check engine SSANGYONG KORANDO 1997 Service User Guide

1B1 -- 34 M162 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.

M162 ENGINE MECHANICAL 1B1 -- 39
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.

1B1 -- 40 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKSHAFT REAR RADIAL SEAL
Preceding Work: Removal of flywheel or drive plate
1 Special Tool
2 Special Tool3 Crankshaft Rear Seal
Tools Required
601 589 03 43 00 Crankshaft Rear 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. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice:Do not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is
stopped.
6. Check for leaks while operating the engine.

1B1 -- 44 M162 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.

1B1 -- 60 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
DW110 -- 120 Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turn-
ing the crankshaft.
Notice:When the OT mark on vibration damper is
aligned with timing gear case cover, the intake and ex-
haust cam of cylinderwill make the slope to the center
and will face up. In this way, the adjustment hole of the
intake and exhaust camshaftwill match in line with the
cylinder head upper end, at 3 o’clock, and 9 o’clock di-
rection each other.
2. Check the timing as below procedure;
-- Check if the camshaft adjustment hole is posi-
tioned to 3 o’clock direction at the intake side and
to 9 o’clock direction at the exhaust side, respec-
tively and align with the cylinder head mating sur-
face.
-- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear
case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30°.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole
with the cylinder head upper surface.
DIntake Side : 3 o’clock direction
DExhaust Side : 9 o’clock direction
5. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin
DW110-- 120 into the holes.
6. Secure the intake and exhaust camshaft.
7. Position the piston of No.1 cylinder at TDC (OT) by
turning the crankshaft.
8. Turn the camshaft adjuster of the intake camshaft to
the left as much as possible (cam adjuster ‘retarded’
position).
9. Install the chain to the intake camshaft sprocket.
Notice:Timing chain must be placed on the guide rail in
gear case cover.

M162 ENGINE MECHANICAL 1B1 -- 61
D AEW OO M Y_2000
10. Install the chain to the exhaust camshaft sprocket
and install it to the camshaft.
Installation Notice (Sprocket Bolt)
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
The sprocket bolt is designed to be used only once,
so replace with new one.
11. Install the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
TorqueTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)
12. Check the camshaft timing.

1B1 -- 64 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
3. Remove the valve tappet using the valve tappet re-
mover DW110-- 100.
4. Install the connecting hose DW110-- 090 (c) to the
spark plug hole.
5. Install the engine lock 602 589 00 40 00 to the ring
gear to prevent the crankshaft from rotating.
6. Blow up with compressed air.
7. Install the supporting bar 111 589 01 59 00 (d) and
the lever pusher 111 589 18 61 00 (a).
8. Mount the thrust piece 111 589 25 63 00 (b) vertical-
ly to the valve spring retainer (2).
9. Press the valve spring (3) by using the lever pusher
111589186100(a).
10. Remove the valve cotter (1) using the pincette.
11. Remove the upper retainer (2) and the valve spring
(3).
12. Remove the valve stem seal (4) and replace if nec-
essary.
Notice:Check the valve stem seal for damage and re-
place if necessary.
13. Remove the lower retainer (5).
Notice:Check the retainer for damages and replace
with a new one if necessary.

1B1 -- 66 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
VALVE STEM SEAL
Preceding Work: Removal of valve spring
1 Drift 119 589 00 43 00
2 Valve Stem Seal3 Protective Sleeve
Tools Required
119 589 00 43 00 Drift
Replacement Procedure
1. Remove the valve stem seal (2) using the pliers.
Notice:Check the valve stem seal for damage and re-
place if necessary.
2. Coat the valve stem seal with oil and assemble it with
the protective sleeve.
3. Insert the valve stem seal by pressing it with the drift
119 589 00 43 00.

M162 ENGINE MECHANICAL 1B1 -- 67
D AEW OO M Y_2000
CHAIN TENSIONER
1 Screw Plug 40 NSm (30 lb-ft) ................
2 Seal
3 Filler Pin
4 Compression Spring
5 Snap Ring6 Thrust Pin
7 Chain Tensioner Housing
72-- 88 NSm (53-- 65 lb-ft) ....................
8Seal
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice:Remove the oil filler cap at adjustment position,
and check whether the intake camshaft cam’s lobe (ar-
row) stays in the upper side.
2. Cover the generator with a clean cloth.
3. Release the tension by unscrewing the screw plug
once.
Notice:In case that the tension is reduced by unscrew-
ing the screw plug, reinstall after completely removing
the chain tensioner. If the chain tensioner is tightened
again without completely reducing its tension, then the
detent spring doesn’t return to the original position and
the tension gets exceeded.

M162 ENGINE MECHANICAL 1B1 -- 69
D AEW OO M Y_2000
4. Lightly apply the grease to the seal (2) and install the
screw plug (1).
Installation Notice
Tightening Torque
40 NSm (30 lb-ft)
5. Check for leaks by operating the engine.
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece13 Chain Tensioner Housing
14 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole