SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 94

DI02-51

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.9

Preceding works:

- Removal of fan belt (including cooling fan and fan clutch)

and fan shroud

- Removal of intake manifold assembly

- Removal of water pump pulley

- Removal of auto tensioner

- Removal of EGR pipe

- Removal of oil dipstic gauge

Notice

• To prevent oil leaks, store the removed auto tensioner it

upright position.

• Be careful not to damage the rubber bellows.

• Plug the oil ports for HP pump with sealing caps.

1. Set crankshaft pulley to OT point. Open the oil filler cap

and check if the cam shaft notch marking is aligned to
OT point.

2. Remove the cooling fan idle pulley with a pulley holder

(special tool).

DISASSEMBLY AND REASSEMBLY

DI02-52

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.9

3. Remove the cooling fan bracket assembly.

4. Place the marks on the chain and HP pump sprocket for

installation.

5. Remove the vacuum modulator bracket.

6. Remvoe the fuel pipes and wiring connectors which

connected to fuel pump.

Notice

Be careful not to get the sealant or foreign materials
into the engine.

7. Turn the crankshaft pulley to the counter clockwise

direction to ATDC 45° then remove the chain tensioner.

Installation Notice

Tightening torque

64 ± 5 Nm

DI02-53

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.9

10. Remove the sprocket bolts and center nut and after

slightly lifted up the chain, remove the pump sprocket.

Installation Notice

11. Remove the HP pump bearing with HP pump bearing

puller (special tool).

Tightening torque

Sprocket bolt

Center nut

Nm

20 Nm + 90°

65 ± 5 Nm

Notice

Do not apply excessive force. The timing chain may
deviates.

9. Install a special tool into the cooling fan bracket hole to

hold the sprocket.

8. While insert finger and push the chain guide backward

direction and turn the crankshaft pulley to ATDC 65° by
counter clockwise direction until feel the chain guide
inclined backward.

DI02-54

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.9

12. Remove the HP pump mounting bracket.

Installation Notice

13. Unscrew the external bolts and remove the HP pump

while rocking and tapping it with a rubber hammer.

Tightening torque

24 ± 2.4 Nm

Notice

• To prevent HP pump shaft damaging, do not apply

excessive impact.

• Do not apply excessive force. The timing chain may

deviates.

14. Remove the HP pump.

15. Install the new HP pump with sealing caps.

16. When replaced the HP pump, initialize the fuel pressure

by using SCAN-100. Refer to “Trouble Diagnosis” section
in this manual.

Notice

Remove the sealing caps only when connecting the
pipes and hoses.