SsangYong Stavic / SsangYong Rodius (2005 year). Service manual — part 83
DI02-7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
10. Remove the cylinder head.
11. Measure the piston protrusion from the mating surface.
9. Measure the length of cylinder head bolts.
Installation Notice
•
If the maximum length is exceeded by 2 mm,
replace the cylinder head bolt.
8. Remove the cylinder head bolts according to the
numerical sequence.
M8 x 25
: 2 EA
M8 x 50
: 2 EA
M12 x 177 : 11 EA
M12 x 158 : 1 EA
(Vacuum pump side)
Notice
•
Inspect the cylinder head surface.
•
Store the removed injectors and glow plugs so that
they will not be damaged.
Length when new
177 mm
158 mm
Maximum Limit
179 mm
160 mm
Standard
0.765 ~ 1.055 mm
DI02-8
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
Reassembly
1. Install the cylinder head with the steel gasket.
2. Tighten the cylinder head bolts to specified torque and
torque angle.
Installation Notice
3. Install the HLA device and finger follower. Check the HLA
device with the diagnosis procedures before installation.
4. Tighten the camshaft bearing cap bolts.
• Intake: #2, #4, #5
• Exhaust: #8, #10, #11
Notice
•
Put the cylinder head on the locating pins.
•
Apply the oil on the bolt thread when installing.
•
Always insert new washer first.
•
The bolts (12) at vacuum pump side are shorter than
others.
Notice
Make sure to place the “TOP” mark upward.
Tightening torque
Step 1 20 ± 2.0 Nm
Step 2 85 ± 5.0 Nm
Step 3 270° (90° x 3) + 10°
DI02-9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
• Exhaust: #1, #3, #6
• Intake: #7, #9, #12
Installation Notice
Tightening torque
25 Nm
5. Install the intake and exhaust camshaft sprockets and
the timing chain.
Installation Notice
Tightening torque
25 Nm + 90°
6. Rotate the crankshaft pulley two revolutions and ensure
that the OT mark on the crankshaft pulley and the OT
mark on the camshaft pulley are aligned.
7. Place the bearing cap with the OT marks on both
camshafts facing upward.
•
Check the finger follower positions and align if
needed.
•
If the sprocket bolt is stretched over 0.9 mm, replace
it with new one.
•
Always install the intake camshaft sprocket first.
•
Ensure that the markings on camshaft sprocket and
timing chain are aligned.
•
Make sure that the timing chain is securely seated
on the guide rail.
Notice
If the markings are not aligned, reinstall the cylinder
head.
Notice
•
Apply the sealant on the cap (#12) for the vacuum
pump when installing.
•
Apply the oil on the bearing journals before
installation.
Exhaust
Intake
DI02-10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
8. Fit the timing chain onto the camshaft sprockets and
install the upper guide rail.
• Install the clamping guide rail pin.
9. Tighten the intake and exhaust camshaft sprocket bolts.
Installation Notice
10. Install the camshaft position sensor.
11. Apply the Loctite to the bolt and tighten it.
Installation Notice
Tightening torque
10 Nm
12. Check the intake camshaft before installing the vacuum
pump.
13. Install the intake manifold. Install the oil cooler with new
gasket.
Installation Notice
Tightening torque
25 ± 2.5 Nm,
90° + 10°
•
Ensure that there is no leaks around the coolant
line for #1 cylinder
Notice
•
Install the guide rail with slanted side facing
forward.
•
Be careful not to change the timing of HP pump
when fitting the timing chain.
Tightening torque
25 Nm
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