Ssangyong REXTON, Y200 User Manual

SECTION 0B

GENERAL INFORMA TION

TABLE OF CONTENTS

Maintenance And Repair .....................................0B-2

Maintenance And Lubrication ...............................0B-2

Normal Vehicle Use .............................................0B-2

Explanation Of Scheduled

Maintenance Services .......................................0B-2

Owner Inspections And Services .........................0B-3

While Operating the Vehicle .................................0B-3

At Each Fuel Fill...................................................0B-3

At Least Twice a Month ....................................... 0B-3

At Least Monthly ................................................. 0B-3

At Least Twice a Year ..........................................0B-3

Each Time The Oil is Changed ............................. 0B-4

At Least Annually ................................................0B-4

Standard Bolts Specifications..............................0B-5

Basic Specification ...............................................0B-6

Dimension ...........................................................0B-6

Specifications ......................................................0B-7

Recommended Fluids And Lubricants..................0B-9

Vehicle Identification Number System .............. 0B-10

Vehicle Identification Number (Vin) ..................... 0B-10

ManufacturerS Plate ........................................... 0B-11

Engine Number.................................................. 0B-12

Vehicle Lifting Procedures.................................. 0B-14

0B-2 GENERAL INFORMATION

MAINTENANCE AND REPAIR

MAINTENANCE AND

LUBRICATION

NORMAL VEHICLE USE

The maintenance instructions contained in the
maintenance schedule are based on the assumption
that the vehicle will be used for the following reasons:

To carry passengers and cargo within the limitation

•

of the tire inflation prassure. Refer to “Tire and
Wheel” in section 2E.

To be driven on reasonable road surfaces and

•

within legal operating limits.

EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES

The services listed in the maintenance schedule are
further explained below. When the following
maintenance services are performed, make sure all
the parts are replaced and all the necessary repairs
are done before driving the vehicle. Always use the
proper fluid and lubricants.

Engine Oil and Oil Filter Change

Always use above the API SH grade or recommended
engine oil.

Engine Oil Viscosity

Engine oil viscosity (thickness) has an effect on fuel
economy and cold weather operation. Lower viscosity
engine oils can provide better fuel economy and cold
weather performance; however, higher temperature
weather conditions require higher viscosity engine oils
for satisfactory lubrication. Using oils of any viscosity
other than those viscosities recommended could result
in engine damage.

Replace the air cleaner element every.

Gasoline Engine : 60,000 km (36,000 miles)

•

Diesel Engine : 30,000 km (18,000 miles)

•

Replace the air cleaner more often under dusty
conditions.

Fuel Filter Replacement

Replace the engine fuel filter every.

Gasoline Engine : 60,000 km (36,000 miles)

•

Diesel Engine : 45,000 km (24,000 miles)

•

Spark Plug Replacement

Replace spark plugs with same type.

Type : BOSCH : F8DC4

•

BERU : 14F-8DU4
Champion : C11YCC

Gap : 0.8 ± 0.1 mm

•

Spark Plug Wire Replacement

Clean wires and inspect them for burns, cracks or other
damage. Check the wire boot fit at the Distributor and
at the spark plugs. Replace the wires as needed.

Brake System Service

Check the disc brake pads or the drum brake linings.
Check the pad and the lining thickness carefully.

Tire and Wheel Inspection and Rotation

Check the tires for abnormal wear or damage. To
equalize wear and obtain maximum tire life, rotate the
tires. If irregular or premature wear exists, check the
wheel alignment and check for damaged wheels. While
the tires and wheels are removed, inspect the brakes.

Tire Rotation (Left-hand Drive Type)

Cooling System Service

Drain, flush and refill the system with new coolant.
Refer to “Recommended Fluids And Lubricants” in
this section.

Air Cleaner Element Replacement

Clean the air cleaner element every.

Gasoline Engine : 15,000 km (10,000 miles)

•

Diesel Engine : 10,000 km (6,000 miles)

•

YAA0B010

SSANGYONG Y200

GENERAL INFORMATION 0B-3

OWNER INSPECTIONS AND SERVICES

WHILE OPERATING THE VEHICLE

Horn Operation

Blow the horn occasionally to make sure it works. Check
all the button locations.

Brake System Operation

Be alert for abnormal sounds, increased brake pedal
travel or repeated puling to one side when braking.
Also, if the brake warning light goes on, or flashes,
something may be wrong with part of the brake system.

Exhaust System Operation

Be alert to any changes in the sound of the system or
the smell of the fumes. These are signs that the system
may be leaking or overheating. Have the system in­spected and repaired immediately.

Tires, Wheels and Alignment Operation

Be alert to any vibration of the steering wheel or the
seats at normal highway speeds. This may mean a
wheel needs to be balanced. Also, a pull right or left
on a straight, level road may show the need for a tire
pressure adjustment or a wheel alignment.

Steering System Operation

Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or
has too much free play, or is unusual sounds are
noticed when turning or parking.

Headlamp Aim

Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.

AT EACH FUEL FILL

A fluid loss in any (except windshield washer) system
may indicate a problem. Have the system inspected
and repaired immediately.

Engine Oil Level

Check the oil level and add oil if necessary. The best
time to check the engine oil level is when the oil is
warm.

1. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan.

2. Pull out the oil level indicator (dip stick).

3. Wipe it clean, and push the oil level indicator back
down all the way.

4. Pull out the oil level indicator and look at the oil
level on it.

5. Add oil, if needed, to keep the oil level above the
lower mark. Avoid overfilling the engine, since this
may cause engine damage.

6. Push the indicator all the way back down into the
engine after taking the reading.

If you check the oil level when the oil is cold, do not
run the engine first. The cold oil will not drain back to
the pan fast enough to give a true oil level reading.

Engine Coolant Level and Condition

Check the coolant level in the coolant reservoir tank
and add coolant if necessary. Inspect the coolant.
Replace dirty or rusty coolant.

Windshield Washer Fluid Level

Check the washer fluid level in the reservoir. Add fluid
if necessary.

AT LEAST TWICE A MONTH

Tire And Wheel Inspection and Pressure
Check

Check the tire for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when
the tires are cold (check the spare also, unless it is a
stow-away).

Maintain the recommended pressures. Refer to “Tire
and Wheel” is in section 0B.

AT LEAST MONTHLY

Lamp Operation

Check the operation of the license plate lamp, the head­lamps (including the high beams), the parking lamps,
the fog lamps, the taillamp, the brake lamps, the turn
signals, the backup lamps and the hazard warning
flasher.

Fluid Leak Check

Periodically inspect the surface beneath the vehicle
for water, oil, fuel or other fluids, after the vehicle has
been parked for a while. Water dripping from the air
conditioning system after use is normal. If you notice
fuel leaks or fumes, find the cause and correct it at
once.

AT LEAST TWICE A YEAR

Power Steering System Reservoir Level

Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to Section 6A,
Power Steering System.

Brake Master Cylinder Reservoir Level

Check the fluid and keep it at the proper level. A low
fluid level can indicate worn disc brake pads which
may need to be serviced. Check the breather hole in
the reservoir cover to be free from dirt and check for
an open pas-sage.

Weather-Strip Lubrication

Apply a thin film silicone grease using a clean cloth.

SSANGYONG Y200

0B-4 GENERAL INFORMATION

EACH TIME THE OIL IS CHANGED

Brake System Inspection

This inspection should be done when the wheels are
removed for rotation. Inspect the lines and the hoses
for proper hookup, binding, leaks, cracks, chafing, etc.
Inspect the disc brake pads for wear. Inspect the
rotors for surface condition. Inspect other brake parts,
the parking brake, etc., at the same time. Inspect the
brakes more often if habit or conditions result in
frequent braking.

Steering, Suspension and Front Drive Axle
Boot And Seal Inspection

Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle
boot and seals for damage, tears or leakage. Replace
the seals if necessary.

Exhaust System Inspection

Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the
exhaust system. Look for broken, damaged, missing,
or out-of-position parts as well as open seams, holes,
loose connections, or other conditions which could
cause heat buildup in the floor pan or could let exhaust
fumes seep into the trunk or passenger compartment.

Throttle Linkage Inspection

Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints
and throttle cable joints, the intermediate throttle shaft
bearing, the return spring at throttle valve assembly,
and the accelerator pedal sliding face with suitable
grease. Check the throttle cable for free movements.

Engine Drive Belts

Inspect all belts for cracks, fraying, wear and proper
tension. Adjust or replace the belts as needed.

Hood Latch Operation

When opening the hood, note the operation of the
secondary latch. It should keep the hood from opening
all the way when the primary latch is released. The
hood must close firmly.

AT LEAST ANNUALLY

Lap and Shoulder Belts Condition and
Operation

Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
and the anchors.

Movable Head Restraint Operation

On vehicles with movable head restraints, the restraints
must stay in the desired position.

Spare Tire and Jack Storage

Be alert to rattles in the rear of the vehicle. The spare
tire, all the jacking equipment, and the tools must be
securely stowed at all times. Oil the jack ratchet or the
screw mechanism after each use.

Key Lock Service

Lubricate the key lock cylinder.

Body Lubrication Service

Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the
latches, the glove box and the console doors, and any
folding seat hardware.

Underbody Flushing

Flushing the underbody will remove any corrosive
materials used for ice and snow removal and dust
control. At least every spring clean the underbody.
First, loosen the sediment packed in closed areas of
the vehicle. Then flush the underbody with plain water.

Engine Cooling System

Inspect the coolant and freeze protection fluid. If the
fluid is dirty or rusty, drain, flush and refill the engine
cooling system with new coolant. Keep the coolant at
the proper mixture in order to ensure proper freeze
protection, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
swollen, or deteriorated hoses. Tighten the clamps.

Clean the outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure
test the cooling system and the cap in order to help
en-sure proper operation.

SSANGYONG Y200

Bolt*

M3 × 0.5

M4 × 0.7

M5 × 0.8

M6 × 1.0

M8 × 1.25

M10 × 1.25

M10 × 1.5

M12 × 1.25

M12 × 1.75

M14 × 1.5

M16 × 1.5

M18 × 1.5

M20 × 1.5

M22 × 0.5

M24 × 1.5

M24 × 2.0

GENERAL INFORMATION 0B-5

STANDARD BOLTS SPECIFICATIONS

Torque (N•m / Ib-in)

Standard Limit

4T

0.5 N•m

(4.5 lb-in)

1.2 N•m
(11 lb-in)

2.4 N•m
(22 lb-in)

4.0 N•m
(36 lb-in)

8.6 N•m
(77 lb-in)

18.6 N•m
(14 lb-in)

18.6 N•m
(14 lb-in)

34.3 N•m

(25lb-in)

32.3 N•m
(24 lb-in)

54.0 N•m
(40 lb-in)

81.3 N•m
(60 lb-in)

117.6 N•m
(87 lb-in)

166.6N•m
(123 lb-in)

225.4N•m
(167 lb-in)

284.2 N•m

(210 lb-in)

274.4 N•m

(203 lb-in)

7T

0.9 N•m
(8 lb-in)

2.0 N•m

(18 lb-in)

4.0 N•m

(36 lb-in)

6.7 N•m

(60 lb-in)

15.7 N•m
(12 lb-in)

32.3 N•m
(24 lb-in)

30.4 N•m
(22 lb-in)

56.8 N•m
(42 lb-in)

53.9 N•m
(40 lb-in)

89.2 N•m
(66 lb-in)

107.8 N•m
(80 lb-in)

196.0 N•m

(145 lb-in)

274.4 N•m

(203 lb-in)

372.4 N•m

(276 lb-in)

480.2 N•m

(355 lb-in)

460.6 N•m

(341 lb-in)

9T

1.3 N•m

(12 lb-in)

3.0 N•m

(27 lb-in)

5.6 N•m

(50 lb-in)

9.7 N•m

(87 lb-in)

22.5 N•m
(17 lb-in)

46.0 N•m
(34 lb-in)

44.1 N•m
(33 lb-in)

82.3 N•m
(61 lb-in)

77.4 N•m
(57 lb-in)

127.4 N•m
(94 lb-in)

196.0 N•m

(145 lb-in)

284.2 N•m

(210 lb-in)

392.0 N•m

(290 lb-in)

529.2 N•m

(392 lb-in)

686.0 N•m

(508 lb-in)

666.4 N•m

(493 lb-in)

4T 7T

0.7 N•m

(6.3 lb-in)

1.6 N•m

(14 lb-in)

3.1 N•m

(28 lb-in)

5.4 N•m

(49 lb-in)

12.7 N•m
(9 lb-in)

25.5 N•m

(19 lb-in)

24.5 N•m

(18 lb-in)

45.0 N•m

(33 lb-in)

43.1 N•m

(32 lb-in)

71.6 N•m

(53 lb-in)

107.8 N•m
(80 lb-in)

156.8 N•m

(116 lb-in)

215.6 N•m

(160 lb-in)

294.0 N•m

(218 lb-in)

382.2 N•m

(283 lb-in)

372.4 N•m

(276 lb-in)

1.2 N•m

(11 lb-in)

2.6 N•m

(23 lb-in)

5.2 N•m

(47 lb-in)

9.0 N•m

(81 lb-in)

20.6 N•m

(15.2 lb-in)

42.1 N•m
(31 lb-in)

41.2 N•m
(30 lb-in)

75.5 N•m
(56 lb-in)

71.5 N•m
(53 lb-in)

117.6 N•m
(87 lb-in)

186.2 N•m

(138 lb-in)

264.6 N•m

(196 lb-in)

362.6 N•m

(268 lb-in)

490.0 N•m

(362 lb-in)

637.0 N•m

(471 lb-in)

617.4 N•m

(457 lb-in)

9T

17 N•m

(15 lb-in)

4.0 N•m

(36 lb-in)

7.6 N•m

(68 lb-in)

12.7 N•m

(114 lb-in)

30.4 N•m
(22 lb-in)

60.8 N•m
(31 lb-in)

58.8 N•m
(44 lb-in)

107.8 N•m
(80 lb-in)

98.0 N•m
(73 lb-in)

166.6 N•m
(123 lb-in)

264.6 N•m
(196 lb-in)

372.4 N•m
(276 lb-in)

519.4 N•m

(384 lb-in)

705.6 N•m
(522 lb-in)

921.2 N•m
(682 lb-in)

891.8 N•m
(660 lb-in)

*Diameter X pitch in millimeters

SSANGYONG Y200

YAA0B020

0B-6 GENERAL INFORMATION

BASIC SPECIFICATION

DIMENSION

* ( ): Gasoline engine equipped vehicle

YAA0B030

SSANGYONG Y200

SPECIFICA TIONS

GENERAL INFORMATION 0B-7

Systems

General

Engine

Manual

transmission

Automatic

transmission

Items

Overall length (mm)

Overall width (mm)

Overall height (mm)

Gross vehicle weight (kg)

Curb weight (kg)

Min. turning radius (m)

Ground clearance (mm)

Fuel

Fuel tank capacity

Model

No. of cyl./Compression ratio

Total displacement

Camshaft arrangement

Max. power
Max. torque

Injection timing

Idle speed

Cooling system

Coolant capacity

Lubrication

Max. oil capacity

Turbo charger and cooling type

Type

st

Gear ratio

1

nd

2

rd

3

th

4

th

5

Rev.

Model

Type

st

Gear ratio

1

nd

2

rd

3

th

4

Rev.

Diesel

4,270
1,870

1,760
AT : 2405,
MT : 2365
AT : 1950,
MT : 1910

5.6

200

Diesel

80 L

OM662LA

5 / 22 : 1

2,874 cc

SOHC

120 ps / 4,000 rpm

25.5 kg.m / 2,400 rpm
BTDC 18° ± 1.0°

770 ± 50 rpm

Water-cooled/forced circulation

10.5 L ~ 11 L

Gear pump, forced circulation

8.9 L

Turbo charger, air-cooled

Remote control,

floor change type

3.969

2.341

1.457

1.000

0.851

3.705

Electronic

Floor change type

2.742

1.508

1.000

0.708

2.429

Gasoline G32D (G23D)

4,745

←

1,780

2415

-

←
←

Gasoline

←

M162 (M161)

6 / 10 : 1

3,199 cc

DOHC

220 ps / 6,000 rpm

31.9 kg.m / 3,000 rpm
BTDC 8°

770 ± 50 rpm

←

11.3 L ~ 11.5 L

←

9.8 L

-

←
←

←
←
←
←
←
←
←
←
←
←
←
←

SSANGYONG Y200

0B-8 GENERAL INFORMATION

SPECIFICA TIONS (Cont’d)

Systems

Transfercase

Clutch

Power

steering

Front axle

Rear axle

Brake

Suspension

Air

conditioner

Electrical

Items

Model

Type

Gear ratio

Type

Disc type

Type

Steering angle

Drive shaft type

Axle housing type

Drive shaft type

Axle housing type

Master cylinder type

Booster type

Type

Parking brake

Front
Rear

Refrigerant

Compressor type

Battery type/Capacity (V-AH)

Starter capacity (V-kW)

Alternator capacity (V-A)

High

Low

Inner

Outer

Front
Rear

Diesel

Part-time

Planetary gear type

1.000 : 1

2.483 : 1

Hydraulic

[A/T: Torque converter]
Dry single diaphragm type
[A/T: 3 elements 1 stage 2

phases]

Rack and pinion

36°17′
32°40′

Ball joint type

Build-up type

Semi-floating type

Build-up type

Tandem type

Vacuum booster

Disc

Drum (Disc)

Cable type (internal expansion)

Wishbone + Coil spring

5-link + Coil spring

R134a

Vane type

MF / 12 - 90

12 - 2.2

12 - 75 (12 - 90)

Gasoline G32D (G23D)

Full-time (Part-Time)

←
←
←

Torque converter

3 elements 1 stage 2 phases

←
←
←
←
←
←
←
←
←
←

Disc (Drum)

←
←
←
←
←

MF / 112 - 75

12 - 1.8

12 - 115

SSANGYONG Y200

GENERAL INFORMATION 0B-9

RECOMMENDED FLUIDS AND LUBRICANTS

Usage

Engine Oil

Automatic Transmission
Fluid*

Manual Transmission Fluid

Clutch Fluid
(For Manual Transmission)
Transfer Case
Fluid

Brake Fluid

Front and Rear
Axle Fluid

Power Steering Fluid
Coolant

Air Cleaner

Fuel filter

D29ST

G32D

G23D

Part-time

Full-time

Front Axle

Rear Axle

D29ST

G23D
G32D

Diesel

Gasoline

Diesel

Gasoline

Specification Service interval Capacity (L)

Approved by MB

Sheet 229.1 or 229.3

Viscosity: See MB

Sheet 224.1

Approved by MB

Sheet 229.1 or 229.3

Viscosity: See MB

Sheet 224.1

CASTROL

TQ95

(ATF DEXRON II or III)

(DOT 4)

ATF DEXRONâ II, III, ATF S-2,

S-3, S-4, TOTAL FLUID ATX

ATF DEXRONâ II,III, ATF S-2,

S-3, S-4, TOTAL FLUID ATX

DOT4

API GL-5 or

SAE 80W/90

API GL-5 or

SAE 80W/90

(ATF DEXRON II)

Change every 3 years. And, inspect and replenish as necessary.

Clean every 10,000 km, Replace every 30,000 km
Clean every 15,000 km, Replace every 60,000 km
Replace every 45,000 km
Replace every 60,000 km

Initial change: 1,000 km, Change
every 10,000 km or 12 months
(But, every 5,000 km or 6 months
under severe conditions)
Initial change: max. 1,000 km,
Change every 15,000 km or 12 months
(But, every 7,500 km or 6 months
under severe conditions)
Inspect every 30,000 km or 12 months
(But, change every 60,000 km
under severe conditions)
Initially change at 12,000 km, and
Inspect every 50,000 km
Inspect frequently, Change every
40,000 km or 2 years
Inspect every 10,000 ~ 15,000 km
Change every 60,000 km
Inspect every 10,000 ~ 15,000 km
Change every 60,000 km
Change every 40,000 km or 2 years
(Inspect frequently)
Inspect frequently
Change every 38,000 km
Inspect frequently
Change every 38,000 km
Check and replenish as necessary.

6.0 ~ 8.0

7.0 ~ 9.0

5.5 ~ 7.5

Approx. 9.5 L

Approx. 3.4 L

As required

1.2 L

1.4 L

As required

1.4 L

1.9 L

Approx. 1.1 L

10.5~11.0 L

10.0~10.5 L

11.0~11.5 L

SSANGYONG Y200

0B-10 GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER SYSTEM

VEHICLE IDENTIFICATION
NUMBER (VIN)

Vehicle Identification Number (VIN) is on the right front
axle upper frame.

* K P T G 0 B 1 9 S 1 P 000000

YAA0B040

12~17. Production Serial Number

: 000001- 999999

11. Plant Code
P: PyongTaek Plant

10. Model Year
2 : 2002
3 : 2003

9. Check Digit
S: All area except North America

8. Engine Type
6 : 2295cc, In-line 4Cylinder, Gasoline (E23)
9 : 3199cc, In-line 6Cylinder, Gasoline (E32)
D: 2874cc, In-line 5Cylinder, Diesel (662LA)

7. Restraint System
1 : 3-Point Seat Belts, 2 : 2-Point Seat Belts

6. Trim Level
A: Standard, B : Deluxe, C: Super Deluxe

5. Body Type
0 : 5-Door
1 : 4-Door
2 : 3-Door

4. Line Models
G: Rexton (LHD)
H: Rexton (RHD)

3. Vehicle Type
T : Passengr Cars, A : Truck

2. Maker Identification : P

1. Nation : K

*. Symbol according to No.

SSANGYONG Y200

MANUF A CTURER’S PLATE

1 Type Approval No.
2 Vehicle Identification No.

Man ufacturer’s Plate Location

Gasoline Engine

GENERAL INFORMATION 0B-11

YAA0B050

Diesel Engine

YAA0B060

YAA0B070

SSANGYONG Y200

0B-12 GENERAL INFORMATION

ENGINE NUMBER

Diesel Engine

662 9 20 1 0 012345

Serial Number

0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M

YAA0B080

The engine number is stamped on the cylinder block
in front of injection pump.

0 : Common
1 : Left - Hand Drive
2 : Right - Hand Drive

5 : REXTON

910 :Non-Intercooler Engine
920 :Intercooler Engine

661 : 2299cc
662 : 2874cc

YAA0B090

SSANGYONG Y200

Gasolind Engine (3.2L DOHC)

GENERAL INFORMATION 0B-13

162 990 1 0 012345

Serial Number

0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M

The engine number is stamped on the lower rear

•

side of the alternator.

