Cylinder Head Bolt ............................ See Table Plug Engine Coolant Temperature Thermo Valve Sensor Cylinder Block Gasket................................................... Replace Cylinder Head Sliding Rail
1B3-28 DIESEL ENGINE MECHANICAL Cylinder Head Bolt Tightening Torque Cylinder Head Bolts (12-sided socket head) (Engine cold)
1st Step
10 N•m (89 lb-in)
2nd Step
35 N•m (26 lb-ft)
3rd Step
180°
M8 Cylinder Head Bolts
25 N•m (18 lb-ft)
Tightening Sequence for Cylinder Head Bolts
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Notice: The cylinder head may only be removed when the engine has cooled down. The cylinder head is removed together with the exhaust manifold. As the cylinder head bolts undergo a permanent tightening. They require to be replaced if they exceed the maximum lengthes indicated in the table. Thread Dia. Length(L) When New
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Max. Length(L)
M10
80 mm
82 mm
M10
102 mm
104 mm
M10
115 mm
117 mm
The twelve-sided socket head bolts are tightened with each stages of torque and torque angle. It is not necessary to retighten the cylinder head bolts at the 1000~1500 km inspection or after 1000~1500 km of repairs.
Threaded Pin T Type Socket Wrench Sliding Hammer Engine Lock Counter Holder
Removal Procedure
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1. 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 00 and remove the bolt and then remove the cooling fan.
4. Remove the bracket oil dipstick tube.
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5. Remove the tensioning lever nut. 6. Remove the nut on the tensioning lever and insert the rod(φ 18, 180 mm). By pushing the rod to the arrow direction, pull back the bolt.
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SSANGYONG Y200
1B3-30 DIESEL ENGINE MECHANICAL 7. Push the tensioning lever to the opposite direction to release the spring tension and remove the poly V-belt.
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8. Unscrew the EGR pipe mounting bolts onto the exhaust manifold. 9. Remove the duct bracket from the cylinder head.
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10. Unscrew the intake duct mounting bolts onto the intake manifold.
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11. Separate the connecting rod from the control lever.
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-31 12. Pull out the accelerator control linkage.
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13. Remove the fuel injection line (1) from the fuel injection nozzle (12).
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14. Remove the fuel injection line from the fuel injection pump.
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15. Remove the bracket mounting bolts and then remove the fuel injection line (1).
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SSANGYONG Y200
1B3-32 DIESEL ENGINE MECHANICAL 16. Disconnect the blow by hose from the cylinder head cover.
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17. Disconnect the glow plug cables.
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18. Remove the intake manifold (10) and gasket.
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19. Remove the cylinder head cover and gasket.
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-33 20. Remove the cable channel.
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21. Disconnect the cables from the glow plug sensor and engine coolant temperature sensor.
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22. Remove the heater pipe bracket from the oil filter. 23. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe.
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24. Disconnect the fuel lines from the fuel filter.
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SSANGYONG Y200
1B3-34 DIESEL ENGINE MECHANICAL 25. Disconnect the fuel lines from the injection pump.
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26. Remove the fuel filter.
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27. Remove the fuel injection nozzle and nozzle washer.
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28. Rotate the crankshaft and set the no.1 cylinder at TDC. Notice: Do not rotate the crankshaft to the opposite direction of engine revolution.
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-35 29. Place alignment marks on the camshaft gear and timing chain.
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30. Ensure that the camshaft and the bearing cap marking are aligned.
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31. Remove the starter motor and install the engine lock 602 589 00 40 00 onto the flywheel ring gear.
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32. Remove the exhaust manifold and exhaust pipe.
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SSANGYONG Y200
1B3-36 DIESEL ENGINE MECHANICAL 33. Remove the chain tensioner and seal.
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34. Remove the bolt and separate the drive sprocket. Notice: During removal, be careful not to drop the sprocket and chain into the timing case. Carefully pull off the chain and then pull out the sprocket.
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35. Remove the camshaft bearing cap bolts according to the numerical sequence. Notice: Remove the No.1 bolts first and then remove the No. 2 bolts. Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged.
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36. Remove the bearing caps and then pull out the camshaft(20) upward. Notice: Be careful not to miss the locking washer. 37. Remove the locking washer. Notice: Check the locking washer and replace if necessary.
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-37 38. Using the sliding hammer 116 589 20 33 00 (36) and the threaded pin 116 589 02 34 00 (37), pull out the sliding rail pins (25, 26) and remove the sliding rail (24).
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39. Remove the vacuum line from the vacuum pump. 40. Disconnect the vacuum pipe from thermo valve.
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41. Remove the socket bolts (13) of the chain box using the T type socket wrench 116 589 03 07 00.
