SsangYong Rexton. Manual — part 356
M161 ENGINE MECHANICAL 1B2-107
SSANGYONG Y200
Special Tools Table (Cont’d)
615 589 01 33 00
Crankshaft Sprocket
Puller
601 589 03 43 00
Crankshaft Rear Seal
Installer
601 589 03 14 00
Crankshaft Front Seal
Installer
603 589 00 40 00
Fan Clutch Holder
DW110 - 090
Connecting Hose
DW110 - 100
Valve Tappet Remover
602 589 00 40 00
Engine Lock
617 589 00 10 00
Allen Wrench Socket
YAD1B790
YAD1B720
YAD1B4K0
YAD1B560
YAD1B2M0
YAD1B0Z0
YAD1B730
YAD1B1A0
SSANGYONG Y200
1B2-108 M161 ENGINE MECHANICAL
Special Tools Table (Cont’d)
111 589 03 15 00
Holding Pin
YAD1B4R0
SECTION 1B3
DIESEL 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
Description and Operation . . . . . . . ... 1B3-2
Valve Device . . . . . . . . . . . . . 1B3-2
Component Locator . . . . . . . . . . .. 1B3-4
Cylinder Head . . . . . . . . . . . . ... 1B3-4
Cylinder Block . . . . . . . . . . . . .. 1B3-6
Engine Component . . . . . . . . . . ... 1B3-8
Repair Instructions . . . . . . . . . . .. 1B3-10
On-Vehicle Service . . . . . . . . . . ... 1B3-10
Engine Assembly . . . . . . . . . . . .. 1B3-10
Poly V-Belt and Tensioning Device . . . . . 1B3-19
Poly V-Belt . . . . . . . . . . . . . .. 1B3-19
Tensioning Device . . . . . . . . . . .. 1B3-23
Crankcase and Cylinder Head . . . . . . ... 1B3-26
Cylinder Head . . . . . . . . . . . . . 1B3-26
Prechamber . . . . . . . . . . . . . 1B3-46
Oil Pan . . . . . . . . . . . . . . . 1B3-48
Timing Case Cover . . . . . . . . . . . 1B3-49
Crankshaft Assembly . . . . . . . . . . 1B3-56
Vibration Damper and Hub . . . . . . . . 1B3-56
Flywheel and Crankshaft End Cover . . . ... 1B3-62
Crankshaft Ball Bearing . . . . . . . . .. 1B3-66
Crankshaft . . . . . . . . . . . . . .. 1B3-67
Crankshaft Sprocket . . . . . . . . . ... 1B3-76
Piston . . . . . . . . . . . . . . . . 1B3-81
Flywheel Ring Gear . . . . . . . . . . . 1B3-87
Timing Device and Valve . . . . . . . . ... 1B3-90
Valve Tappets . . . . . . . . . . . . 1B3-90
Valve Spring (Cylinder Head Removed) . . . 1B3-92
Valve Spring (Cylinder Head Installed) . . ... 1B3-95
Valve Stem Seals . . . . . . . . . . . 1B3-98
Valve Guides . . . . . . . . . . . . 1B3-102
Valve Seat Rings . . . . . . . . . . .. 1B3-105
Camshaft . . . . . . . . . . . . . .. 1B3-112
Timing Chain . . . . . . . . . . . . 1B3-118
Chain Tensioner . . . . . . . . . . . 1B3-122
Lubrication System . . . . . . . . . . .. 1B3-124
Oil Filter . . . . . . . . . . . . . . 1B3-124
Oil Spray Nozzle . . . . . . . . . . ... 1B3-126
Oil Pump . . . . . . . . . . . . . ... 1B3-127
Unit Repair . . . . . . . . . . . . . . 1B3-129
Milling of Prechamber Sealing Surface . . . 1B3-129
TDC(TDC Sensor Bracket) Setting . . . . 1B3-133
Machining of Flywheel . . . . . . . . .. 1B3-135
Hydraulic Valve Clearance Compensation
Element Check . . . . . . . . . . .. 1B3-136
Valve Springs Check . . . . . . . . . 1B3-138
Check and Machining of Valves . . . . ... 1B3-139
Machining of Valve Seat . . . . . . . ... 1B3-144
Camshaft Timing Test . . . . . . . . ... 1B3-149
Cylinder Head Pressure Leakage Test . . . 1B3-151
Facing Cylinder Head Mating Surface . . .. 1B3-152
Replacement of Crankcase Core Plug . . .. 1B3-154
Facing Crankcase Contacting Surface . . .. 1B3-156
Cylinder Bore Measurement . . . . . . . 1B3-157
Specifications . . . . . . . . . . . . 1B3-158
Fastener Tightening Specifications . . . ... 1B3-158
Special Tools and Equipment . . . . . .. 1B3-160
Special Tools Table . . . . . . . . . .. 1B3-160
SSANGYONG Y200
1B3-2 DIESEL ENGINE MECHANICAL
DESCRIPTION AND OPERATION
VALVE DEVICE
Operation
The diesel engines have valves with bucket tappets
and automatic valve clearance adjustment. This
eliminates the need to re-set the valve clearance.
The compact design of the valve timing gear from the
cam through the bucket tappet to the valve contributes
to weight savings, to low drag power and also to
increased rigidity. Oil is supplide to the bucket tappets
through oil bores in the cylinder head.
1 Cam
2 Camshaft
3 Tappet
The maintenance-free hydraulic valve clearance
adjusting elements automatically compensates the
valve clearance resulting from thermal expansion and
wear.
This produces a quiet-running valve train.
1 Cam
2 Tappet
3 Guide Sleeve
4 Thrust Piece
The hydraulic valve clearance adjusting elements are
installed in the bucket tappets and operate the valves
directly through the thrust pins and guide sleeves.
When the engine is running and a load is applied on
the element by cam tip, the element cam go down
fully. The oil displaced from the working chamber flows
via the annular gap (clearance between guide sleeve
and thrust pin) to the supply chamber.
As soon as the cam lobe rotates upwards from the
tappet (2), the load on the guide sleeve (3) is relieved.
The spring (5) pushes the thrust pin (4) up until the
tappet is resting against the cam (1). The vacuum
produced in the working chamber (b) as a result of the
upward movement of the guide sleeve opens the ball
valve (6) and oil flows out of the supply chamber (a)
into the working chamber (b).
The ball valve closes when the cam presses against
the tappet and thus applies pressure on the thrust
pin.
The oil in the working chamber acts as a “hydraulic
rigid connection” when the engine is running and the
relevant valve is opened. The oil required for this
p u r p o s e i s s u p p l i e d t o t h e e l e m e n t s a l o n g a
longitudinal passage in the cylinder head. From here,
the oil flows through a bore to the relevant adjustment
element.
The oil to the supply chamber flows via the groove
provided in the base of the tappet.
Function
5 Pressure Spring
6 Ball Valve
a Supply Chamber
b Working Chamber
4 Oil
5 Valve
YAD1BA10
YAD1BA20
YAD1BA30
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