Gasolind Engine (2.3L DOHC)

YAA0B100

0 : Common
1 : Left - Hand Drive
2 : Right - Hand Drive

5 : REXTON

99 : 3.2L
97 : 2.3L

ENGINE TYPE

YAA0B120

The engine number is stamped on the upper rear

•

left-hand side of the cylinder block.

SSANGYONG Y200

YAA0B110

0B-14 GENERAL INFORMATION

VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the lifting equipment only
at the points indicated. Failure to use these precise
positions may result in permanent vehicle body
deformation.

Many dealer service facilities and service stations are
equipped with automative hoists that bear upon some
parts of the frame in order to lift the vehicle. If any
other hoist method is used, take special care to avoid
damaging the fuel tank, the filter neck, the exhaust
system, or the underbody.

Using Floor Jack

Front Side

Using Jack

YAA0B130

Rear Side

YAA0B140

Rearward of Front Tire

YAA0B150

YAA0B160

Forward of Rear Tire

SSANGYONG Y200

SECTION 1

ENGINE

SECTION 1A

ENGINE GENERAL INFORMA TION

TABLE OF CONTENTS

Description and Operation............................... 1A-2

Cleanliness and Care ....................................... 1A-2

On-Engine Service............................................ 1A-2

Component Locator .......................................... 1A-3

M162 Engine..................................................... 1A-3

M161 Engine..................................................... 1A-5

Diesel Engine.................................................... 1A-7

Diagnostic Information and Procedure.......... 1A-9

Oil Leak Diagnosis ........................................... 1A-9

Compression Pressure Test

(Gasoline Engine) ........................................ 1A-10

Compression Pressure Test

(Diesel Engine) ............................................ 1A-12

Cylinder Pressure Leakage Test

(Gasoline Engine) ........................................ 1A-14

Cylinder Pressure Leakage Test

(Diesel Engine) ............................................ 1A-16

General Diagnosis .......................................... 1A-18

Specifications .................................................. 1A-23

Engine Specifications..................................... 1A-23

Performance Curve ......................................... 1A-24

Special Tools and Equipment ....................... 1A-27

Special Tools Table ........................................ 1A-27

1A-2 ENGINE GENERAL INFORMATION

DESCRIPTION AND OPERATION

CLEANLINESS AND CARE

An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating
of enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on
initial operation. Proper cleaning and protection of
machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.

Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same
mating surfaces, as when they were removed.

Battery cables should be disconnected before any

major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

ON-ENGINE SERVICE

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.

Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against
accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-3

COMPONENT LOCATOR

M162 ENGINE

Front View

1 HFM Sensor
2 Intake Air Duct
3 Resonance Flap
4 Cylinder Head Cover
5 Exhaust Camshaft
6 Intake Camshaft
7 Cylinder Head
8 Spark Plug Connector

9 Valve Tappet
10 Injector
1 1 Exhaust Valve

SSANGYONG Y200

YAD1A010

1 2 Intake Manifold
1 3 Connecting Rod
1 4 Exhaust Manifold
15 Crankshaft
1 6 Engine Mounting Bracket
17 Starter
18 Crankcase
19 Oil Pump Sprocket
2 0 Oil Strainer
2 1 Oil Pan
2 2 Drain Plug

1A-4 ENGINE GENERAL INFORMATION

Side View

2 3 Camshaft Adjuster
2 4 Cooling Fan and Viscous Clutch
25 Piston
2 6 Flywheel of Drive Plate

YAD1A020

2 7 Oil Pump Drive Chain
2 8 Oil Return Pipe
2 9 Timing Chain
3 0 Oil Pump

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-5

M161 ENGINE

Front View

1 HFM Sensor

2 Intake Air Duct

3 Cylinder Head Cover

4 Ignition Coil

5 Spark Plug Connector

6 Fuel Distributor

7 Injector

8 Exhaust Camshaft

9 Intake Camshaft
1 0 Valve Tappet
1 1 Intake Valve

SSANGYONG Y200

YAD1A030

1 2 Intake Manifold
1 3 Cylinder Head
1 4 Exhaust Manifold
15 Dipstick Guide Tube and Gauge
1 6 Connecting Rod
17 Crankshaft
1 8 Engine Mounting Bracket
19 Starter
20 Crankcase
21 Oil Pump Sprocket
2 2 Oil Pan

1A-6 ENGINE GENERAL INFORMATION

Side View

2 3 Camshaft Adjuster
2 4 Oil Filler Cap
2 5 Engine Hanger Bracket
2 6 Cooling Fan and Viscous Clutch
2 7 Oil Filter
2 8 Timing Chain

YAD1A040

2 9 Oil Pump Drive Chain
3 0 Oil Strainer
3 1 Oil Pump
3 2 Ring Gear and Flywheel of Drive Plate
33 Piston

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-7

DIESEL ENGINE

Front View

SSANGYONG Y200

YAD1A050

1A-8 ENGINE GENERAL INFORMATION

Side View

YAD1A060

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-9

DIAGNOSTIC INFORMATION AND PROCEDURE

OIL LEAK DIAGNOSIS

Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following
procedures may help you in locating and repairing
most leaks.

Finding the Leak

1. Identify the fluid. Determine whether it is engine
oil, automatic transmission fluid, power steering
fluid, etc.

2. Identify where the fluid is leaking from.

2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large
sheet of paper.

2.2 Wait a few minutes.

2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.

3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.

4. If the leak still cannot be found, it may be
necessary to clean the suspected area with a
degreaser, steam or spray solvent.

4.1 Clean the area well.

4.2 Dry the area.

4.3 Operate the vehicle for several miles at
normal operating temperature and varying
speeds.

4.4 After operating the vehicle, visually check the
suspected component.

4.5 If you still cannot locate the leak, try using
the powder or black light and dye method.

Powder Method

1. Clean the suspected area.

2. Apply an aerosol-type powder (such as foot
powder) to the suspected area.

3. Operate the vehicle under normal operating
conditoins.

4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.

Black Light and Dye Method

A dye and light kit is available for finding leaks, Refer
to the manufacturer's directions when using the kit.

1. Pour the specified amount of dye into the engine
oil fill tube.

2. Operate the vehicle normal operating conditions
as directed in the kit.

3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.

Repairing the Leak

Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must
be determined in order for it to be repaired properly.
If a gasket is replaced, but the sealing flange is bent,
the new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
leak, check for the following conditions and correct
them as they may cause a leak.

Gaskets

The fluid level/pressure is too high.

•

The crankcase ventilation system is malfunctioning.

•

The fasteners are tightened improperly or the

•

threads are dirty or damaged.
The flanges or the sealing surface is warped.

•

There are scratches, burrs or other damage to the

•

sealing surface.
The gasket is damaged or worn.

•

There is cracking or porosity of the component.

•

An improper seal was used (where applicable).

•

Seals

The fluid level/pressure is too high.

•

The crankcase ventilation system is malfunctioning.

•

The seal bore is damaged (scratched, burred or

•

nicked).
The seal is damaged or worn.

•

Improper installation is evident.

•

There are cracks in the components.

•

The shaft surface is scratched, nicked or damaged.

•

A loose or worn bearing is causing excess seal

•

wear.

SSANGYONG Y200

1A-10 ENGINE GENERAL INFORMATION

COMPRESSION PRESSURE TEST (GASOLINE ENGINE)

1 Compression Pressure Tester
2 Diagram Sheet

Standard Service Data

Application

Compression Ratio
Normal Engine Temperature
Normal Compression Pressure
Permissible Pressure Difference Between Individual

Cylinders

3 Adaptor
4 Sealing Cone

M162 Engine

10 : 1

80 °C (176 °F)

Min. 10 bar, Max. 14 bar

Max. 1.5 bar

YAD1A070

M161 Engine

10.4 : 1

←

Min. 11 bar, Max. 15 bar

←

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-11

T ools Required

001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench

Measuring Procedure

1. Warm the engine up to normal operating
temperature.

2. Remove the spark plugs using the spark plug
wrench 119 589 01 09 00.

3. Place the diagram sheet to compression pressure
tester 001 589 76 21 00.

4. Connect the adaptor to compression pressure
tester 001 589 76 21 00 and install it into the spark
plug hole.

5. Crank the engine approx. eight revolutions by
using the start motor.

6. Compare the measurements of compression
pressure tester 001 589 76 21 00 with the
specifications.

7. Measure the compression pressure of the other
cylinders in the same way.

8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.

Notice:

Discharge the combustion residues in the

•

cylinders before testing the compression
pressure.

Apply the parking brake before cranking the

•

engine.

SSANGYONG Y200

1A-12 ENGINE GENERAL INFORMATION

COMPRESSION PRESSURE TEST (DIESEL ENGINE)

1 Test Adaptor
2 Flexible Connector

Standard Service Data

Compression Ratio
Normal Engine Temperature
Normal Compression Pressure
Minimum Compression Pressure
Permissible Pressure Difference Between Individual

Cylinders

YAD1A080

3 Compression Pressure Tester

22 : 1

80 °C (176 °F)

28bar

Approx.18bar

Max. 3bar

SSANGYONG Y200

YAD1A090

ENGINE GENERAL INFORMATION 1A-13

T ools Required

001 589 76 21 00 Compression Pressure Tester
001 589 73 21 00 Hand Vacuum Pump
601 589 65 09 00 Socket

Measuring Procedure

Notice: Ensure that no gear is engaged and that

the vehicle is protected from rolling.

1. Run the engine to be the coolant temperature
80 °C (176 °F).

2. Remove the fuel injection nozzle.

3. Install the test adapter (1) and connect the flexible
connector (2) to the compression pressure tester
001 589 76 21 00.

YAD1A100

4. Disconnect the vacuum line from the stop unit and
connect the hand vacuum pump 001 589 73 21 00
to the stop unit.

5. Pump the hand vacuum pump 001 589 73 21 00
and make the fuel injection pump in stop position.

Operating Pressure Approx. 500bar

6. Using a starter motor, crank the engine 8
revolutions.

7. Measure the remaining cylinder compression
pressure in the same manner and compare it with
service data.

Notice: If out of standard, do cylinder pressure
leakage test.

8. Remove the compression pressure tester 001 589
76 21 00.

9. Install the fuel injection nozzle.

SSANGYONG Y200

1A-14 ENGINE GENERAL INFORMATION

CYLINDER PRESSURE LEAKAGE TEST (GASOLINE ENGINE)

1 Engine Oil Filler Cap
2 Vibration Damper

At Whole Engine
At Valve and Cylinder Head Gasket
At Piston and Piston Ring

Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark (M162 Engine)

Cylinder Number

TDC Mark (M161 Engine)

Cylinder Number

3 Cylinder Pressure Leakage Tester with

Connecting Hose

Permissible Pressure Leakage

OT (TDC)

1, 6

OT (TDC)

1, 4

Universal Tool

Max. 25 %
Max. 10 %
Max. 20 %

a (120 °)

2, 5

YAD1A110

b (240 °)

3, 4

UT (BDC 180 °)

2, 3

Cylinder Pressure Leakage Tester Bosch, EFAW 210A

Sun, CLT 228

SSANGYONG Y200

M162 Engine

ENGINE GENERAL INFORMATION 1A-15

Leakage Test

1. Warm the engine up to normal operating
temperature.

2. Disconnect the negative battery cable.

3. Remove the spark plugs.

4. Check the coolant level by opening the coolant
reservoir cap and replenish if insufficient.

5. Open the engine oil filler cap.

6. Connect the tester to air pressure line and adjust
the scale of tester.

7. Install the connecting hose to spark plug hole.

8. Position the piston of No.1 cylinder at TDC by
rotating the crankshaft.

M161 Engine

YAD1A120

9. Connect the connecting hose to tester and
measure the leakage volume after blowing up
5 bar of compressed air.

Notice: Measure the leakage volume in the
completely opening condition of throttle valve by
pulling the acceleration cable.

