SsangYong Stavic / SsangYong Rodius (2005 year). 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