crankcase and cylinder head -...

SSANGYONG Y200

1B3-26 DIESEL ENGINE MECHANICAL

CRANKCASE AND CYLINDER HEADCYLINDER HEAD

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DIESEL ENGINE MECHANICAL 1B3-27

SSANGYONG Y200

1 Bolt .................................. 25 N•m (18 lb-ft)+90°2 Washer3 Camshaft Drive Sproket ......................... Relace4 Camshaft5 Bolt .......................................... 10 N•m (89 lb-in)6 Threaded Ring ...................... 130 N•m (96 lb-ft)7 Prechamber8 Bolt .......................................... 25 N•m (18 lb-ft)9 Camshaft Bearing Cap

10 Cylinder Head Bolt ............................ See Table11 Plug12 Engine Coolant Temperature13 Thermo Valve Sensor14 Cylinder Block15 Gasket................................................... Replace16 Cylinder Head17 Sliding Rail

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1st Step

2nd Step

3rd Step

Cylinder Head Bolt Tightening Torque

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Tightening Sequence for Cylinder HeadBolts

Notice: The cylinder head may only be removed whenthe engine has cooled down. The cylinder head isremoved together with the exhaust manifold. As thecylinder head bolts undergo a permanent tightening.They require to be replaced if they exceed themaximum lengthes indicated in the table.

The twelve-sided socket head bolts are tightened witheach stages of torque and torque angle.

It is not necessary to retighten the cylinder head boltsat the 1000~1500 km inspection or after 1000~1500km of repairs.

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Length(L) When New

80 mm

102 mm

115 mm

Thread Dia.

M10

M10

M10

Max. Length(L)

82 mm

104 mm

117 mm

Cylinder Head Bolts (12-sided socket head)(Engine cold)

M8 Cylinder Head Bolts

10 N•m (89 lb-in)

35 N•m (26 lb-ft)

180°

25 N•m (18 lb-ft)


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Tools Required116 589 02 34 00 Threaded Pin

116 589 03 07 00 T Type Socket Wrench

116 589 20 33 00 Sliding Hammer

602 589 00 40 00 Engine Lock

603 589 00 40 00 Counter Holder

Removal Procedure1. Completely drain the coolant from the radiator and

cylinder block.

2. Remove the cooling fan shroud.

3. Hold the fan with counter holder 603 589 00 40 00and remove the bolt and then remove the coolingfan.

4. Remove the bracket oil dipstick tube.

5. Remove the tensioning lever nut.

6. Remove the nut on the tensioning lever and insertthe rod(φ 18, 180 mm). By pushing the rod to thearrow direction, pull back the bolt.

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7. Push the tensioning lever to the opposite directionto release the spring tension and remove the polyV-belt.

8. Unscrew the EGR pipe mounting bolts onto theexhaust manifold.

9. Remove the duct bracket from the cylinder head.

10. Unscrew the intake duct mounting bolts onto theintake manifold.

11. Separate the connecting rod from the control lever.


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13. Remove the fuel injection line (1) from the fuelinjection nozzle (12).

14. Remove the fuel injection line from the fuel injectionpump.

15. Remove the bracket mounting bolts and thenremove the fuel injection line (1).

12. Pull out the accelerator control linkage.

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16. Disconnect the blow by hose from the cylinderhead cover.

17. Disconnect the glow plug cables.

18. Remove the intake manifold (10) and gasket.

19. Remove the cylinder head cover and gasket.


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21. Disconnect the cables from the glow plug sensorand engine coolant temperature sensor.

22. Remove the heater pipe bracket from the oil filter.

23. Pry off the clamp and push the heater feed pipeforward and then pull out the pipe.

24. Disconnect the fuel lines from the fuel filter.

20. Remove the cable channel.

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25. Disconnect the fuel lines from the injection pump.

27. Remove the fuel injection nozzle and nozzlewasher.

26. Remove the fuel filter.

28. Rotate the crankshaft and set the no.1 cylinder atTDC.

Notice: Do not rotate the crankshaft to theopposite direction of engine revolution.


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30. Ensure that the camshaft and the bearing capmarking are aligned.

31. Remove the starter motor and install the enginelock 602 589 00 40 00 onto the flywheel ring gear.

32. Remove the exhaust manifold and exhaust pipe.

29. Place alignment marks on the camshaft gear andtiming chain.

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33. Remove the chain tensioner and seal.

34. Remove the bolt and separate the drive sprocket.

Notice: During removal, be careful not to drop thesprocket and chain into the timing case.

Carefully pull off the chain and then pull out thesprocket.

35. Remove the camshaft bearing cap bolts accordingto the numerical sequence.

Notice: Remove the No.1 bolts first and thenremove the No. 2 bolts. Do not remove the boltsat a time completely but remove them step bystep evenly or camshaft can be seriouslydamaged.

36. Remove the bearing caps and then pull out thecamshaft(20) upward.

Notice: Be careful not to miss the locking washer.