10. Perform the pressure test according to the firing
order.

Notice:

Firing Order

M162 Engine: 1 - 5 - 3 - 6 - 2 - 4

•

M161 Engine: 1 - 3 - 4 - 2

•

11. Compare the leakage pressure with the
specifications.

SSANGYONG Y200

YAD1A130

1A-16 ENGINE GENERAL INFORMATION

CYLINDER PRESSURE LEAKAGE TEST (DIESEL ENGINE)

1 Connector
2 Connection Piece

3 Connection Hose

P ermissible Pressure Leakage (Engine at Normal Operating Temperature of 80°C)

At Whole Engine
At Valve and Cylinder Head Gasket
At Piston and Piston Ring

Max. 25 %
Max. 10 %
Max. 20 %

Univer sal Tools

Cylinder Pressure Leakage Tester
Connection Piece

Bosch, EFAW 210 A or Sun CLT 228

Bosch order no. 1 687 010 016

YAD1A140

SSANGYONG Y200

YAD1A150

ENGINE GENERAL INFORMATION 1A-17

Leakage Test

1. Run the engine to be the coolant temperature
80 °C (176 °F).

2. Remove the fuel injection nozzle.

3. Open the coolant reservoir.

4. Check the coolant level and replenish if necessary.

5. Open the oil filler cap.

6. Remove the air cleaner cover and element.

7. Position the piston at TDC.

8. Install the connector (1) and connection piece (2).

9. Calibrate the tester and connect the connection
hose (3)

10. Pressurize with compressed air and compare the
pressure changes with permissible pressure
leakage.

11. If permissible pressure leakage is out of standard,
check followings :

- Intake and exhaust lines.

- Sounds in oil filler area.

- Air bubbles in radiator coolant.

12. Do pressure leakage test for the remaining
cylinders according to the firing order.

firing order: 1-2-4-5-3

•

1 3. Remove the tester.

14. Close the coolant reservoir cap and oil filler cap.

1 5. Install the air cleaner element and cover.

16. Install the fuel injection nozzle.

SSANGYONG Y200

1A-18 ENGINE GENERAL INFORMATION

GENERAL DIAGNOSIS

Hard Starting
(With normal
cranking)

Condition

Malfunction of
Ignition System

Malfunction of
Fuel System

Decline of
Compression
Pressure

Others

Probable Cause

Faulty fuse.

•

Faulty spark plug.

•

Electric leakage at the high

•

tension cable.
Poor connection of the high

•

tension cable or lead wires.
Improper ignition timing.

•

Faulty ignition coil.

•

Lock of fuel in the fuel tank.

•

Dirty or clogged fuel filter.

•

Clogged fuel pipe.

•

Malfunction of the fuel pump.

•

Malfunction of the fuel injector.

•

The foreign material in the fuel

•

tank.
Poor tightening spark plug.

•

Cracked cylinder head gasket.

•

Inadequate the valve clearance.

•

Leakage of the valve clearance.

•

Interference of the valve stem.

•

Low elasticity or damage of the

•

valve spring.
Abnormal interference of

•

pistons and cylinders.
Excessive wear of pistons,

•

rings, or cylinders.

Broken timing belt.

•

Loosening, damage or leakage

•

of the vacuum hose.
Leakage of intake system.

•

Correction

Replace the fuse.

•

Clean, adjust the plug gap or

•

replace.
Replace the cable.

•

Replace the cable or wires.

•

Adjust the ignition timing.

•

Replace the ignition coil.

•

Feed the fuel.

•

Replace the filter.

•

Clean the fuel pipe.

•

Replace the fuel pump.

•

Replace the injector.

•

Clean the fuel tank.

•

Tighten to the specified torque.

•

Compression
Replace the gasket.

•

Adjust the clearance.

•

Repair the valve.

•

Replace the valve or the valve

•

guide.
Replace the valve spring.

•

Replace the piston ring.

•

Replace the ring or the piston

•

and boring or replace the
cylinder.

Replace the belt.

•

Connect the hose correctly or

•

replace it.
Replace intake system.

•

Lack of Engine
Power

Decline of
Compression
Pressure

Malfunction of
Ignition System

Refer to above in this page.

•

Improper ignition timing.

•

Faulty spark plug.

•

Electric leakage or poor

•

connection of the high tension
cable.

Refer to above in this page.

•

Adjust the ignition timing.

•

Adjust or replace the spark

•

plug.
Connect the cable correctly or

•

replace it.

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-19

General Diagnosis (Cont’d)

Condition

Lack of Engine
Power

Rough Engine
Idling

Engine Hesitate
(Upon pressing
accelerating
pedal, the
engine makes
delayed
response This
situation is
remarkable
when cruising
or starting.)

Malfunction of
Fuel System

Others

Decline of
Compression
Pressure

Malfunction of
Fuel System

Malfunction of
Ignition System

Others

Decline of
Compression
Pressure

Malfunction of
Ignition System

Others

Probable Cause

Clogged fuel pipe.

•

Clogged or contaminated fuel

•

filter.
Clogged exhaust system.

•

Clogged or contaminated air

•

cleaner element.
Leak of the intake manifold

•

gasket.
Dragging brakes.

•

Refer to “Page 1A-10”.

•

Clogged fuel pipe.

•

Clogged or contaminated fuel

•

filter.
Malfunction of the fuel pressure

•

regulator.
Malfunction of the spark plug.

•

Electric leakage or poor con-

•

nection of the high tension
cable.

Poor ignition timing.

•

Malfunction of the ignition coil.

•

Clogged or contaminated air

•

cleaner element.
Leak of the intake manifold

•

gasket.
Poor connection or damage or

•

leakage of the vacuum hose.
Refer to “Page 1A-10”.

•

Poor ignition timing.

•

Poor spark plug or Poor adjust-

•

ment of the plug gap.
Electric leakage or poor con-

•

nection of the high tension
cable.

Malfunction of the air cleaner

•

system.
Leak of the intake manifold

•

gasket.

Correction

Clean the pipe.

•

Replace the filter.

•

Check and repair the system.

•

Clean or replace the air cleaner

•

element.
Replace the gasket.

•

Repair or replace the brakes.

•

Refer to “Page 1A-10”.

•

Clean the pipe.

•

Replace the filter.

•

Replace the regulator.

•

Adjust or replace the spark

•

plug.
Connect the cable correctly or

•

replace it.

Adjust the ignition timing.

•

Replace the ignition coil.

•

Clean or replace the air cleaner

•

element.
Replace the gasket.

•

Connect the hose correctly or

•

replace it.
Refer to “Page 1A-10”.

•

Adjust the ignition timing.

•

Replace the plug or adjust the

•

gap.
Connect the cable correctly or

•

replace it.

Clean or replace the air cleaner

•

system.
Replace the gasket.

•

SSANGYONG Y200

1A-20 ENGINE GENERAL INFORMATION

General Diagnosis (Cont’d)

Condition

Engine Surging
(Engine power
makes
fluctuation in a
fixed speed
and speed
changes
without
operating the
accelerating
pedal.)

Excessive
Detonation
(According to
the opening
range of
Malfunction of
metallic is
made with
abnormal
explosion )

Overheat

Decline of
Compression
Pressure

Malfunction of
Fuel System

Malfunction of
Ignition System

Others

Overtheated
Engine

Malfunction of
Fuel System

Malfunction of
Ignition System

Others

Malfunction of
Cooling System

Malfunction of
Lubrication
System

Other

Probable Cause

Refer to “Page 1A-10”.

•

Clogged fuel pipe.

•

Clogged or contaminated fuel

•

filter.
Malfunction of the fuel pressure

•

regulator.
Malfunction of the spark plug.

•

Electric leakage or poor

•

connection of the high tension
cable.

Poor ignition timing.

•

Leak of the intake manifold

•

gasket.
Leakage of the vacuum hose.

•

Refer to “Overheat” in this

•

page.
Abnormal spark plug.

•

Poor ignition timing.

•

Electric leakage or poor con-

•

nection of the high tension
cable.

Clogged or contaminated fuel

•

filter and fuel pipe.
Leak of the intake manifold

•

gasket.
Excessive carbon deposit due

•

to abnormal combustion.
Lack of coolant.

•

Malfunction of the thermostat.

•

Malfunction of the cooling fan.

•

Poor water pump performance.

•

Clogged or leaky radiator.

•

Poor engine oil.

•

Blocking oil filter or strainer.

•

Lack of engine oil.

•

Poor oil pump performance.

•

Leakage of oil

•

Damaged cylinder head gas-

•

ket.

Correction

Refer to “Page 1A-10”.

•

Clean the pipe.

•

Replace the filter.

•

Replace the fuel pressure

•

regulator.
Adjust or replace the spark

•

plug.
Connect the cable correctly or

•

replace it.

Adjust the ignition timing.

•

Clean or replace the gasket.

•

Connect the hose correctly or

•

replace it.
Refer to “Overheat” in this

•

page.
Replace the spark plug.

•

Adjust the ignition timing

•

Connect the cable correctly or

•

replace it.

Clean or replace the fuel filter

•

and the fuel pipe.
Replace the gasket.

•

Remove the carbon.

•

Refill coolant.

•

Replace the thermostat.

•

Check or replace the cooling

•

fan.
Replace the pump.

•

Clean, repair or replace the

•

radiator.
Replace engine oil with the

•

specified one.
Clean or repair the oil filter or

•

the strainer.
Refill oil.

•

Replace or repair the pump.

•

Repair.

•

Replace the gasket.

•

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-21

General Diagnosis (Cont’d)

Condition

Poor Fuel
Consumption

Excessive
Consumption of
Engine Oil

Low Oil
Pressure

Decline of
Compression
Pressure

Malfunction of
Fuel System

Malfunction of
Ignition System

Malfunction of
Cooling System

Others

Leakage of
Engine Oil

Oil Mixing in
Combustion
Chamber

Malfunction of
Lubrication
System

Probable Cause

Refer to “Page 1A-10”.

•

Leakage of the fuel tank or the

•

fuel pipe.
Improper ignition timing.

•

Abnormal spark plug

•

(Excessive carbon deposit,
inadequate gap, burnt elec­trode).

Electric leakage or poor

•

connection of the high tension
cable.

Malfunction of the thermostat.

•

Improperly installed valve.

•

Low pressure of tires.

•

Loosened oil drain plug.

•

Loosened oil pan bolt.

•

Loosened oil filter.

•

Loosened oil pressure switch.

•

Leakage of camshaft front oil

•

seal.
Leakage of crankshaft front oil

•

seal.
Leakage at the cylinder head

•

cover gasket.
Damage of the cylinder head

•

gasket.
Stuck piston ring.

•

Worn piston or cylinder.

•

Worn piston ring or ring groove.

•

Inadequate position of the

•

piston ring cutting part.
Abrasion or damage of the

•

valve system.
Inadequate oil viscosity.

•

Loosening of the oil pressure

•

switch.
Lack of engine oil.

•

Blocking oil strainer.

•

Lowered function of the oil

•

pump.
Abrasion or damage of the oil

•

pump relief valve.

