SsangYong Rexton. Service 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