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.