1. INTORDUCTION of DI SST [ DI Injector / Glow Plug Remover & Repair Tool Set] June 9 th, 2009 Ssangyong Motor Company

2. REWORK PROCEDURE Glow Plug Stuck in Cylinder Head Required Tools [Glow Plug Remover & Repair Tool Set] A.Helicoil Tap Set [M10 x 1.0] B.Drill [ 9.8] B.Drill [Φ 9.8] C.Drill Holder D.Helicoil Installer E.Helicoil [M10 x 1.0 x 1.5D] [M10 x 1.0 x 1.5D] F. Glow Plug Adaptor [M10 x 80] [M10 x 80] AB C D E F

3. REWORK PROCEDURE Remove glow plug connector by turning cw direction using pliers Make the plastic protection around all cylinder head for cleanness Broken glow plug

4. REWORK PROCEDURE Insert drill holder [C] into glow plug hole Get rid of glow plug nut area after drilling process Incompletely inserted condition

5. REWORK PROCEDURE A.After step 4, clean out the remaining chips by air blowing B. Entire insert the drill holder [C] and drill to the depth of 75 mm from cylinder head surface Check the gap between glow plug and cylinder head and then push up glow plug remaining tip can be moved by hand Clean out the remaining chips inside glow plug hole by air blowing

6. REWORK PROCEDURE Make a tap to the depth of 70 mm from cylinder head upper surface using helicoil tapping tool [A] (while tapping process, carry out air blowing operation and take care not to be damaged teeth) After tapping process, clean out the remaining chips by air blowing process (helicoil can’t be inserted, if the glow plug hole is contaminated)

7. REWORK PROCEDURE Insert helicoil [E] (refer to right pictures)

8. REWORK PROCEDURE After helicoil installation, remove the helicoil tip using ‘-’ driver

9. REWORK PROCEDURE Cautions  Do the tape masking around all cylinder head upper area and it should be attached gasket sealing area around glow plug (fine chips inside cylinder head can’t be washed and it’s caused of engine internal stuck. Therefore tape making should be done carefully)  Use the appropriate cutting fluid such as WD-40 and do the air blowing operations frequently to prevent generated chips from adhering to aluminum cylinder head  When you install the helicoil, take care not to be incorrectly installed and do not install the helicoil forcibly. (if the helicoil is installed incorrectly and can’t be removed, cylinder head should be replaced with new one)

10. REWORK PROCEDURE Injector Stuck in Cylinder Head Required Tools [Injector Remover & Repair Tool Set] A.Injector Remover B.Injector Tap [M16 x 2.0 x 3/8”] [M16 x 2.0 x 3/8”] C. Adaptor A B C

11. REWORK PROCEDURE Removal Procedure Remove broken valve and needle stuck Cylinder head broken broken Injector cap Cylinder head Note  Do not use sliding hammer to remove the injector in case of stuck on cylinder head  #4 and #5 Injector could be stuck caused by leaked washer fluid, in this case injector is not easily removed and possibly broken by excessive torque to remove  Appropriate special tools should be used from the start 1

12. REWORK PROCEDURE Make a tap as deep as possible inside stuck injector cap using special tool [B] In case of not enough tapping depth, stuck injector cap couldn’t be removed or broken in the middle of cap Tightening torque : 10 Nm Clean out remaining chip after tapping process and install the special tool [C] 23

13. REWORK PROCEDURE Install the Injector Remover [A] Turn the Injector Remover nut cw while holding the special tool [A] HOLD 54

14. REWORK PROCEDURE Removed broken injector cap Pull out the remaining broken injector cap Finishing  Remove injector washer after broken injector cap removal  Make a sealing rework to prevent washer fluid leaking from washer nozzle of hood 76