Correction

Refer to “Page 1A-10”.

•

Repair or replace the fuel tank

•

or the fuel pipe
Adjust the ignition timing.

•

Replace the plug.

•

Connect the cable normally or

•

replace it.

Repair the thermostat.

•

Repair or replace the valve.

•

Adjust the pressure of tires.

•

Tighten the plug.

•

Tighten the bolt. Engine Oil

•

Tighten the filter.

•

Tighten the switch.

•

Replace the seal.

•

Replace the seal.

•

Replace the gasket.

•

Replace the gasket.

•

Remove carbon and replace the

•

ring.
Replace the piston or the

•

cylinder.
Replace the piston or ring.

•

Adjust the position.

•

Replace the valve system.

•

Replace with the specified one.

•

Tighten the switch.

•

Refill oil.

•

Clean the strainer.

•

Replace the pump.

•

Replace the valve.

•

SSANGYONG Y200

1A-22 ENGINE GENERAL INFORMATION

General Diagnosis (Cont’d)

Condition

Valve NoiseEngine Noise

Piston, Ring,
Cylinder Noise

Connecting
Rod Noise

Crankshaft
Noise

Probable Cause

Inadequate valve clearance

•

Abrasion of valve stem or

•

guide.
Weak valve spring.

•

Abrasion of the piston, the ring

•

or the cylinder.

Abrasion of the connecting rod

•

bearing.
Loosened the connecting rod

•

nut.
Abrasion of the crankshaft

•

bearing.
Abrasion of the crankshaft

•

journal.
Loosened bearing cap bolt.

•

Excessive clearance of the

•

crankshaft thrust bearing.
Low oil pressure.

•

Correction

Adjust the valve clearance.

•

Replace the valve stem or the

•

guide.
Replace the spring.

•

Boring the cylinder or replace

•

the piston, the ring or the
cylinder.

Replace the bearing.

•

Tighten to the specified torque

•

Replace the bearing.

•

Grind or replace the crankshaft

•

journal.
Tighten to the specified torque.

•

Adjust or replace.

•

Refer to “Page 1A-21” in this

•

section.

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-23

SPECIFICATIONS

ENGINE SPECIFICATIONS

Application

Engine Model
Displacement (CC)
Cylinder (Bore x Stroke) (mm)

Fuel Injection / Ignition System
Compression Ratio

Number of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type
Max. Output (ps/rpm)
Max. Torque (kg•m/rpm)
Firing Order

Ignition Type
Ignition Timing

Valve Timing Intake Open/

Close

Exhaust Open/

Close

M162.990

3199

89.9 x 84.0
MSE 3.63D

10 : 1

6

DOHC

Chain-Driven

220 / 6000

31.6 / 3900

1 - 5 - 3 - 6 - 2 - 4

Distributorless

Double Ignition

BTDC 8°

ATDC 11° /

ABDC 34°

BBDC 31° /

BTDC 14°

M161 EngineM162 Engine Diesel Engine

M161.970

2295

90.9 x 88.4
MSE 3.53D

10.4 : 1
4

DOHC

←

149 / 5500

22.4 / 4000
1 - 3 - 4 - 2

←

BTDC 6° ± 2°

ATDC 13.15° /

ABDC 13.57°

BBDC 16.58° /

BTDC 17.05°

Four-Stroke Diesel

2874

89 x 92.4

PES 5 M55

C320 RS 168

22 : 1

5

SOHC

←

120 / 4000

25.5 / 4000

1 - 2 - 4 - 5 - 3

-

BTDC 18° ± 10°

ATDC 11.33° /

ABDC 17°

BBDC 28° /

BTDC 15.25°

Valve Clearance Adjustment
Idle Speed (rpm)
Fuel Injection Pressure (kg/cm²)
Oil Capacity (liter)
Lubrication Type

Oil Filter Type
Fuel

MSE : Engine Control Module

3.63D : 6 Cylinder V ersion

3.53D : 4 Cylinder V ersion

Automatic Control

700 ± 50

3 - 4

8.2

Forced by Gear Pump

Full Flow with

Paper Filter

Unleaded Gasoline

←

750 ± 50

3.2 - 4.2

7.5

←

←

←

←

720 - 820
138 - 146

8.0 - 9.5

←

Combined Full-Flow and

Partial Flow Filter

Diesel

SSANGYONG Y200

1A-24 ENGINE GENERAL INFORMATION

PERFORMANCE CURVE

M162 Engine

YAD1A160

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-25

M161 Engine

SSANGYONG Y200

YAD1A170

1A-26 ENGINE GENERAL INFORMATION

Diesel Engine

YAD1A180

SSANGYONG Y200

ENGINE GENERAL INFORMATION 1A-27

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

YAD1A190

YAD1A220

001 589 73 21 00

Hand Vacuum Pump

120 589 02 09 00

Spark Plug Wrench

001 589 76 21 00

Compression Pressure

Tester

YAD1A210

610 589 65 09 00

Socket

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

Cylin der He ad ................................................. 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

1 Engine Assembly

T ools Required

000 589 10 99 01 Torque Wrench
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor

YAD1B010

SSANGYONG Y200

YAD1B020

M162 ENGINE MECHANICAL 1B1-3

Removal & Installation Procedure

1. Disconnect the negative terminal of battery.

2. Remove the hood.

3. Remove the under cover.

Installation Notice

Tightening Torque

4. Disconnect the Hot Film Air Mass (HFM) sensor
connector.

5. Disconnect the HFM sensor from the air filter
housing.

6. Remove the intake air duct mounting nuts.

Installation Notice

Tightening Torque

28 - 47 N•m

(21 - 35 lb-ft)

9 - 11 N•m

(80 - 97 lb-in)

KAA1C010

YAD1B030

7. Remove the air cleaner cover. Remove the
mounting bolts and air cleaner housing and
element assembly.

8. Loosen the radiator drain cock and drain the
coolant.

Notice: Open the coolant reservoir cap.

SSANGYONG Y200

YAD1B040

1B1-4 M162 ENGINE MECHANICAL

9. Loosen the cylinder block drain plug and then drain
the coolant completely.

Installation Notice

Tightening Torque 30 N•m (22 lb-ft)

Replace the seal before installation of the drain
plug.

YAD1B050

10. Remove the cooling fan shroud. Refer to Section

1D , Engine Cooling.

YAD1B060

YAD1B070

11. Disconnect the each hose from radiator.

12. Remove the upper mounting bolts of radiator and
then remove the radiator.

YAD1B080

SSANGYONG Y200

YAD1B090

M162 ENGINE MECHANICAL 1B1-5

13. Remove the hydraulic pipe of power steering.

Installation Notice

Tightening Torque

Completely drain the oil.

14. Discharge the refrigerant from A/C system, and
disconnect the discharge pipe and suction pipe
from the compressor . R efer to Section 7B , Manual

Control Heating, Ventilation, and Air Conditioning
System.

Installation Notice

40 - 50 N•m

(30 - 37 lb-ft)

YAD1B100

YAD1B4M0

Tightening Torque

20 - 30 N•m

(15 - 22 lb-ft)

15. Remove the acceleration control cable and
automatic transmission pressure cable.

16. Remove the fuel feed and return line.

Installation Notice

Tightening Torque

21 - 25 N•m

(15 - 18 lb-ft)

SSANGYONG Y200

Before removing the fuel lines, release the pressure
in the fuel system.

KAA1F070

1B1-6 M162 ENGINE MECHANICAL

17. Disconnect the terminals from the generator.

YAD1B110

18. Disconnect the terminal from starter motor and
remove the starter motor.

19. Disconnect the engine main harness ground.

YAD1B120

YAD1B130

20. Disconnect the engine ground wire.

21. Disconnect following sensors connector.

Coolant temperature sensor.

•

2 knock sensors.

•

Camshaft and crankshaft sensors.

•

YAA1F150

SSANGYONG Y200

YAD1B140

M162 ENGINE MECHANICAL 1B1-7

22. After removing the ignition coil cover, disconnect
the ignition coil connector.

23. Remove the harness cover and disconnect the 6
injection valve connectors. Disconnect the main
harness.

24. Separate the hose toward engine from canister
purge solenoid valve.

YAD1B4N0

YAD1B150

25. Remove the automatic transmission oil cooler line.

Installation Notice

Tightening Torque

25 - 35 N•m

(18 - 26 lb-ft)

26. Separate the vacuum hose for brake booster.

27. Separate the other vacuum hoses.

SSANGYONG Y200

YAD1B160

1B1-8 M162 ENGINE MECHANICAL

KAA5A2N0

28. Remove the service hole cover in the engine block.

29. Put the alignment mark for installation, and remove
the six mounting bolts for torque converter from
drive plate through the service hole by rotating the
engine and remove the torque converter.

Installation Notice

Tightening Torque 42 N•m (31 lb-ft)

Screw the six bolts mounting the torque

•

converter through the service hole by using a
mirror and rotating the engine.

30. Remove the exhaust manifold and exhaust pipe.

Installation Notice

Tightening Torque 30 N•m (22 lb-ft)

YAD1B180

YAD1B190

31. Remove the transmission mounting bolts and
separate the transmission from the engine.

Installation Notice

Tightening Torque

54 - 68 N•m

(40 - 50 lb-ft)

32. Install a chain to the bracket of engine, by using
a hoist or crane.

33. Remove the engine mounting bracket nuts.

Installation Notice

Tightening Torque

Upper : 70 N•m (52 lb-ft)

Lower : 38 N•m (28 lb-ft)

YAD1B200

SSANGYONG Y200

YAD1B210

M162 ENGINE MECHANICAL 1B1-9

34. Carefully separate the engine assembly from the
vehicle.

35. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200

1B1-10 M162 ENGINE MECHANICAL

POLY V-BELT AND TENSIONING DEVICE

POLY V - BELT

Preceding Work : Removal of cooling fan

1 Poly V-belt 2 Belt Tensioning Pulley

Removal & Installation Procedure

1. Release the belt tension by turning the belt
tensioning pulley nut clockwise.

Installation Notice

Tightening Torque

2. Remove the poly v-belt.
Notice: Check the belt for damage and tensioning

pulley bearing point for wear and replace them if
necessary.

YAD1B250

3. Install the belt by turning the nut of tensioning
pulley clockwise.

YAD1B330

40.5 - 49.5 N•m

(29.9 - 36.5 lb-ft)

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-11

Poly V-Belt Arrangement

1 Belt Tensioning Pulley
2 Crankshaft Belt Pulley
3 A/C Compressor Pulley
4 Cooling Fan Pulley

YAD1B340

5 Generator Pulley
6 Idler
7 Power Steering Pump Pulley
8 Cooling Fan and Water Pump Pulley

SSANGYONG Y200

1B1-12 M162 ENGINE MECHANICAL

YAD1B370

POLY V - BELT INSPECTION

Make marks on the belt with chalk.

•

Rotate the engine and check the belt for damage.

•

Notice: If one of the following types of damages
is found, replace the belt.

1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.

