SsangYong Stavic / SsangYong Rodius (2005 year). Service manual — part 101
DI03-17
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
INTAKE SYSTEM
DI ENG SM - 2004.9
Name and Part Number
Application
Intake manifold guide pin
Y99220112B
Installation of intake manifold
Special Tools and Equipment
DI03-18
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
INTAKE SYSTEM
DI ENG SM - 2004.9
Intake Manifold - Removal/Installation
Preceding Work: Disconnection of negative battery cable
1. Lift up the vehicle and remove the skid plate.
Notice
• Replace the pipes (2, 3) at both sides of EGR cooler
(1) and gaskets with new ones.
• Make sure that the convex surface of gasket is facing
to the pressurized direction.
2. Open the coolant reservoir cap and remove loosen the
drain cock to drain the coolant.
3. Remove the air inlet hose (1) from intake manifold.
4. Loosen the clamp and remove the coolant inlet hose (2).
5. Remove the coolant inlet port housing.
6. Remove the vacuum hose from EGR valve.
7. Remove the EGR valve mounting bolts and gasket.
Remove the EGR exhaust pipe (primary) mounting bolts
and gasket.
DI03-19
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
INTAKE SYSTEM
DI ENG SM - 2004.9
8. Remove the brackets and connectors from top section of
the engine.
- Vacuum hose bracket in turbo charger
- Booster pressure sensor
- Main wiring bracket
- Ground cable bracket
- Fuel pressure sensor connector
9. Unscrew the bolts and remove the vacuum modulator
bracket.
Installation Notice
Tightening torque
9.0 Nm
10. Remove the HP pump fuel supply line bolts.
11. Remove the HP pump fuel supply line mounting bracket.
12. Remove the HP pump fuel return line at fuel filter.
13. Remove the injector return line at HP pump.
Notice
• Be careful not to damage the pipes to HP pump.
• Plug the fuel return port of the HP pump with a
sealing cap.
Notice
• Plug the openings of pipes and ports with sealing
caps to keep the cleanness of the fuel system.
• Replace the pipes with new one once removed.
DI03-20
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
INTAKE SYSTEM
DI ENG SM - 2004.9
14. Remove the intake manifold mounting bolts.
Installation Notice
15. Lift up the vehicle and remove the propeller shaft joint
bolts.
16. Unscrew the bolt in oil filter and remove the intake
manifold and gasket.
17. Install in the reverse order of removal.
•
Check the length of the bolts before installation.
M8 x 45: 6EA
M8 x 130: 6EA
Notice
•
Replace the gasket with new one.
•
Make sure that the residual coolant in intake
manifold gets into the inside of inlet port.
Notice
•
Replace the gasket with new one.
•
If replaced only gasket without any other service
operation, completely remove the coolant and other
contaminants from the engine before installation.
Tightening torque
25 ± 2.5 Nm
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