steering SSANGYONG KORANDO 1997 Service User Guide

1B1 -- 88 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
OIL PAN
Preceding Work: Removal of front stabilizer
Removal of steering gear box
1 Gasket Replace...........................
2 Bolt (M6 x 22, 6 pieces) 10 NSm (89 lb-in) .....
3 Drain Plug (M6 x 20) 25 NSm (18 lb-ft) .......
4 Bolt (M6 x 20, 22 pieces) 10 NSm (89 lb-in) ....5 Bolt (M6 x 85) 10 NSm (89 lb-in) .............
6 Bolt (M8 x 40) 25 NSm (18 lb-ft) .............
7 Bolt (M10) 40 NSm (30 lb-ft) .................
8OilPan
Removal & Installation Procedure
1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket.
Notice:Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then
apply the sealant.
4. Replace the gasket with new one.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine.

1F1 -- 2 M162 ENGINE CONTROLS
D AEW OO M Y_2000
ENGINE AND ECM PROBLEM CHECK REPORT
VEHICLE AND CUSTOMER INFORMATION
Date problem Occurred
Customer NameVehicle Model
Driver NameVIN
Purchase dateEngine Model
License No.MileageKm
miles
MIL INFORMATION
Condition of MILjRemains onjSometimes illuminatesjDoes not illuminate
DTC inspection
(if available)jNormaljMalfunction code(s) (code )
jFreezed frame data ( )
PROBLEM DESCRIPTION
jEngine Does Not StartjNo crankingjNo initial combustionjNo complete combustion
jHard to StartjSlow cranking
jOthers
jPoor IdlingjIncorrect first IdlejAbnormal idle rpmjHigh (rpm)jLow (rpm)
jIdling UnstablejOthers
jPoor DriveabilityjHesitationjBack firejMuffler explosion (after-burning)
jSurgingjKnockingjPoor performancejOther
jEngine StalljSoon after startingjAfter accelerator pedal depressed
jAfter accelerator pedal releasedjDuring A/C operation
jShifting from N to D or D to N
jAt full steeringjOthers
jOthers
CONDITION WHEN PROBLEM OCCURS
Problem FrequencyjConstantjIntermittent (times per day/month)jOnce onlyjOthers
WeatherjFinejCloudyjRainyjSnowyjVarious/Others
Ambient TemperaturejHotjWar mjCooljCold (approx.____°F/____°C)
PlacejHighwayjSuburbsjInner CityjUphilljDownhill
jRough RoadjOthers
Engine TemperaturejColdjWarming UpjBefore warming upjAfter warm-up
jAny temp.jOthers
Engine OperationjStartingjJust after starting (min.)jIdlingjRacingjDriving
jConstant speedjAccelerationjDeceleration
jA/C switch ON/OFFjOther

GENERAL ENGINE INFORMATION 1A2 -- 7
D AEW OO M Y_2000
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair. The following procedures may
help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate loca-
tion of the leak by the drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-- type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating condi-
toins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil fill
tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid willappear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a gas-
ket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. Thebent flange must be
repaired also. Before attempting to repair a leak, check
for the following conditions and correct them as they
may cause a leak.
Gaskets
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe fasteners are tightened improperly or the threads
are dirty or damaged.
DThe flanges or the sealing surface is warped.
DThere are scratches, burrs or other damage to the
sealing surface.
DThe gasket is damaged or worn.
DThere is cracking or porosity of the component.
DAn improper seal was used (where applicable).
Seals
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe seal bore is damaged (scratched, burred or
nicked).
DThe seal is damaged or worn.
DImproper installation is evident.
DThere are cracks in the components.
DThe shaft surface is scratched, nicked or damaged.
DA loose or worn bearing is causing excess seal wear.

