SsangYong Rexton. Service manual — part 299
SSANGYONG Y200
1A-26 ENGINE GENERAL INFORMATION
Diesel Engine
YAD1A180
ENGINE GENERAL INFORMATION 1A-27
SSANGYONG Y200
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
001 589 73 21 00
Hand Vacuum Pump
120 589 02 09 00
Spark Plug Wrench
001 589 76 21 00
Compression Pressure
Tester
610 589 65 09 00
Socket
YAD1A190
YAD1A220
YAD1A210
YAD1A200
SSANGYONG Y200
SECTION 1B1
M162 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Repair Instructions . . . . . . . . . . . .. 1B1-2
On-Vehicle Service . . . . . . . . . . . . 1B1-2
Engine Assembly . . . . . . . . . . . . . 1B1-2
Poly V-Belt and Tensioning Device . . . . . .. 1B1-10
Poly V-Belt . . . . . . . . . . . . . .. 1B1-10
Poly V-Belt Inspection . . . . . . . . . .. 1B1-12
Tensioning Device . . . . . . . . . . ... 1B1-14
Crankcase and Cylinder Head . . . . . . . . 1B1-16
Crankcase Ventilation System . . . . . . .. 1B1-16
Generator . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Engine Mount . . . . . . . . . . . . .. 1B1-22
Cylinder Head Cover . . . . . . . . . . 1B1-24
Cylinder Head Front Cover . . . . . . . ... 1B1-26
Cylinder Head . . . . . . . . . . . . . 1B1-28
Oil Pan . . . . . . . . . . . . . . . 1B1-31
Timing Gear Case Cover . . . . . . . . .. 1B1-33
Crankshaft Sealing Rear Cover . . . . . . 1B1-35
Crankshaft Assembly . . . . . . . . . . . 1B1-37
Belt Pulley and Vibration Damper . . . . . . 1B1-37
Crankshaft Front Radial Seal . . . . . . . 1B1-40
Crankshaft Rear Radial Seal . . . . . . . . 1B1-42
Crankshaft . . . . . . . . . . . . . ... 1B1-44
Connecting Rod . . . . . . . . . . . ... 1B1-50
Piston . . . . . . . . . . . . . . . .. 1B1-52
Piston Ring . . . . . . . . . . . . . .. 1B1-55
Flywheel / Driven Plate . . . . . . . . . . 1B1-57
Timing Device and Valve . . . . . . . . . 1B1-60
Camshaft Adjuster . . . . . . . . . . ... 1B1-60
Camshaft Sprocket Bolt . . . . . . . . ... 1B1-65
Camshaft . . . . . . . . . . . . . . 1B1-66
Camshaft Timing Position . . . . . . . . 1B1-71
Valve Spring . . . . . . . . . . . . . 1B1-74
Valve Stem Seal . . . . . . . . . . . .. 1B1-78
Chain Tensioner . . . . . . . . . . . ... 1B1-79
Timing Chain . . . . . . . . . . . . ... 1B1-83
Tensioning Rail . . . . . . . . . . . . 1B1-88
Cylinder Head Guide Rail . . . . . . . . . 1B1-89
Crankcase Guide Rail . . . . . . . . . .. 1B1-90
Crankshaft Sprocket . . . . . . . . . . 1B1-91
Lubrication System . . . . . . . . . . . . 1B1-93
Engine Oil Specification . . . . . . . . ... 1B1-93
Oil Circulation . . . . . . . . . . . . .. 1B1-94
Engine Oil and Oil Filter Element . . . . . .. 1B1-95
Oil Filter . . . . . . . . . . . . . . ... 1B1-97
Oil Pump . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . 1B1-100
Oil Non-Return Valve . . . . . . . . . .. 1B1-101
Oil Dipstick Guide Tube . . . . . . . . . 1B1-102
Unit Repair . . . . . . . . . . . . . .. 1B1-103
Oil Gallery in Crankcase . . . . . . . . 1B1-103
Oil Gallery in Cylinder Head . . . . . . ... 1B1-105
Core Plugs in Crankcase . . . . . . . . 1B1-108
Cylinder Bore . . . . . . . . . . . . 1B1-110
Crankcase Mating Surface . . . . . . . . 1B1-112
Cylinder Head Mating Surface . . . . . . 1B1-114
Specifications . . . . . . . . . . . . . 1B1-116
Fastener Tightening Specifications . . . . . 1B1-116
Special Tools and Equipment . . . . . . 1B1-118
Special Tools Table . . . . . . . . . . 1B1-118
SSANGYONG Y200
1B1-2 M162 ENGINE MECHANICAL
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 10 99 01
Torque Wrench
000 589 40 37 00
Hose Clamp
112 589 00 72 00
Oil Extractor
1 Engine Assembly
YAD1B010
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