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42. Remove the cylinder head bolts in numerical sequence. 43. Remove the cylinder head and gasket.
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SSANGYONG Y200
1B3-38 DIESEL ENGINE MECHANICAL Installation Procedure 1. Replace the cylinder head gasket.
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2. Install the cylinder head onto the crankcase. Notice: Align the cylinder head holes with the guide pins.
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3. Measure the length(L) of cylinder head bolts. Notice: If the max. length is exceeded, replace the bolts. Thread Dia. Length (L) when New
Max. Limit(L)
M10
80 mm
82 mm
M10
102 mm
104 mm
M10
115 mm
117 mm
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4. Coat the head contact surface of bolts and thread with 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
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-39 5. Tighten the cylinder head bolts to specified torque and torque angle.
Tightening Torque
1st Step
10 N•m (89 lb-in)
2nd Step
35 N•m (26 lb-ft)
Torque Angle
90°
Wait for
10 minutes
Torque Angle
90°
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6. Install the socket bolts in the chain box using the T type socket wrench 116 589 03 07 00. Installation Notice Tightening Torque
25 N•m (18 lb-ft)
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7. Connect the vacuum pipe to the thermo valve. 8. Connect the vacuum lines to the vacuum pump.
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SSANGYONG Y200
1B3-40 DIESEL ENGINE MECHANICAL 9. Install the fuel filter and connect the pipe. Installation Notice Tightening Torque
25 N•m (18 lb-ft)
Be careful not to be confused the connections and hoses.
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10. Connect the fuel line to the injection pump. Installation Notice Tightening Torque
13 N•m (10 lb-ft)
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11. Install the sliding rail (24) and insert the sliding rail pins (25, 26) using the sliding hammer 116 589 20 33 00 (36) and threaded pin 116 589 02 34 00 (37). Notice: Apply sealing compound on the each collar of the sliding rail pins.
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12. Insert the locking washer. 13. Inspect the valve tappet and check that the tappet moves smoothly.
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-41 14. Coat the camshaft with oil and install the camshaft on 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 proper thickness of locking washer.
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16. Install the bearing caps on the camshaft according to the number on the caps.
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17. Tighten the bearing cap bolts according to the numerical sequence. Installation Notice Tightening Torque
25 N•m (18 lb-ft)
Tighten the No. 1 bolts (light arrow) first and then tighten the No. 2 bolts (dark arrow) stage by stage.
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18. Position the camshaft on marking and install the camshaft sprocket. Notice: Align the alignment marks on the chain and sprocket.
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SSANGYONG Y200
1B3-42 DIESEL ENGINE MECHANICAL
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19. Check the TDC position of the crankshaft.
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20. Install the camshaft sprocket bolt. Installation Notice Tightening Torque
1st Step 25 N•m (18 lb-ft) 2nd Step 90°
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Notice: Measure the max. length ‘L’ and replace the bolt if it exceeds 53.6 mm.
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-43 21. Install the exhaust manifold and gasket. Installation Notice Tightening Torque
25 N•m (18 lb-ft)
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22. Replace the seal and then install the chain tensioner. Installation Notice Tightening Torque
80 N•m (59 lb-ft)
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23. Remove the engine lock 602 589 00 40 00.
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24. Insert the nozzle washer into the hole to face round part downward. 25. Install the fuel injection nozzle. Installation Notice Tightening Torque
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SSANGYONG Y200
40 N•m (30 lb-ft)
1B3-44 DIESEL ENGINE MECHANICAL 26. Connect the fuel hose. 27. Install the cable channel and connect the cables to glow plugs.
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28. Replace the gasket and install the cylinder head cover. Installation Notice Tightening Torque
10 N•m (89 lb-in)
29. Install the blow-by hose.
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30. Connect the wires to the engine coolant temperature sensor and the glow plug sensor.
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31. Replace the intake manifold gasket. 32. Install the intake manifold. Installation Notice Tightening Torque
25 N•m (18 lb-ft)
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SSANGYONG Y200
DIESEL ENGINE MECHANICAL 1B3-45 33. Replace the O-ring of heater feed pipe and install it to the cylinder head. Notice: For installation, clean the hole. 34. Install the bracket of heater feed pipe to the oil filter.
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35. Install the fuel pipe and the accelerator control linkage.
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36. Connect the fuel lines to the injection nozzles and to the injection pump. Installation Notice Tightening Torque
18 N•m (13 lb-ft)
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37. Install the poly V-belt. Notice: Be careful not to contaminate the belt.
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SSANGYONG Y200
1B3-46 DIESEL ENGINE MECHANICAL 38. By inserting a rod into the tensioning lever upper hole and pulling the rod, install the bolt and then tighten the nut. Installation Notice Tightening Torque
