SsangYong Rexton. Service manual — part 354
M161 ENGINE MECHANICAL 1B2-99
SSANGYONG Y200
YAD1B4E0
YAD1B4F0
Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore
size in axial and transverse direction at three
points (1,2,3).
1, 2, 3 Measuring Points
A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
Cylinder Bore Size (mm)
φ
89.900 -
φ
89.906
φ
89.906 -
φ
89.912
φ
89.912 -
φ
89.918
φ
90.150 -
φ
90.156
φ
89.156 -
φ
90.162
φ
90.162 -
φ
90.168
φ
90.400 -
φ
90.406
φ
90.406 -
φ
90.412
φ
90.412 -
φ
90.418
Group Code Letter 1)
A
X
B
A
X
B
A
X
B
Group Code Letter Cylinder
Standard Size
∅
90.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5)
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
Service Data Standard
Wear Limit in Longitudinal and Transverse Direction
Permissible Deviation of Cylinder Out-of-round
When new
Wear limit
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)
Basic Peak-to-valley Height After Final Honing and Brushing
Chamfer Angle
Honing Angle
0.1 mm
0.007 mm
0.05 mm
0.05 mm
0.003 - 0.006 mm
75 °
50 ° ± 10 °
SSANGYONG Y200
1B2-100 M161 ENGINE MECHANICAL
CRANKCASE MATING SURFACE
YAD1B4G0
Service Data Standard
Height of The Crankcase ‘H’ (When new)
Minimum Height After Milling
Flatness
Crankcase Upper Mating Surface
Crankcase Lower Mating Surface
Permissible Deviation of Parallelismof The
Axial Direction
Upper to Lower Mating Surface
Transverse Direction
Peak-to-valley Height
Crankcase Upper Mating Surface
Crankcase Lower Mating Surface
289.35 - 289.45 mm
289.05 mm
0.03 mm
0.04 mm
0.1 mm
0.05 mm
0.012 - 0.009 mm
0.025 - 0.020 mm
M161 ENGINE MECHANICAL 1B2-101
SSANGYONG Y200
YAD1B4F0
YAD1B4H0
Chamfering Procedure
1. Chamfer angle : 75 °
2. Polish the lower chamfered area evenly with a
grinder after finishing the chamfering with a
suitable tool (e.g., hand milling cutter).
SSANGYONG Y200
1B2-102 M161 ENGINE MECHANICAL
YAD1B4J0
CYLINDER HEAD MATING SURFACE
Preceding Work:
Removal of valves
Service Data Standard
Notice: Do not exceed 0.4 mm for the milling of the mating surface of crankcase and cylinder head.
Axial Direction
Transverse Direction
Standard Size
Intake
Exhaust
Repair Size
Intake
Exhaust
Overall Height of Cylinder Head
Minimum Height After Machining
135.9 - 136.0 mm
135.5 mm
0.08 mm
0.0 mm
24.21 - 24.75 mm
22.21 - 22.75 mm
23.96 - 24.51 mm
21.96 - 22.51 mm
Flatness
Distance ‘T’
(Between Camshaft Bearing
and Valve Stem)
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