YAD1B380

YAD1B390

3. Pointed rib.

4. Belt cord visible in the base of rib.

5. Cord torn out at the side.

6. Outer cords frayed.

YAD1B400

SSANGYONG Y200

YAD1B410

M162 ENGINE MECHANICAL 1B1-13

7. Rib detached from the base of belt.

8. Splits across the rib.

9. Sections of rib torn out.

YAD1B420

YAD1B430

10. Splits across several ribs.

11. Splits across the back of the belt.

SSANGYONG Y200

YAD1B440

1B1-14 M162 ENGINE MECHANICAL

TENSIONING DEVICE

Preceding Work : Removal of poly v-belt

1 Belt (L = 2245)
2 Bolt Combi (M8 x 14, 3 pieces) + Washer

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

YAD1B350

3 Water Pump Pulley
4 Nut
5 Belt Tensioning Pulley

SSANGYONG Y200

YAD1B250

M162 ENGINE MECHANICAL 1B1-15

Removal & Installation Procedure

1. Remove the poly v-belt.

2. Remove the tensioning pulley by turning its

mounting nut counter clockwise as shown in figure.

Installation Notice

Tightening Torque

3. Remove the bolts and remove the water pump

pulley.

Installation Notice

40.5 - 49.5 N•m

(29.9 - 36.5 lb-ft)

YAD1B360

Tightening Torque

22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

4. Remove the mounting bolts(M8 x 30, 3 pieces) at

the tensioning device, and remove the tensioning
device.

Installation Notice

Tightening Torque 26 - 32 N•m (19 - 24 lb-ft)

5. Installation should follow the removal procedure

in the reverse order.

SSANGYONG Y200

1B1-16 M162 ENGINE MECHANICAL

CRANK CASE AND CYLINDER HEAD

CRANKCASE VENTILATION SYSTEM

1 Crankcase
2 Air Admission Port in Crankcase
3 Oil Drain Port
4 Filter
5 Gasket
6 A/C Bracket
7 Oil Drain Pipe
8 Oil Pan

9 Air Admission Line
1 0 Vent Line
1 1 Restriction Hole (Diameter = 2 mm)
1 2 Intake Manifold

YAD1B220

1 3 Intake Air Duct (Cross Pipe)
1 4 Cylinder Head Cover
1 5 Oil Separator
1 6 Oil Separator
1 7 Air Admission and Vent Connection
1 8 Air Admission and Vent Connection
1 9 Throttle Valve
2 0 Vent Line

A Fresh Air
B Blowby Gas in Partial Load
C Blowby Gas in Full Load

SSANGYONG Y200

Operation at Idling and Mid-Load

It show that the throttle valve (19) is closed or very

•

partially opened and the vacuum pressure in intake
manifold is high.

The blowby gas in the crankcase in partial load
flows into the intake manifold through the vent line
(20) after passing the air conditioner bracket (6)
and the filter (4). The air reentered into the intake
manifold will be dilluted on the flow through the
restriction hole (11) in the vent line (10).

The circulated engine oil is separated at the air
conditioner bracket (6) and then returns into the oil
pan through the drain pipe (7).

The vacuum pressure generated at the crankcase
sucks fresh air from intake air line(13) through the
air admission and vent connection (17, 18).

The fresh air prevents engine oil from being
contaminated and the air admission and vent
connection (17, 18) is designed to control the rapid
pressure changes in intake air line (13).

M162 ENGINE MECHANICAL 1B1-17

Operation at Full-Load

The throttle valve (19) is fully opened.

•

All the blowby gases flow into the intake air duct
(13) after passing through the oil separator (15,16)
of the cylinder head cover (14) when fully loaded.
This dilluted air will be supplied to the combustion
chamber through the intake manifold (12).

SSANGYONG Y200

1B1-18 M162 ENGINE MECHANICAL

GENERATOR

1 Nut (M8) .............22.5-27.5 N•m (16.5-20.5 lb-ft)

2 Bolt (M8 x 30, 3 pieces)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

3 Bolt (M8 x 40, 1 piece)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

YAD1B230

4 Bolt (M8 x 70, 1 piece)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

5 Bolt (M8 x 75, 1 piece)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

Removal & Installation Procedure

1. Remove the drive belt.

2. Remove the generator.

3. Unscrew the generator carrier bolts and remove
the carrier.

Installation Notice

Tightening T orque 25 N•m (18 lb-ft)

YAD1B240

4. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200

POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud

M162 ENGINE MECHANICAL 1B1-19

1 Vent Hose
2 Bolt (M8 x 91, 2 pieces)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

3 Power Steering Pump
4 Bolt (M8 x 105, 4 pieces)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

5 Washer
6 A/C Compressor
7 Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

YAD1B5A0

8 A/C Bracket

9 Gasket.................................................... Replace

10 Bracket
11 Bolt (M8 x 22, 2 pieces)

...........................22.5-27.5 N•m (16.5-20.5 lb-ft)

1 2 Tensioning Pulley

13 Nut .....................40.5-49.5 N•m (29.9-36.5 lb-ft)

SSANGYONG Y200

1B1-20 M162 ENGINE MECHANICAL

YAD1B250

Removal & Installation Procedure

1. Remove the belt tensioning pulley.

Installation Notice

Tightening T orque

Pull the tensioning pulley clockwise as shown in
the figure.

2. Disconnect the hydraulic pipe of the power
steering pump and drain the oil.

40.5 - 49.5 N•m
(29.9 - 36.5 lb-ft)

YAD1B090

YAD1B260

3. Unscrew the bolts and remove the steering pump.

Installation Notice

Tightening T orque

22.5 - 27.5 N•m
(16.6 - 20.3 lb-ft)

4. Remove the compressor after disconnecting the
wiring connector and refrigerant pipe of A/C
compressor.

Notice: Discharge all the refrigerant before
removing the pipes.

YAD1B270

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-21

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5. Disconnect the vent hose from the A/C bracket.

Installation Notice

YAD1B280

Tightening Torque

20 - 30 N•m

(15 - 22 lb-ft)

6. Unscrew all the mounting bolts and remove the
A/C bracket and the gasket.

Installation Notice

Tightening Torque

22.5 - 27.5 N•m
(16.6 - 20.3 lb-ft)

YAD1B290

7. Clean the sealing surface.

8. Replace the gasket with new one.

9. Installation should follow the removal procedure
in the reverse order.

10. Check the oil leakage by operating the engine after
installation.

SSANGYONG Y200

1B1-22 M162 ENGINE MECHANICAL

ENGINE MOUNT

YAD1B300

SSANGYONG Y200

YAD1B310

M162 ENGINE MECHANICAL 1B1-23

Removal and Installation Procedure

1. Unscrew the upper engine mounting nut.

Installation Notice

Tightening Torque 70 N•m (52 lb-ft)

2. Unscrew the lower engine mounting nut.

Installation Notice

Tightening Torque 38 N•m (28 lb-ft)

3. Remove the hydraulic engine mounting insulator.
Notice: If the insulator is spotted with oil, replace

the hydraulic insulator asseambly.

YAD1B320

4. Installation should follow the removal procedure in
the re verse order.

SSANGYONG Y200

1B1-24 M162 ENGINE MECHANICAL

CYLINDER HEAD COVER

1 Ignition Cable Dust Cover
2 Bolt (M6 x 65, 8 pieces)

.......................................9-11 N•m (80-97 lb-in)

3 Bolt (M6 x 50, 4 pieces)

.......................................9-11 N•m (80-97 lb-in)

4 Spacer Sleeve

YAD1B450

5 Thrust Piece
6 Cylinder Head Cover

7 Gasket.................................................... Replace

8 Spart Plug Hole Seal ............................. Replace

9 Camshaft Seal ....................................... Replace

Composition of The Cylinder Head Cover
Bolts

A. M6 x 50, 4 Pieces - Bolts + Washers
B. M6 x 65, 8 Pieces - Bolts + Washers

YAD1B460

SSANGYONG Y200

YAD1B470

M162 ENGINE MECHANICAL 1B1-25

Removal & Installation Procedure

1. Remove the intake air duct.

Installation Notice

Tightening Torque

2. Remove the spark plug cover.

Installation Notice

Tightening Torque

Unscrew the seven (M6 x 60) bolts and remove
the spark plug cover.

9 - 11 N•m

(80 - 97 lb-in)

9 - 11 N•m

(80 - 97 lb-in)

YAD1B480

YAD1B490

3. Remove the spark plug connector and ignition
cable.

4. Unscrew all the bolts (2,3) and remove the head
cover and the gasket.

Installation Notice

Tightening Torque

9 - 11 N•m

(80 - 97 lb-in)

Replace the gasket with a new one if necessary.

5 . Installation should follow the removal procedure in

the re verse order .

6. Check for oil leaks by operating the engine.

SSANGYONG Y200

YAD1B500

1B1-26 M162 ENGINE MECHANICAL

CYLINDER HEAD FRONT COVER

Preceding Work : Removal of cylinder head cover

Removal of coolant connection fitting

1 Camshaft Position Sensor
2 Camshaft Actuator
3 Upper Guide Rail
4 Bolt (M6 x 60, 3 pieces)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

YAD1B510

5 Bolt (M8 x 80, 3 pieces)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

6 Front Cover

7 Rubber Gasket ...................................... Replace

8 Bolt (M6 x 16, 3 pieces)

.... .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ... .9-11 N•m (80-97 lb-in)

Removal & Installation Procedure

1. Remove the camshaft actuator.

Installation Notice

Tightening Torque

9 - 11 N•m

(80 - 97 lb-in)

YAD1B520

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-27

2. Remove the cylinder head front cover (6).

Installation Notice

YAD1B530

Tightening Torque

22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

Apply the sealant at the mating surface of the
cylinder head and the front cover.

3. Remove the upper guide rail pin and the guide
rail (3).

Notice: Install it while the chain tensioner is loose.

4. Remove the gasket (arrow).
Notice: Replace the gasket with new one and

apply the sealant.

5. Installation should follow the removal procedure
in the reverse order.

YAD1B540

SSANGYONG Y200

1B1-28 M162 ENGINE MECHANICAL

CYLINDER HEAD

Preceding Work : Removal of cylinder head cover

Removal of cylinder head front cover
Removal of upper intake manifold

1 Cylinder Head Bolt (14 pieces)

........................ 1st step 55 N•m (141 lb-ft)

2nd step 90 °

3rd step 90 °
2 Washers (14 pieces)
3 Flange Bolts (3 pieces)

........................ 1st step 18-22 N•m (13-16 lb-ft)

2nd step 90°±5°

YAD1B550

4 Exhaust Camshaft Sprocket
5 Cylinder Head

6 Gasket.................................................... Replace

7 Dowel Sleeve

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-29

T ools Required

116 589 01 34 00 Threaded Pin
116 589 20 33 00 Sliding Hammer
617 589 00 10 00 Allen Wrench Socket

Removal & Installation Procedure

1. Rotate the crankshaft so that the piston of number
1 cylinder is at TDC.

Notice: Rotate the crankshaft in the normal engine
direction.

YAD1B590

2. Put the alignment marks (arrows) on the timing
chain and camshaft sprocket.

3. Drain the coolant from the crankcase.

4. Remove the three flange bolts in the exhaust
camshaft sprocket.

Installation Notice

1st step: 18 - 22 N•m

Tightening Torque

(13 - 16 lb-ft)

2nd step: 9 0° ± 5°

SSANGYONG Y200

Do not reuse the removed bolts.

YAD1B600

5. Separate the chain from the camshaft sprockrt.
Notice: Be careful not to drop the chain into the

timing case.

YAD1B610

1B1-30 M162 ENGINE MECHANICAL

YAD1B620

6. Remove the guide rail fixing pin from the cylinder
head using the threaded pin 116 589 01 34 00 (1)
and sliding hammer 116 589 20 33 00 (2).

