SsangYong Rexton. Service manual — part 395

DIESEL ENGINE MECHANICAL 1B3-155

SSANGYONG Y200

YAD1B3Z0

YAD1B4B0

YAD1BK80

Tools Required

102 589 00 15 00

Drift

102 589 12 15 00

Drift

Replacement Procedure

1. Completely drain the coolant.

2. Remove any parts which impede access.

(Example : transmission, injection pump)

3. Place the screwdriver to the deepdrawn edge of

the core plug and pull forward and then rotate 90°.

5. Thoroughly clean the sealing surface and apply

Loctite 241.

6. Install the new core plug by using a drift.

7. Install the removed parts and fill the coolant.

Notice: The adhesive must be allowed to harden
for about 45 minutes before filling of coolant.

8. Warm up the engine and check the coolant for

leaks.

4. Pull out the core plug with pliers.

SSANGYONG Y200

1B3-156 DIESEL ENGINE MECHANICAL

FACING CRANKCASE CONTACTING SURFACE

1 Crankcase
2 Crankcase Contacting Surface

Y Height (crankcase upper surface - crankcase

lower surface)

B Longitudinal Direction
C Transverse Direction

Service Data

YAD1BK90

Min. 299.62 mm

0.06 mm

0.06 mm

0.0006 - 0.0016 mm

0.05 mm

0.965 mm

0.735 mm

Height ‘Y’

Permissible unevenness of contacting surface

Permissible roughness upper contacting surface

Permissible variation of parallelism of crankcase upper

surface to lower surface in longitudinal direction

Piston protrusion at TDC to crankcase upper surface

In longitudinal direction (B)

In transverse direction (C)

Max.

Min.

DIESEL ENGINE MECHANICAL 1B3-157

SSANGYONG Y200

CYLINDER BORE MEASUREMENT

YAD1BKA0

1 Crankcase Contacting Surface
2 TDC of 1 st Piston Ring
3 BDC of Ring

a Longitudinal Direction

b Transverse Direction

c,d,e Measuring Point

Service Data

89.000 - 89.006 mm

89.006 - 89.012 mm

89.012 - 89.018 mm

Max. 0.20 mm

0.01 mm

0.05 mm

50° ± 10°

Code letter ‘A’

Code letter ‘X’

Code letter ‘B’

When new

Wear limit

Standard size

Wear limit in direction of travel and in transverse direction

Permissible deviation of cylinder shape

Honing angle

SSANGYONG Y200

1B3-158 DIESEL ENGINE MECHANICAL

Application

12-Sided Stretch Bolt (Flywheel)

Camshaft Bearing Cap Bolt

Camshaft Sprocket Bolt

Chain Tensioner

Connecting Rod Bearing Cap Bolt

Cooling Fan Belt Pulley Bolt

Cooling Fan Shroud Bolt

Crankshaft Bearing Cap Bolt

Crankshaft Belt Pulley Bolt

Cylinder Head Bolt

Cylinder Head Cover Bolt

Damper Bolt

Drain Plug (Cylinder Head)

End Cover Bolt

Engine Mounting Bolt

Exhaust Manifold Nut

Fuel Filter Pipe Bolt

Fuel Line (to Injection Pump)

Fuel Pipe (to Injection Nozzle)

Fuel Pipe (to Injection Pump)

Generator Bracket Bolt

Generator Mounting Bolt

Guide Pulley Bolt

Guide Pulley Bracket Bolt

Hub Bolt

Idle Pulley Bolt

Injection Nozzle

Injection Pump Mounting Bolt

Intake Manifold Nut

Oil Dipstick Tube Bracket Bolt

Oil Filter Housing Bolt

Oil Filter Housing Cap

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

N • m

45 + 90°

25

25 + 90°

80

35 + 90°

10

3 - 7

55 + 90°

23

10

35

90°

10 min

90°

10

21

30

10

50 - 75

25

25

13

18

18

25

25

45

23

9

200 + 90°

23

40

23

25

10

25

25

Lb-Ft

33 + 90°

18

18 + 90°

59

26+ 90°

-

-

41 + 90°

17

-

26

90°

10 min

90°

-

15

22

-

37 - 55

18

18

10

13

13

18

18

33

17

-

148 + 90°

17

30

17

18

-

18

18

Lb-In

-

-

-

-

-

89

27 - 62

-

-

89

-

-

-

-

89

-

-

89

-

-

-

-

-

-

-

-

-

-

80

-

-

-

-

-

89

-

-

1st Step

2nd Step

Torque Angel

Wait For

Torque Angel

Upper

Lower