SsangYong Rexton. Manual - part 39

DI02-47

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.4

1. Install the compression ring and oil ring on the piston

with a special tool.

Piston - Reassembly

2. Check the clearance of piston oil ring and compression

ring with a thickness gauge and adjust if necessary.

3. Check the clearance of piston rings with a thickness

gauge and adjust if necessary.

Notice

• Install the No.1 and No.2 pistons so that “Y” marking

on piston head is facing upward.

• No.1 piston ring is thicker than No.2 piston ring.

• Arrange the oil ring end to opposite position of

current ring end.

• Oil ring is not directional.

• Make sure that the piston ring end is not aligned to

axial direction and lateral direction.

1st groove

2nd groove

3rd groove

0.20 ~ 0.35 mm

0.20 ~ 0.35 mm

0.20 ~ 0.40 mm

No.1 compression ring

2nd compression ring

3rd oil ring

0.075 ~ 0.119 mm

0.050 ~ 0.090 mm

0.040 ~ 0.080 mm

Arrange the piston ring ends to be 120° apart.

* Piston ring end play (mm)

1st groove: 11.0 mm

2nd groove: 10.5 mm

3rd groove: 7.0 mm

Y220_02118

Y220_02119

Y220_02120

Y220_02121

DI02-48

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.4

Notice

The snap rings should be replaced with new one.

5. Lubricate piston pin and push in by hand.

4. Fit the piston onto connecting rod so that the marking

on piston crown and locking slot are facing to straight
ahead direction.

Notice

Install the piston so that the piston recess (marking)
or the stamped surface of connecting rod is facing to
straight ahead direction.

Notice

Do not heat up the piston.

6. Place new snap rings into the grooves.

7. Lubricate the cylinder bore, connecting rod bearing

journals, connecting rod bearing shells and pistons.

8. Push piston into the cylinder with a wooden stick.

Notice

The marking on the piston crown must be facing to
straight ahead direction.

9. Insert connecting rod bearing shells.

Notice

•

The upper and lower connecting rod bearings have
same appearance. Therefore, make sure to check
the part number before replacing them.

•

Install bearing rod bearing cap so that so that the
retaining lugs are on the same side of the
connecting rod bearing.

Y220_02122

Y220_02123

Y220_02124

Y220_02125

DI02-49

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.4

10. Measure stretch shaft diameter of the connecting rod

bolts.

Limit “C”

7.1 mm

0.5 ~ 1.5 mm

Specified value

Y220_02126

Y220_02127

Y220_02128

40 ± 5.0 Nm,

90° + 10°

Tightening torque

12. Position piston to TDC and measure the distance between

piston and parting surface of crankcase.

• Measure at both ends of axial direction.

11. Lubricate the new connecting rod bolts and tighten.

• End play of connecting rod cap

Permissible piston

protrusion

0.765 ~ 1.055 mm

DI02-50

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE HOUSING

DI ENG SM - 2004.4

Y220_02132

Y220_02131

Y220_02130

Y220_02129

Special Tools and Equipment

Name and Part Number

Application

Piston protrusion measuring jig

Piston insertion jig