SsangYong Rexton. 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