SsangYong Rexton. 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)