SsangYong Stavic / SsangYong Rodius (2005 year). Manual — part 82
DI02-3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
Cylinder Head Pressure Leakage Test
Preceding Works:
- Removal of cylinders
- Removal of intake and exhaust manifold
- Removal of valves
Test Procedures
1. Place the pressure plate on a flat-bed work bench.
2. Install the cylinder head on the pressure plate.
3. Immerse the cylinder head with the pressure plate into
warm water (approx. 60°C) and pressurize with
compressed air to 2 bar.
Tightening torque
60 Nm
Notice
Examine the cylinder head for air bubbling. If the air
bubbles are seen, replace the cylinder head.
DI02-4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
Height “A” (cylinder head parting surface - cylinder head cover parting surface)
Minimum height after machining
Flatness
Permissible variation of parallelism of top parting surface to bottom in longitu-
dinal direction
Peak-to-valley height
Valve recess “a”
Specifications
in longitudinal direction
in transverse direction
Intake valve
Exhaust valve
142.9 ~ 143.1 mm
142.4 mm
0.08 mm
0.0 mm
within 0.1 mm
0.004 mm
0.1 ~ 0.7 mm
0.1 ~ 0.7 mm
Cylinder Head Mating Surface Check
Measurement
1. Measure the cylinder head height “A”.
2. Insert the valves into the valve guides and measure the
recesses.
Notice
If the height is less than the limit, the cylinder head
must be replaced.
Limit
Over 142.4 mm
Valve recess “a”
0.1 ~ 0.7 mm
Notice
If the measured value is out of the specified range,
machine the valve seat as much as necessary until
the specified value is achieved.
DI02-5
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
3. Mark on the intake camshaft sprocket and exhaust
camshaft sprocket for timing setting during installation.
2. Remove the camshaft position sensor.
Installation Notice
•
The intake manifold can be interfered by the sensor
when installing.
Disassembly
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of EGR related pipes and oil dipstick tube
- Removal of intake manifold mounting bracket
- Removal of injector fuel line and connector, and glow plug
connector
1. Remove the cylinder head cover.
Cylinder Head
- Disassembly and Reassembly
Notice
•
Plug the openings of injector holes and common
rail with the protective caps.
DI02-6
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
5. Hold the camshafts and remove the intake camshaft
sprocket and exhaust camshaft sprocket.
4. Remove the chain tensioner.
6. Pull out the lock pins with a sliding hammer and remove
the upper guide rail.
7. Remove the oil cooler, then remove the intake manifold.
Installation Notice
•
The intake manifold can be interfered by the
cylinder head bolt (M8 x 50).
Notice
Correctly align the electronic control module onto
the shift plate by using two central pins when
installing.
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