Autopapyrus · SsangYong Kyron 2.0 D20DT (2008)
https://autopapyrus.com/guides/ssangyong/kyron/valve-cover-gasket-cylinder-head-cover-gasket-replacement/

Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

SsangYong Kyron 2.0 D20DT (2008): Valve Cover Gasket (Cylinder Head Cover Gasket) Replacement

On the D20DT diesel (Kyron I, 141 hp), an oily film around the edge of the valve cover usually means the gasket has aged. Before replacing it, make sure the leak is actually coming from the cover and not from neighboring components. Suspects include the crankcase ventilation oil separator, the fuel injectors, the turbocharger and its oil lines, the front crankshaft seal, and the cylinder head plugs.

Difficulty: Medium Time: 1.5-3 hours Steps: 10 Tools: socket set and ratchet, extension, torque wrench (low range, 5-15 N·m), screwdriver, plastic scraper, brake cleaner or degreaser, shop rags, tweezers or magnet, marker

Part

🔩 Valve cover gasket, supplied with spark plug or injector well seals and bolt sealing washers if they are included in the kit. Choose between OE and aftermarket manufacturers. If the cover is cracked or the plastic is warped, replace the whole cover, which is a separate part

There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes AutoFix (online). See manuals →

Step by step

10 steps

Let the engine cool down. Disconnect the negative battery terminal. Clean the dirty areas around the cover in advance with a pressure washer or cleaner so dirt doesn't get into the engine.
Remove the decorative plastic engine cover. Then remove the air ducts, the crankcase ventilation hoses, and anything else that blocks access to the cover: the intake manifold or intercooler hoses, sensor connectors, and wiring brackets. Photograph or label connectors and hoses before disconnecting them.
If fuel lines, return lines, or injector wiring run on or next to the cover, move them aside. Do not contaminate open fuel passages. Plug disconnected fittings with clean caps or a clean cloth.
Loosen the cover bolts evenly, starting at the edges and working toward the center, in 2-3 passes. Remove the bolts, note their locations (lengths may differ), and carefully lift off the cover. If it is stuck, pry gently with a plastic tool without damaging the mating surface.
Remove the old gasket and the well seals. Clean the mating surfaces of the cylinder head and the cover of oil and any sealant residue. Make sure no debris falls into the oil passages or onto the camshaft. Wipe everything with degreaser and dry it completely.
Inspect the cover for cracks and warping. Check for deposits and clogging in the oil separator area. Clean or replace the separator if it is clogged, otherwise oil will be pushed out through the gasket again.
Install the new gasket in the cover groove without twisting it. At the joints specified by the gasket manufacturer, apply a thin layer of oil-resistant sealant only if the kit calls for it. Do not use excess sealant, because it will end up inside the engine.
Set the cover on the cylinder head. Insert the bolts with new washers or seals. Tighten them by hand first, then with a torque wrench evenly, from the center outward, in 2-3 passes. The torque is low, about 8-12 N·m (6-9 lb-ft) (verify the exact value against the manufacturer's specification for the D20DT). Do not overtighten: a plastic or aluminum cover warps easily.
Reconnect all hoses, connectors, air ducts, and brackets. Make sure the clamps are tight and the crankcase ventilation is connected correctly.
Reconnect the battery, start the engine, and let it run for 5-10 minutes. Inspect the joint for leaks and check for air leaks after removing the air ducts. Check the cover again after one day.

Common mistakes and warnings

Keep everything clean when working on a diesel fuel system: dirt that gets in can ruin the injectors. If you find excessive cam lobe wear, metal shavings, or sludge when you remove the cover, replacing the gasket alone is not enough and the engine needs diagnosis. If you lack experience, or if the leak is heavy or oil is getting onto the turbocharger, take the car to a repair shop.