7. Remove the cylinder head bolts in numerical order
using allen wrench socket 617 589 00 10 00.

Installation Notice

1st step: 55 N•m

Tightening Torque

2nd step : 90°

(41 lb-ft)

3rd step : 90°

YAD1B630

YAD1B640

8. Check the length of the cylinder head bolt.

Installation Notice

Length (L)

New 160 ± 0.8 mm

Max. 162 ± 0.7 mm

Replace the bolt if the measured length exceed

•

the max. length.
Apply the oil to the thread surface of bolt.

•

9. Carefully remove the cylinder head and check the
mating surface.

10. Installation should follow the removal procedure
in the reverse order.

SSANGYONG Y200

OIL PAN

M162 ENGINE MECHANICAL 1B1-31

1 Gasket.................................................... Replace

2 Bolt (M6 x 22, 6 pieces)

.......................................9-11 N•m (80-97 lb-in)

3 Drain Plug ........22.5-27.5 N•m (16.6-20.3 lb-ft)

4 Bolt (M6 x 20, 22 pieces)

.......................................9-11 N•m (80-97 lb-in)

YAD1B5B0

5 Bolt (M6 x 85, 3 pieces)

.......................................9-11 N•m (80-97 lb-in)

6 Bolt (M8 x 40, 4 pieces)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

7 Bolt (M10) ................................ 4 0 N•m (30 lb-ft)

8 Oil Pan

SSANGYONG Y200

1B1-32 M162 ENGINE MECHANICAL

YAD1B5C0

M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
M6 X 22, 6 pieces
M6 X 20, 28 piecesOthers

Removal & Installation Procedure

1. Remove the drain plug and drain the oil
completely.

2. Unscrew the bolts and remove the oil pan and
gasket.

Notice: Arrange the bolts according to each size.

3. Clean the inside of oil pan and sealing surface,
then apply the sealant.

4. Replace the gasket with new one.

5. Install the oil pan with gasket, and tighten each
bolt in specified torque.

6. Check for oil leaks while running the engine.

SSANGYONG Y200

TIMING GEAR CASE COVER

Preceding Work : Removal of cylinder head front cover

Removal of generator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper

M162 ENGINE MECHANICAL 1B1-33

1 Bolt (M8 x 60, 3 pieces)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

2 A/C Bracket
3 Bolt (M8 x 65, 3 pieces)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

4 Bolt (M8 x 40, 1 piece)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

YAD1B690

5 Bolt (M8 x 60, 1 piece)

...........................22.5-27.5 N•m (16.6-20.3 lb-ft)

6 Seal
7 Timing Gear Case Cover
8 Roll Pin
9 Bolt (M6 x 22, 6 pieces)

.... .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ... .9-11 N•m (80-97 lb-in)

SSANGYONG Y200

1B1-34 M162 ENGINE MECHANICAL

YAD1B590

Removal & Installation Procedure

1. Put the alignment marks (arrows) on the timing
chain and camshaft sprocket.

2. Unscrew the A/C bracket bolts (1) and remove the
bracket.

Installation Notice

Tightening Torque

3. Remove the cooling fan and the viscous clutch.
Unscrew the three bolts from the cooling fan
bracket and remove the bracket.

Installation Notice

Tightening Torque

22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

22.5 - 27.5 N•m

(16.6 - 20.3 lb-ft)

YAD1B700

4. Remove the timing gear case cover after
unscrewing the bolts (3) and (4) from the timing
gear case cover and the bolt (9) from the oil pan.

Notice: Be careful not to damage the oil pan
gasket.

Installation Notice

Bolt (3, 4) :

22.5 - 27.5 N•m

Tightening Torque

(16.6 - 20.3 lb-ft)

Bolt (9) :

9 - 11 N•m
(80 - 97 lb-in)

Apply the sealant after cleaning the timing gear

•

case cover surface.
Be careful not to stain the oil chamber of chain

•

tensioner with the sealant.

5. Installation should follow the removal procedure
in the reverse order.

6. Warm up the engine and check for oil leaks.

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-35

CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate

1 Bolt (M6 x 20, 6 pieces)

.........................................9-11 N•m (80-97 lb-in)

2 Radial Shaft Seal
3 Rear Cover

YAD1B710

4 Sleeve
5 Bolt (M6 x 85, 2 pieces)

.... .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ... .9-11 N•m (80-97 lb-in)

6 Washer

SSANGYONG Y200

1B1-36 M162 ENGINE MECHANICAL

YAD1B740

T ools Required

601 589 03 43 00 Crankshaft Rear Seal Installer

Removal & Installation Procedure

1. Unscrew the bolts (1) and (5) and remove the
closing cover by pulling the rear cover lug (arrows).

Notice: Be careful not to damage the oil pan
gasket.

2. Clean the sealing surface of the crankcase and
the rear sealing cover.

3. Check the radial shaft seal and replace it if
necessary.

4. Apply the Loctite 573 to the rear cover sealing
surface.

5. Apply the engine oil to the dust lip of the radial
shaft seal.

YAD1B750

YAD1B760

Notice: Do not use the grease.

6. Install the crankshaft rear radial seal and the
crankshaft sealing rear cover, using crankshaft rear
seal installer 601 589 03 43 00.

7. Install the crankshaft sealing rear cover mounting
bolts and remove the crankshaft rear seal installer
601 589 03 43 00.

Installation Notice

Tightening T orque

9 - 11 N•m

(80 - 97 lb-in)

YAD1B770

SSANGYONG Y200

CRANKSHAFT ASSEMBLY

BELT PULLEY AND VIBRATION DAMPER

Preceding Work : Removal of cooling fan and viscous clutch

Removal of fan shroud
Removal of drive belt

M162 ENGINE MECHANICAL 1B1-37

1 Center Bolt (M18 x 50)

.......... 1st step 180- 220 N•m (133-162 lb-ft)

.......... 2nd step 9 0°+10°

2 Vibration Damper Disk
3 Bolt (M6 x 20, 6 pieces)

............................ 7.7-9.5 N•m (68.1-84.1 lb-in)

YAD1B650

4 Vibration Damper Assembly
5 Woodruff Key
6 Bolt (M6 x 12, 4 pieces)

.......................................9-11 N•m (80-97 lb-in)

7 Cooling Fan Pulle y

SSANGYONG Y200

1B1-38 M162 ENGINE MECHANICAL

Components

1 Center Bolt (M18 x 50)
2 Vibration Damper Disk
3 Vibration Damper and Pulley Assembly
4 Woodruff Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover

Service Data Standard

Permissble Deviation of The Vibration Damper

7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil Pump Driven)

9 Crankshaft
1 0 Oil Pan
1 1 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

Radial Runout

Axial Runout

0.6 mm

0.6 mm

YAD1B660

SSANGYONG Y200

YAD1B670

M162 ENGINE MECHANICAL 1B1-39

T ools Required

602 589 00 40 00 Engine Lock

Removal & Installation Procedure

1. Adjust the piston of number 1 cylinder to the TDC.

2. Remove the start motor and install the engine lock
602 589 00 40 00 to the flywheel ring gear.

3. Remove the vibration damper center bolt.

Installation Notice

1st step: 180 - 220 N•m

Tightening Torque

2nd step: 9 0° + 10°

(133 - 162 lb-ft)

YAD1B680

YAD1B250

4. Remove the vibration damper assembly using the
puller.

5. Installation should follow the removal procedure
in the reverse order.

Notice: If possible, don’t separate the vibration
damper and the pulley.

SSANGYONG Y200

1B1-40 M162 ENGINE MECHANICAL

CRANKSHAFT FRONT RADIAL SEAL

Preceding Work : Removal of belt pulley and vibration damper

1 Center Bolt (M18 x 50)

.......... 1st step 180- 220 N•m (133-162 lb-ft)

2nd step 90°+10°

2 Center Bolt Washer

YAD1B780

3 Sleeve (Special Tool)
4 Crankshaft Front Seal
5 Key

SSANGYONG Y200

YAD1B800

M162 ENGINE MECHANICAL 1B1-41

Tools Required

601 589 03 14 00 Crankshaft Front Seal Installer

Replacement Procedure

1. Remove the radial seal with a screw driver.
Notice: Use a clean cloth not to damage the radial

seal mounting hole and the crankshaft.

2. Coat the radial sealing lip with engine oil.

3. Using the crankshaft front seal installer 601 589
03 14 00, assemble the radial seal.

4. Align the sleeve groove and the woodruff key and
tighten the center bolt until the center bolt and
the damper disk stop in the movement.

Installation Notice

1st step: 180 - 220 N•m

Tightening Torque

2nd step: 9 0° + 10°

5 . Remove the crankshaft front seal installer 601 589

03 14 00, and install the belt pulley and the
vibration damper.

6. Check for leaks while operating the engine.

(133 - 162 lb-ft)

SSANGYONG Y200

1B1-42 M162 ENGINE MECHANICAL

CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate

1 Special Tool
2 Special Tool

YAD1B840

3 Crankshaft Rear Seal

SSANGYONG Y200

YAD1B850

M162 ENGINE MECHANICAL 1B1-43

T ools Required

601 589 03 43 00 Crankshaft Rear Seal Installer

Replacement Proceudre

1. Remove the radial seal with a screw driver.
Notice: Use a clean cloth not to damage the radial

seal mounting hole and the crankshaft.

2. Install the crankshaft rear seal installer 601 589
03 43 00 (2) to the crankshaft.

3. Apply the engine oil on the crankshaft rear seal
installer 601 589 03 43 00 (2).

Notice: Do not use the grease.

4. Install the radial seal on the inner parts assembler.

5. Press in the crankshaft rear seal installer 601 589
03 43 00 (1) until the radial seal is stopped.

6. Check for leaks while operating the engine.

SSANGYONG Y200

1B1-44 M162 ENGINE MECHANICAL

CRANKSHAFT

Preceding Work : Removal of engine assembly

Removal of timing gear case cover
Removal of cylinder head
Removal of crankshaft sealing rear cover
Removal of oil pan
Removal of oil pump
Removal of baffle plate

1 Crankshaft Bearing Cap Bolt

(M8 x 55, 14 pieces)

.......... 1st step 50- 60 N•m (37-44 lb-ft)

2nd step 90°+5°

YAD1B860

2 Crankshaft Bearing Cap
3 Crankshaft Lower Main Bearing
4 Crankshaft Lower Thrust Bearing
5 Crankshaft

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-45

Arrangement of the Thrust Bearing and the Main Bearing

1 Upper Main Bearing
2 Upper Thrust Bearing
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

1 - 12 Weight Balance/Color Marking Point
j1 - j7 Journal Main Bearing #1 - #7

l Color Dot Marking

The color dot marking are put on the 1 , 2 , 4 ,
6 , 8 , 10 , 12 and it indicates the diameter of
crankshaft journal by color as below.

YAD1B870

A Crankcase Side
B Bearing Cap Side (Oil Pan Side)
C Axial Fit Bearing (Number 5 Bearing Point)
D Radial Bearing

SSANGYONG Y200

1B1-46 M162 ENGINE MECHANICAL

YAD1B880

Color Dot Marking

Blue

Yellow

Red

White

Violet

Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating

surface to oil pan. This mark is correspondent to
the bearing distinguished by color. Select the
relevant bearing according to the punching mark
when repaired.

