SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 81

DI01-19

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.9

Auto tensioner

Water pump assembly

Water pump pulley

Hot water inlet pipe assembly

Alternator bracket

Alternator

Air conditioner compressor assembly

Air conditioner compressor bracket

assembly

Air conditioner compressor sub

bracket assembly

Intake manifold

Bracket

Knock sensor

Camshaft position sensor

Booster pressure sensor

Exhauster manifold

Turbo charger assembly

Turbo charger adaptor piece

Nut

Combination bolt

T/C oil supply pipe

T/C oil return pipe

EGR valve assembly

EGR-LH pipe bolt

EGR combination bolt

EGR-RH pipe nut

Glow plug cable nut

Vacuum pump

Cooling fan bracket assembly

Cylinder head cover

M8 x 45(LOWER)

M12 x 90

M6 x 50

M6 x 12

M6 x 12

M8 x 32

M10 x 90

M8 x 95

M8 x 25

M8 x 60

M6 x 14

M8 x 16

M8 x 45

M8 x 130

M6 x 16

M8 x 28

M8 x 16

M6 x 16

M8

M8

M8

M8 x 22

M6 x 16

 (Cylinder block side)

M16 (T/C side)

M6 x 16 (T/C side)

M6 x 16

 (Cylinder block side)

M8 x 22

M6 x 16

M8 x 22

M6 x 16

M8 x 16

M8

M5

M6 x 20

M6 x 25

M6 x 65

M6 x 85

M6 x 35

Size

Name

NO.

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

32 ± 3

82 ± 6

10 ± 1

10 ± 1

10 ± 1

25 ± 2.5

46 ± 4.6

46 ± 4.6

25 ± 2.5

25 ± 2.5

10 ± 1.0

25 ± 2.5

25 ± 2.5

25 ± 2.5

10 ± 1.0

20 ± 2.6

12 ± 1.7

10 ± 1.0

40 ± 4

25 ± 2.5

32 ± 3.2

25 ± 2.5

25 ± 2.5

25 ± 2.5

20 ± 2.0

10 ± 1.0

10 ± 1.0

25 ± 2.5

10 ± 1.0

35 ± 2.0

10 ± 1.0

25 ± 2.5

35 ± 2.0

15 ± 3

10 ± 1.0

10 ± 1.0

10 ± 1.0

10 ± 1.0

23 ± 2.3

Tightening Torque

1

1

7

4

2

4

2

4

1

3

1

1

6

6

1

2

1

2

10

4

1

1

1

1

1

2

2

2

2

2

4

4

2

5

3

5

1

3

21

Quantity

DI01-20

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.9

Vacuum modulator

WDT combination bolt

Oil dipstick tube

Oil filter assembly

Fuel rail assembly

Injector clamp washer

Fuel pipe clip (H-C)

Fuel pipe clip (C-I)

Crankshaft position sensor

Crankshaft position sensor

Fuel pressure sensor

Wiring

Intake manifold bracket

Power steering pump

Piston protrusion

Clearance between connecting rod

and pin boss

End play of crankshaft

Name

NO.

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

NEW: 0.100 ~ 0.245 mm // USED: 0.300 mm

10 ± 1.0

10 ± 1.0

10 ± 1.0

25 ± 2.5

25 ± 2.5

25 ± 2.5

25 ± 2.5

10 ± 1.0

180 + 20°

10 ± 1.0

10 ± 1.0

0.8 ± 0.4

0.7 ~ 1.5

10 ± 1.0

25 ± 2.5

25 ± 2.5

25 ± 2.5

25 ± 2.5

0.765 ~ 1.055

0.05 ~ 0.31

Tightening Torque

4

3

1

1

2

1

3

5

1

5

1

1

5

2

2

2

2

5

5

Quantity

M6 x 16SOC

M6 x 16

M6 x 16

M8 x 35SOC

M8 x 50SOC

M8 x 55SOC

M8 x 35SOC

M6 x 60

M6 x 19

M6 x 16

M5 x 17

GAP

M6 x 16

M8 x 16

M8 x 40

M8 x 100

NUT

Size

DI02-1

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.9

ENGINE HOUSING

 00

SECTION DI02

Table of Contents

CYLINDER HEAD/CYLINDER BLOCK ....................... DI02-2

Cylinder head .......................................................... DI02-2

Camshaft assembly .............................................. DI02-16

Timing chain assembly .......................................... DI02-24

Cylinder block ....................................................... DI02-28

CRANKSHAFT ........................................................... DI02-31

Arrangement of thrust washers and bearings ...... DI02-32

Torsional vibration damper ................................... DI02-37

Diassembly and reassembly ................................. DI02-38

FLYWHEEL ................................................................ DI02-41

Dual mass flywheel (DMF, Manual transmission
equipped vehicle) ................................................. DI02-41

PISTON AND CONNECTING ROD ............................ DI02-43

Piston ring ............................................................. DI02-44

Cylinder inner diameter and piston size ............... DI02-45

Disassembly and reassembly ............................... DI02-46

HIGH PRESSURE PUMP (HPP) ............................... DI02-50

Components locator ............................................. DI02-50

Disassembly and reassembly ............................... DI02-51

VACUUM PUMP ........................................................ DI02-56

DI02-2

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.9

CYLINDER HEAD/CYLINDER BLOCK

CYLINDER HEAD

System Characteristics

• 4-valve DOHC valve mechanism

• Swirl and tangential port

• 4-bolt type cylinder head bolt

• Water jacket integrated casting

• Integrated chain housing and cylinder head

• Oil gallery: drilled and sealing with cap and screw plug

Oil return check valve

Cylinder head bolt

Intake port

Exhaust port