torque SSANGYONG KORANDO 1997 Service Owners Manual

1B2 -- 32 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
6. Remove the intake camshaft sprocket (E20 engine).
7. Remove the camshaft adjuster (E23, M161.970 en-
gine).
Installation Notice (Flange Bolt)
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
Notice:The flange bolt is designed to be used only
once, so always replace with new one.
1 Flange Shaft
2FlangeBolt
3 Compression Spring
4 Adjust Piston
5 Camshaft Sprocket
6 Seal Cover
7Nut
8. Remove the guide rail pin using the sliding hammer
116 589 20 33 00 (02) and the threaded pin 116 589
01 34 00 (03).
Notice:Apply the sealant on guide rail pin when installa-
tion.
9. Unscrew the bolts (A).
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
Bolt (A) : (M8 X 35, 4 pieces)

M161 ENGINE MECHANICAL 1B2 -- 33
D AEW OO M Y_2000
10. Remove the cylinder head bolts in the reverse order
of the numerics (No.10→No.1) using allen wrench
socket617589001000.
Installation Notice
Tighten the bolts as numerical order with specified
torque (No.1→No.10).
1st step: 55 NSm (41 lb-ft)
Tightening Torque2nd step: + 90°ggq
3rd step: + 90°
Notice:Operate during engine cooling.
11. Remove the No. 1 bearing cap of the exhaust cam-
shaft.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
12. Carefully remove the cylinder head.
13. Check the cylinder head mating surface and clean
the crankcase head bolt mounting hole.
14. Replace the cylinder head gasket with new one.
15. Check the length of the cylinder head bolt.
Installation Notice
Length(L)When New 100 mmLength(L)Max. Length 105 mm
Notice:Replace the bolt if the measured length exceed
the max. length.
16. Installation should follow the removal procedure in
the reverse order.

M161 ENGINE MECHANICAL 1B2 -- 35
D AEW OO M Y_2000
Tools Required
116 589 20 33 00 Sliding Hammer
116 589 01 34 00 Threaded Pin
Removal & Installation Procedure
1. Remove the power steering belt pulley and A/C com-
pressor bracket.
2. Remove the oil line from power steering pump.
3. Rotate the crankshaft so that the piston of number,
cylinder is at ATDC20°.
4. Put the alignment marks (arrows) on the timing chain
and camshaft sprocket.
5. Remove the chain tensioner.
Installation Notice
Tightening Torque
72 -- 88 NSm (53 -- 65 lb-ft)
6. Remove the intake and exhaust camshaft sprocket
(remove the camshaft adjuster assembly in E23 en-
gine).
Installation Notice
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
Notice:The flange bolt is designed to be used only
once, so always replace with new one.
7. Remove the guide rail pin using the sliding hammer
116 589 20 33 00 (02) and the threaded pin 116 589
01 34 00 (03).
Notice:Apply the sealant on guide rail pin when installa-
tion.

1B2 -- 36 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
8. Unscrew the bolts (A).
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
9. Remove the belt pulley and vibration damper.
Installation Notice (Center Bolt)
Ti
ghteningTo rque
1st step: 200 + 20NSm
(148 + 15 lb-ft)
TighteningTorque
2nd step: 90°+10°
10. Unscrew the bolts (1, 2) on timing gear case cover
and remove the timing gear case cover.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
Notice:Be careful not to damage the cylinder head gas-
ket.
11. Remove the radial shaft seal.
Notice:Installation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase
sealing surface.
13. Replace the O -- ring with new one and apply the
sealant on the sealing surface.
Notice:Be careful not to stain the oil chamber of chain
tensioner with the sealant.
14. Installation should follow the removal precedure in
the reverse order.
15. Warm up the engine and check for oil leaks.

1B2 -- 38 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools 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 sur-
face.
5. Apply the engine oil to the dust lip of the radial shaft
seal.
Notice:Do not use the grease.
6. Install the crankshaft rear radial seal and the crank-
shaft sealing rear cover, using crankshaft rear seal in-
staller 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 Torque
9--11NSm (80 -- 97 lb-in)
8. Installation should follow the removal procedure in
the reverse order.

M161 ENGINE MECHANICAL 1B2 -- 41
D AEW OO M Y_2000
Tools Required
602589004000 EngineLock
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
Ti
ghteningTo rque
1st step: 200 + 20 NSm
(148 + 15 lb-ft)
TighteningTorque
2nd step: 90°+10°
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.

M161 ENGINE MECHANICAL 1B2 -- 43
D AEW OO M Y_2000
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
Ti
ghteningTo rque
1st step: 200 + 20 NSm
(148 + 15 lb-ft)
TighteningTorque
2nd step: 90°+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.

1B2 -- 48 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and re-
move the bearing cap.
Installation Notice
Tightening Torque
40 NSm (30 lb-ft) + 90°
DMake sure that the upper and lower bearing shells
do not change each other.
DCoat the bearing shell with engine oil.
DInstall the bearing cap according to the consecu-
tive number.
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
2. Unscrew the crankshaft bearing cap bolts and sepa-
rate the upper and lower bearing shells and thrust
washers.
Installation Notice
Tightening Torque
55 NSm (41 lb-ft) + 90°
DRemove the bearing cap from front (pulley side) to
rear.
DMake sure that the upper and lower bearing shells
do not change each other and coat with engine oil.
DThe oil grooves (arrows) in the thrust washers
must face outward and insert the thrust bearing
into the bearing cap.
DThere are five kinds of thrust washers by thick-
ness. 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 ro-
tating condition of the crankshaft.
Installation Notice
DMake 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).
DAssemble so that the projected part of the cap and
crankcase face the same direction.

M161 ENGINE MECHANICAL 1B2 -- 51
D AEW OO M Y_2000
FLYWHEEL / DRIVEN PLATE
Preceding Work: Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces)
1st step 45+5 NSm (33+3.7 lb-ft) ............
2nd step 90°+10°
2Plate3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)
Nominal SizeD--Mx1.5
Stretch Side DiameterdWhen New8.5 -- 0.2 mm
Min. Diameter8.0 mm
Bolt LengthLWhen New21.8 -- 22.2 mm
Tightening Torque1ststep45+5NSm (33 + 3.7 lb-ft), 2nd step 90°+10°

1B2 -- 52 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal & Installation Procedure
1. Unscrew the flywheel mounting bolt.
Installation Notice
Ti
ghteningTo rque
1st step: 45 + 5 NSm
(33+3.7lb-ft)
TighteningTorque
2nd step: 90°+10°
DReplace the bolt when the stretch side diameter (d)
of the flywheel mounting bolt is less than 8.0mm.
DFor the flywheel mounting bolt tightening, keep the
socket wrench and Tommy -- bar to be 90°and tight-
en as specified.
2. Remove the flywheel for manual transmission ve-
hicles, or the driven plate (3), and plate (2) for Auto.
transmission vehicle.
3. Installation should follow the removal procedure in
the reverse order.