Punching Mark

•

••

•••

Crankshaft Journal Diameter (mm)

57.960 - 57.965

57.955 - 57.960

57.950 - 57.955

57.945 - 57.950

57.940 - 57.945

Bearing Color Selected

Blue

Yellow

Red

Service Data

Crankshaft Standard

and Repair Size

Standard size

1st repair size

2nd repair size

3rd repair size
4th repair size

Crankshaft

Bearing Jour-

nal Diameter

57.950 - 57.965

57.700 - 57.715

57.450 - 57.465

57.200 - 57.215

56.950 - 56.965

2. Crankshaft Bearing Cap Side
Select the crankshaft main bearing according to the

marking letter on the crankshaft main journal when
repaired.

Marking Letter

YAD1B890

Thrust Washer

Thickness

2.15 or 2.20 24.50 - 24.533

2.25 or

2.35 or

2.40

Crankshaft

Journal Width

at fit bearing

-

W

B
Y
R

V

Connecting Rod
Bearing Journal

47.94 - 47.96

Bearing Color Selected

Blue

Yellow

Red

White

Violet

Connecting Rod

Bearing Jourmal

Diameter

27.958 - 28.042

47.75

47.50

47.25

47.00

Unit : mm

Width

-

SSANGYONG Y200

YAD1B900

M162 ENGINE MECHANICAL 1B1-47

Removal & Installation Procedure

1. Unscrew the connecting rod bearing cap bolt and
remove the bearing cap.

Installation Notice

1st step: 40 + 5 N•m

Tightening Torque

2nd step: 9 0° + 10°

Make sure that the upper and lower bearing

•

shells do not change each other.
Coat the bearing shell with engine oil.

•

Install the bearing cap according to the

•

consecutive number.

2. Unscrew the crankshaft bearing cap bolts and
separate the upper and lower bearing shells and
thrust washers.

Installation Notice

1st step: 50 - 60 N•m

Tightening Torque

2nd step: 9 0 °

(30 + 3.7 lb-ft)

(37 - 44 lb-ft)

Part No. : 601 030 00 62 2.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm

YAD1B910

Remove the bearing cap from front (pulley side)

•

to rear.
Make sure that the upper and lower bearing

•

shells do not change each other and coat with
engine oil.

The oil grooves (arrows) in the thrust washers

•

must face outward and insert the thrust bearing
into the bearing cap.

There are five kinds of thrust washers by

•

thickness. Select the proper washer when
repaired.

3. Remove the crankshaft.

4. Installation should follow the removal procedure
in the reverse order.

5. After completion of the installation, check for the
rotating condition of the crankshaft.

Notice:

Make sure the crankshaft bearing cap properly

•

seated in place in the crankcase side. When
perfectly installed, the projected part (arrow)
locates in the left side (intake manifold side).

Assemble so that the projected part of the cap

•

and crankcase face the same direction.

SSANGYONG Y200

YAD1B920

1B1-48 M162 ENGINE MECHANICAL

YAD1B930

Inspection

1. If the length ‘L’ of the crankshaft bearing cap bolt
exceeds 63.8 mm, replace it.

2. Make sure the crankshaft bearing cap is properly
seated on the cylinder block (arrows).

YAD1B940

YAD1B950

3. Measure and record the inner diameter of the
crankshaft bearing.

Notice:

Measure at 2 points (1, 2).

•

Measure ‘A’,‘B’and ‘C’ as shown. If average

•

value of ‘B’ and ‘C’is less than value ‘A’, then
the average value of ‘B’ and ‘C’ is actual
average value. If average value of ‘B’ and ‘C’ is
more than value ‘A’, then the value ‘A’ is actual
average value.

4. Measure and record the diameter of the crankshaft
bearing journal.

Notice:

Record the mean value when measured at 3

•

points (A, B, C).
Measure the inner diameter of bearing and the

•

diameter of journal and if it is out of the standard
data, replace the bearing shell.

YAD1B960

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-49

Service Data Standard (Crankshaft Main Bearing Gap)

Item

Main Bearing Journal

( NO. 1, 5, 7)

Main Bearing Journal

( NO. 3, 4, 6)

Item

Connecting Rod Bearing

Measuring Position

Radial

Axial

Radial

Axial

(Connecting Rod Bearing Gap)

Measuring Position

Radial

Gap (mm)

Static condition :0.015 - 0.039

Dynamic condition: 0.031 - 0.051

(Consider the expansion 0.011 - 0.016)

0.010 - 0.254

Static condition :0.011 - 0.039

Dynamic condition: 0.031 - 0.051

(Consider the expansion 0.015 - 0.022)

0.010 - 0.254

Gap (mm)

0.030 - 0.050

SSANGYONG Y200

1B1-50 M162 ENGINE MECHANICAL

CONNECTING ROD

Preceding Work : Removal of piston

YAD1B970

1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt (M9 x 52, 12 pieces)

.......... 1st step 40+5 N•m (30+3.7 lb-ft)

5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]

2nd step 90°+10°

Service Data Standard

Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing Bore Center
Width of The Connecting Rod (B) at Bearing Bore
Width of The Connecting Rod (b) at Bushing Bore
Basic Bore at The Bearing Shell (D1)
Basic Bore at The Bushing (d1)
Bushing Inner Diameter (d)
Clearance Between The Piston Pin and The Bushing
Peak-to-valley Height of Connecting Rod Bushing on Inside
Permissible Twist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore

Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting

Rod Bushing Core
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity
Permissible Difference of Each Connecting Rod in Weight

145 ± 0.05 mm

21.940 - 22.000 mm

21.940 - 22.000 mm

51.600 - 51.614 mm

24.500 - 24.571 mm

22.007 - 22.013 mm

0.007 - 0.018 mm

0.005 mm

0.15 mm

0.07 mm

0.01 mm

0.4 g

SSANGYONG Y200

YAD1B980

M162 ENGINE MECHANICAL 1B1-51

Inspection

1. Measure the basic bore of the connecting rod
bearing.

Notice: If the basic bore exceeds the value of

51.614 mm, replace the bearing or check the
connecting rod.

2. Check connecting rod bolts.

YAD1B990

Length When New (L)

Max. Length (L)

Tightening Torque

51.7 - 52 mm

52.9 mm

1st step: 40 + 5 N•m

(30 + 3.7 lb-ft)

2nd step: 90°+10°

Notice: If the length exceeds max. length, replace
it.

3. Check the assembly mark(indication//or number:
arrow) of the connecting rods and the bearing cap
when installing.

Notice:

Make sure it doesn’t exceed over 4g with other

•

connecting rods when replacing the connecting
rods.

Check if the connecting rod and the bearing

•

cap are accurately seated on the groove when
replacing the bearing.

SSANGYONG Y200

YAD1B0A0

1B1-52 M162 ENGINE MECHANICAL

Preceding Work : Removal of engine

Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate

PISTON

1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bearing Cap Bolt

(M9 x 52, 12 pieces)

.......... 1st step 40+5 N•m (30+3.7 lb-ft)

2nd step 90°+10°

YAD1B2P0

4 Piston
5 Snap Ring
6 Piston Pin

SSANGYONG Y200

YAD1B2Q0

M162 ENGINE MECHANICAL 1B1-53

Removal Procedure

1. Unscrew the connecting rod bearing cap bolt (3)
and remove the cap.

2. Remove the connecting rod and the piston upward.
Notice: Make sure that the bearing cap and shell

are not changed each other.

3. Remove the snap ring (5) and pull out the piston
pin (6).

Notice: Remove the snap ring using a clean cloth
as shown in the right picture so that the piston,
piston ring, and the snap ring don’t get damaged.

SSANGYONG Y200

1B1-54 M162 ENGINE MECHANICAL

Installation Procedure

YAD1B2S0

YAD1B2R0

1. Check the piston ring gap and apply the engine
oil to the piston pin and the connecting rod
bushing.

2. Connect the piston and the connecting rod by
pressing in the piston pin (6) and install the snap
ring to the groove.

3. Clean the cylinder bore, connecting rod bearing
journal, connecting rod bearing shell and the
piston and coat them with engine oil.

4. Install the piston ring.

5. Install the piston so that the arrow on the piston
head faces to the forward of the vehicle.

6. After aligning the connecting rod and the bearing
cap mark (// or a number), tighten the bolts.

Installation Notice

1st step: 40 + 5 N•m

Tightening T orque

(30 + 3.7 lb-ft)

2nd step:90 ° + 10°

Apply the engine oil to the bearing cap upper and
lower bearing shells.

7. Check if the crankshaft rotates without any trouble
by rotating it.

SSANGYONG Y200

Preceding Work : Removal of piston

M162 ENGINE MECHANICAL 1B1-55

PISTON RING

1 Piston Compression Ring
2 Piston Compression Ring
3 Piston Oil Ring

YAD1B2T0

4 Coil Spring and Control Ring
5 Hook Spring

SSANGYONG Y200

1B1-56 M162 ENGINE MECHANICAL

Replacement Procedure

1. Measure the piston ring’s gap.

Groove 1 0.20 - 0.40 mm

End Gap of The

Piston Ring

Gap Between

The Piston and

The Piston Ring

Notice: If out of specification, replace the piston
ring.

2. Remove the piston ring with a pliers.

Groove 2 0.20 - 0.40 mm

Groove 3 0.20 - 0.45 mm
Groove 1 0.015 - 0.050 mm
Groove 2 0.020 - 0.040 mm
Groove 3 0.010 - 0.045 mm

YAD1B2U0

YAD1B2V0

3. For installation, position the piston ring to be the
‘TOP’ mark on the piston ring upward and arrange
the piston ring ends to be 120° apart.

4. Adjust the hook spring joint in the oil ring 180°
away from the ring end.

SSANGYONG Y200

FLYWHEEL / DRIVEN PLATE

Preceding Work : Removal of manual or automatic transmission

M162 ENGINE MECHANICAL 1B1-57

1 Flywheel Mounting Bolt (M10 x 22, 8 pieces)

.......... 1st step 45+5 N•m (33+3.7 lb-ft)

2nd step 90°+10°

2 Plate

Service Data Standard (Stretch Bolt)

Nominal Size

Stretch Side Diameter

Bolt Length

Tightening Torque

D

d

L

3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)

-

When New

Min. Diameter

When New

1st step 45 + 5 N•m (33 + 3.7 lb-ft),

2nd step 90° + 10°

YAD1B810

M x 1.5

8.5 - 0.2 mm

8.0 mm

21.8 - 22.2 mm

SSANGYONG Y200

1B1-58 M162 ENGINE MECHANICAL

YAD1B820

Removal & Installation Procedure

1. Unscrew the flywheel mounting bolt.

Installation Notice

1st step: 40 + 5 N•m

Tightening T orque

2nd step:90 ° + 10°

Replace the bolt when the stretch side diameter

•

(d) of the flywheel mounting bolt is less than

8.0 mm.
For the stretch bolt tightening, keep the socket

•

wrench and Tommy-bar to be 90° and tighten
as specified.

2. Remove the flywheel for manual transmission
vehicles, or the driven plate (3), and plate (2) for
automatic transmission vehicle.

3. Installation should follow the removal procedure
in the reverse order.

(30 + 3.7 lb-ft)

SSANGYONG Y200

M162 ENGINE MECHANICAL 1B1-59

Sectional View

1 Oil Pan
2 Cover
3 Crankshaft Front Seal
4 Flywheel Mounting Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (thickness = 3.5 mm)

YAD1B830

8 Washer

9 Bolt
1 0 Front Drive Plate
1 1 Rear Drive Plate
12 Rivet
13 Segment
1 4 Ring Gear

SSANGYONG Y200