SSANGYONG KORANDO 1997 Service Repair Manual

M162 ENGINE MECHANICAL 1B1 -- 105
D AEW OO M Y_2000
Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side
comes out using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.
Notice:Wait for about 45minutes before filling the cool-
ant so that the Loctite 240 hardens.
6. Warm up the engine and check the coolant for leaks.

1B1 -- 106 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER BORE
Group Code Letter and Cylinder Bore Size
Group Code Letter of CylinderPiston Type to be UsedCylinder Bore Size (mm)
AAorXφ89.900 --φ89.906
XA, X or Bφ89.906 --φ89.912
BXorBφ89.912 --φ89.918
X+5X+5φ89.950 --φ89.968
X+10X+10φ90.000 --φ90.018
Repair Size
Ty peGroup Code Letter 1)Cylinder Bore Size (mm)
Standard Sizeφ89.9Aφ89.900 --φ89.906φ
Xφ89.906 --φ89.912
Bφ89.912 --φ89.918
1st Repair Size
(StddSi025)
Aφ90.150 --φ90.156p
(Standard Size + 0.25)Xφ89.156 --φ90.162
Bφ90.162 --φ90.168
2nd Repair Size
(StddSi05)
Aφ90.400 --φ90.406p
(Standard Size + 0.5)Xφ90.406 --φ90.412
Bφ90.412 --φ90.418
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

M162 ENGINE MECHANICAL 1B1 -- 107
D AEW OO M Y_2000
ServiceDataStandard
Wear Limit in Longitudinal and Transverse Direction0.1 mm
Permissible Deviation of Cylinder Out -- of -- roundWhen new0.007 mmy
Wear limit0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)0.05 mm
Basic Peak -- to-- valley Height After Final Honing and Brushing0.003 -- 0.006 mm
Chamfer Angle60°
Honing Angle50°±10°
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

1B1 -- 108 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKCASE MATING SURFACE
ServiceDataStandard
Height of The Crankcase ‘H’ (When new)282.25 -- 282.35mm
Minimum Height After Milling281.95mm
FlatnessCrankcase Upper Mating Surface0.03mm
Crankcase Lower Mating Surface0.04mm
Permissible Deviation of Parallelism of The
UtLMtiSf
Axial Direction0.1mm
Upper to Lower Mating SurfaceTransverse Direction0.05mm
Peak -- to-- valley HeightCrankcase Upper Mating Surface0.005 -- 0.020mmyg
Crankcase Lower Mating Surface0.025mm

M162 ENGINE MECHANICAL 1B1 -- 109
D AEW OO M Y_2000
Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder
after finishing the chamfering with a suitable tool
(e.g., hand milling cutter).

1B1 -- 110 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD MATING SURFACE
Preceding Work: Removal of valves
ServiceDataStandard
Overall Height of Cylinder Head135.9 -- 136.0 mm
Minimum Height After Machining135.5 mm
FlatnessAxial Direction0.08 mm
Transverse Direction0.0 mm
Distance ‘T’
(BtChftBi
Standard SizeIntake24.21 -- 24.75 mm
(Between Camshaft Bearing
andValveStem)Exhaust22.21 -- 22.75 mmandValveStem)
Repair SizeIntake23.96 -- 24.51 mmp
Exhaust21.96 -- 22.51 mm
Notice:Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.

D AEW OO M Y_2000
SECTION 1D1
M162 ENGINE COOLING
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other -
wise noted.
TABLE OF CONTENTS
Specifications 1D1 -- 2............................
General Specifications 1D1-- 2....................
Fastener Tightening Specifications 1D1 -- 2..........
Special Tools 1D1 -- 3.............................
Special Tools Table 1D1-- 3.......................
Diagnosis 1D1 -- 4.................................
System Leakage Test 1D1-- 4.....................
Maintenance and Repair 1D1 -- 5...................
On-- Vehicle Service 1D1-- 5.........................Coolant Drain and Fill Up 1D1 -- 5..................
Coolant Connection Fitting 1D1 -- 7.................
Wat er Pum p 1D1 -- 8.............................
Thermostat 1D1 -- 10.............................
Oil Cooler Pipe Line 1D1 -- 11.....................
Cooling Fan and Viscous Clutch 1D1 -- 12...........
Cooling Fan Shroud 1D1 -- 14.....................
Radiator 1D1-- 15................................

1D1 -- 2 M162 ENGINE COOLING
D AEW OO M Y_2000
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Cooling TypeWater Cooling Forced Circulation
RadiatorCirculation TypeDouble Cross Flow
Radiation Capability70,000 kcal/h
Dimension(Width x Height x Thickeness)580 x 482 x 45 mm
Cooling Fanφ460, Six Blades
Anti-- Freeze AgentALUTEC -- P78
Mixing Ratio of Anti-- Freeze Agen with Water (Anti-- Freeze Agent : Water)50 : 50
Coolant Capacity11. 3 L
Reservoir Capacity3.4 L
Cap Operating Pressure (Reservoir Tank Pressure Cap)1.4 bar
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-FtLb-In
Coolant Drain Plug3022--
Engine Hanger Bracket and Coolant Outlet
Port Bolt22.5 -- 27.516.6 -- 20.3--
Thermostat Cover Bracket Bolts9--11--80 -- 97
Oil Cooler Pipe Line Bolts9--11--80 -- 97
Cooling Fan Bolts9--11--80 -- 97
Viscous Clutch Mounting Bolts40.5 -- 49.529.8 -- 36.5--
Automatic Transmission Fluid Cooler Pipe2015--
Cooling Fan Shroud Bolts3--7--27 -- 62
Automatic Transmission Radiator Tube
Assembly Mounting Bolt7--62
Radiator Bracket Mounting Bolts3--7--27 -- 62

M162 ENGINE COOLING 1D1 -- 3
D AEW OO M Y_2000
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
124 589 15 21 00
Tester603 589 00 40 00
Fan Clutch Holder

1D1 -- 4 M162 ENGINE COOLING
D AEW OO M Y_2000
DIAGNOSIS
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test Procedure
1. Loosen the cap a little and release pressure and re-
move the cap.
Notice:For the risk of scalding, cap must not be opened
unless the coolant temperature is below 90°C.
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the special tool to the reservoir filler cap and
apply 1.4 bar of pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at
the all coolant hoses and pipes and each connec-
tions. Replace or retighten if necessary.