37. Remove the locking washer.

Notice: Check the locking washer and replace ifnecessary.


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39. Remove the vacuum line from the vacuum pump.

40. Disconnect the vacuum pipe from thermo valve.

42. Remove the cylinder head bolts in numericalsequence.

43. Remove the cylinder head and gasket.

38. Using the sliding hammer 116 589 20 33 00 (36)and the threaded pin 116 589 02 34 00 (37), pullout the sliding rail pins (25, 26) and remove thesliding rail (24).

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41. Remove the socket bolts (13) of the chain boxusing the T type socket wrench 116 589 03 07 00.

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Installation Procedure1. Replace the cylinder head gasket.

2. Install the cylinder head onto the crankcase.

Notice: Align the cylinder head holes with the guidepins.

3. Measure the length(L) of cylinder head bolts.

Notice: If the max. length is exceeded, replacethe bolts.

4. Coat the head contact surface of bolts and threadwith oil and insert them as shown.

- Cylinder head bolts arrangement

Bore

1 .............................................. M10 × 80

2 .............................................. M10 × 102

3 .............................................. M10 × 115

4 .............................................. M 8 × 50

5 .............................................. M 8 × 80

Max. Limit(L)

82 mm

104 mm

117 mm

Thread Dia.

M10

M10

M10

Length (L) when New

80 mm

102 mm

115 mm


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5. Tighten the cylinder head bolts to specified torqueand torque angle.

6. Install the socket bolts in the chain box using theT type socket wrench 116 589 03 07 00.

Installation Notice

7. Connect the vacuum pipe to the thermo valve.

8. Connect the vacuum lines to the vacuum pump.

Tightening Torque 25 N•m (18 lb-ft)

TighteningTorque

1st Step

2nd Step

Torque Angle

Wait for

Torque Angle

10 N•m (89 lb-in)

35 N•m (26 lb-ft)

90°

10 minutes

90°

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9. Install the fuel filter and connect the pipe.

Installation Notice


10. Connect the fuel line to the injection pump.

Installation Notice

11. Install the sliding rail (24) and insert the slidingrail pins (25, 26) using the sliding hammer 116589 20 33 00 (36) and threaded pin 116 589 02 3400 (37).

Notice: Apply sealing compound on the eachcollar of the sliding rail pins.

12. Insert the locking washer.

13. Inspect the valve tappet and check that the tappetmoves smoothly.


Be careful not to be confused the connections andhoses.


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14. Coat the camshaft with oil and install the camshafton the cylinder head to be TDC mark(arrow)upward.

15. Measure the axial end play of the camshaft.

Installation Notice

End Play 0.06 ~ 0.21 mm

If out of standard, adjust it with the properthickness of locking washer.

16. Install the bearing caps on the camshaft accordingto the number on the caps.

17. Tighten the bearing cap bolts according to thenumerical sequence.

Installation Notice


Tighten the No. 1 bolts (light arrow) first and thentighten the No. 2 bolts (dark arrow) stage by stage.

18. Position the camshaft on marking and install thecamshaft sprocket.

Notice: Align the alignment marks on the chainand sprocket.

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19. Check the TDC position of the crankshaft.

20. Install the camshaft sprocket bolt.

Installation Notice

Notice: Measure the max. length ‘L’ and replacethe bolt if it exceeds 53.6 mm.

Tightening Torque25 N•m (18 lb-ft)

90°

1st Step

2nd Step


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22. Replace the seal and then install the chaintensioner.

Installation Notice

23. Remove the engine lock 602 589 00 40 00.

24. Insert the nozzle washer into the hole to face roundpart downward.

25. Install the fuel injection nozzle.

Installation Notice



21. Install the exhaust manifold and gasket.

Installation Notice


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26. Connect the fuel hose.

27. Install the cable channel and connect the cablesto glow plugs.

28. Replace the gasket and install the cylinder headcover.

Installation Notice

30. Connect the wires to the engine coolanttemperature sensor and the glow plug sensor.

31. Replace the intake manifold gasket.

32. Install the intake manifold.

Installation Notice

29. Install the blow-by hose.

Tightening Torque 10 N•m (89 lb-in)



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35. Install the fuel pipe and the accelerator controllinkage.

36. Connect the fuel lines to the injection nozzles andto the injection pump.

Installation Notice


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37. Install the poly V-belt.

Notice: Be careful not to contaminate the belt.

33. Replace the O-ring of heater feed pipe and installit to the cylinder head.

Notice: For installation, clean the hole.

34. Install the bracket of heater feed pipe to the oilfilter.

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38. By inserting a rod into the tensioning lever upperhole and pulling the rod, install the bolt and thentighten the nut.

Installation Notice

39. Install the oil dipstick tube bracket.

Installation Notice

40. Hold the cooling fan with the counter holder 603589 00 40 00 and tighten the bolt.


Tightening Torque 10 N•m (89 lb-in)

crankcase and cylinder head -...

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