fuel System Check Procedure
If several DTCs are output simultaneously, check the electric wiring for open or short circuit.
Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities.
Carry out the high pressure fuel system check.

03-14
(6) Low Pressure System Pressure Test
Inspection procedure ▶
All wirings/connectors and fuel lines should
be connected and the engine should work
properly.
Prepare a special tool for low pressure test
and clean it thoroughly to prevent foreign
materials from entering. 1.
2.
Disconnect the key connector for fuel filter connection, and connect both connectors to the
fuel filter and hose. 3.
Start the engine and check visually for clogged low pressure fuel system, excessive air or air
entry.
If the fuel flow is not sufficient or air is in the fuel, repair the leak area. 4.
5.