SSANGYONG KORANDO 1997 Service Repair Manual

1B1 -- 74 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
17. Rivet the link pin.
Check the condition and it again if necessary.
18. Install the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
TorqueTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)
19. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1 -- 75
D AEW OO M Y_2000
TENSIONING RAIL
Preceding Work: Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide3 Tensioning Rail Pin
4 Guide Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and
the timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the tensioning rail (1) from the tensioning rail
pin (3).
Notice:
DReplace the plastic guide (2) if it is damaged.
DFor installation, exactly align the plastic guide (2) with
the tensioning rail (1).
4. Installation should follow the removal procedure in
the reverse order.
5. Check the camshaft timing position.

1B1 -- 76 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD GUIDE RAIL
Preceding Work: Removal of cylinder head front cover
1 Chain Tensioner
2 Upper Guide Rail3 Upper Guide Rail Pin
4 Wrench
Removal & Installation Procedure
1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating
direction using the wrench (4) and loosen the timing
chain at upper guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction
of rotation using the wrench.
5. Check for damages at the upper sliding rail and re-
place it if necessary. Install the upper guide rail pin.
6. Install the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
TorqueTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)

M162 ENGINE MECHANICAL 1B1 -- 77
D AEW OO M Y_2000
CRANKCASE GUIDE RAIL
Preceding Work: Removal of timing gear case cover
1 Guide Rail
2 Plastic Guide3 Guide Rail Pin
4 Tensioning Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and
the timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the guide rail (1) from the guide rail pin (3).
Notice:
DReplace the plastic guide (2) if damaged.
DConnect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
4. Installation should follow the removal procedure in
the reverse order.
5. Check the camshaft timing position.

1B1 -- 78 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
1 Oil Pump Chain Tensioner
2 Oil Pump Chain Bushing
3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5Key6 Bolt (M8 x 20, 1 piece) / Washer
29-- 35 NSm (21-- 26 lb-ft) ....................
7 Oil Pump Sprocket
8OilPump
9 Oil Pump Roller Chain
10 Timing Chain

1B1 -- 80 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
PISTON
Preceding Work: Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bearing Cap Bolt
(M9 x 52, 12 pieces)
1ststep40NSm (30 lb-ft) ..................
2nd step 90°4Piston
5 Snap Ring
6 Piston Pin

M162 ENGINE MECHANICAL 1B1 -- 81
D AEW OO M Y_2000
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. Removethesnapring(5) andpulloutthepistonpin
(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.

1B1 -- 82 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Installation Procedure
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 press-
ing in the piston pin (6) and install the snap ring to the
groove.
3. Clean the cylinder bore, connecting rod bearing jour-
nal, 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
TighteningTorque1st step: 40 NSm (30 lb-ft)TighteningTorque2nd step: 90°
Apply the engine oil to the bearing cap upper and low-
er bearing shells.
7. Check if the crankshaft rotates without any trouble by
rotating it.

M162 ENGINE MECHANICAL 1B1 -- 83
D AEW OO M Y_2000
CONNECTING ROD
Preceding Work: Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bearing Cap Bolt
(M9 x 52, 12 m pieces)
1ststep40NSm (30 lb-ft) ..................
2nd step 90°5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 Bearing Shell Lug
9 Marking [Indication(//) or Numbers]
ServiceDataStandard
Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing
Bore Center145±0.05 mm
Width of The Connecting Rod (B) at Bearing Bore21.940 -- 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore21.940 -- 22.000 mm
Basic Bore at The Bearing Shell (D1)51.600 -- 51.614 mm
Basic Bore at The Bushing (d1)24.500 -- 24.521 mm
Bushing Inner Diameter (d)22.007 -- 22.013 mm
Clearance Between The Piston Pin and The Bushing0.007 -- 0.018 mm
Peak -- to-- valley Height of Connecting Rod Bushing on Inside0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing
Bore0.15 mm
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to
Connecting Rod Bushing Core0.07 mm
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity0.01 mm
Permissible Difference of Each Connecting Rod in Weight0.4 g

1B1 -- 84 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Inspection
1. Measure the basic bore of the connecting rod bear-
ing.
Notice:If the basic bore exceeds the value of
51.614mm, replace the bearing or check the connecting
rod.
2. Check connecting rod bolts.
Length When New (L)
51.7 -- 52 mm
Max. Length (L)52.9 mm
Tightening Torque
1st step: 40 NSm
(30 lb-ft)
TighteningTorque
2nd step: 90°
Notice:If the length exceeds max. length, replace it.
3. Check the assembly mark(indication//or number:ar-
row) of the connecting rods and the bearing cap when
installing.
Notice
DMake sure it doesn’t exceed over 4g with other con-
necting rods when replacing the connecting rods.
DCheck if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.