1B2 -- 2 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-FtLb-In
Fuel Feed and Return Line21 -- 2515 -- 18--
Exhaust Manifold and Pipe3022--
Engine Mounting Nuts7052--
Generator Carrier Bolts2518--
Tensioning Pulley Bolt40.5 -- 49.529.9 -- 36.5--
Steering Pump Bolts22.5 -- 27.516.6 -- 20.3--
A/C Bracket Bolts22.5 -- 27.516.6 -- 20.3--
Intake Air Duct Mounting Nuts9--11--80 -- 97
Spark Plug Cover Bolts9--11--80 -- 97
Cylinder Head Cover Bolts9--11--80 -- 97
Magnetic Assembly Bolt9--11--80 -- 97
Cylinder Head Front Cover BoltsM822.5 -- 27.516.6 -- 20.3--y
M69--11--80 -- 97
Cylinder Head Bolts55
+90°
+90°41
+90°
+90°
--
Timing Gear Case Cover Bolts22.5 -- 27.516.6 -- 20.3--
Crankshaft Sealing Rear Cover Mounting Bolts9--11--80 -- 97
Vibration Damper Center Bolt200 + 20
+90°+10°148 + 15
+90°+10°--
Connecting Rod Bearing Cap Bolts40
+90°30
+90°--
Flywheel Mounting Bolt45 + 5
+90°+10°33 + 3.7
+90°+10°--
Amarture Bolt in Flywheel3526--
Camshaft Adjuster Flange Bolts18 -- 22
60°±5°13 -- 16
60°±5°--
Intake Flange Shaft Bolts18 -- 22
60°±5°13 -- 16
60°±5°--
Exhaust Camshaft Sprocket Bolts18 -- 22
60°±5°13 -- 16
60°±5°--
Camshaft Bearing Cap Bolts22.5 -- 27.516.6 -- 20.3--
Chain Tensioner Screw Plug4030--
Chain Tensioner Assembly72 -- 8853 -- 65--
Oil Pump Sprocket Bolt29 -- 3521 -- 26--
Tensioning Device Bolts26 -- 3219 -- 24--
Water Pump Pulley22.5 -- 27.516.6 -- 20.3--
Upper Intake Manifold Bolt22.5 -- 27.516.6 -- 20.3--
Lower Intake Mainfold Bolt22.5 -- 27.516.6 -- 20.3--
Flange Bolt to Exhaust Mainfold3022--

1B2 -- 10 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
11. Remove the hydraulic pipe of power steering.
Notice:Completely drain the oil.
12. Discharge the refrigerant from A/C system, and dis-
connect the discharge pipe and suction pipe from
the compressor.
13. Remove the fuel feed and return line.
Notice:Before removing the fuel lines, release the pres-
sure in the fuel system.
Installation Notice
Tightening Torque
21 -- 25 NSm (15 -- 18 lb-ft)
14. Disconnect the terminals from the generator.

M161 ENGINE MECHANICAL 1B2 -- 21
D AEW OO M Y_2000
Poly V - Belt Arrangement
1 Belt Tensioning Pulley
2 Crankshaft Belt Pulley
3 A/C Compressor Pulley5 Generator Pulley
7 Power Steering Pump Pulley
8 Water Pump Pulley

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.

1F2 -- 2 M161 ENGINE CONTROLS
D AEW OO M Y_2000
ENGINE AND ECM PROBLEM CHECK REPORT
VEHICLE AND CUSTOMER INFORMATION
Date problem Occurred
Customer NameVehicle Model
Driver NameVIN
Purchase dateEngine Model
License No.MileageKm
miles
MIL INFORMATION
Condition of MILjRemains onjSometimes illuminatesjDoes not illuminate
DTC inspection
(if available)jNormaljMalfunction code(s) (code )
jFreezed frame data ( )
PROBLEM DESCRIPTION
jEngine Does Not StartjNo crankingjNo initial combustionjNo complete combustion
jHard to StartjSlow cranking
jOthers
jPoor IdlingjIncorrect first IdlejAbnormal idle rpmjHigh (rpm)jLow (rpm)
jIdling UnstablejOthers
jPoor DriveabilityjHesitationjBack firejMuffler explosion (after-burning)
jSurgingjKnockingjPoor performancejOther
jEngine StalljSoon after startingjAfter accelerator pedal depressed
jAfter accelerator pedal releasedjDuring A/C operation
jShifting from N to D or D to N
jAt full steeringjOthers
jOthers
CONDITION WHEN PROBLEM OCCURS
Problem FrequencyjConstantjIntermittent (times per day/month)jOnce onlyjOthers
WeatherjFinejCloudyjRainyjSnowyjVarious/Others
Ambient TemperaturejHotjWar mjCooljCold (approx.____°F/____°C)
PlacejHighwayjSuburbsjInner CityjUphilljDownhill
jRough RoadjOthers
Engine TemperaturejColdjWarming UpjBefore warming upjAfter warm-up
jAny temp.jOthers
Engine OperationjStartingjJust after starting (min.)jIdlingjRacingjDriving
jConstant speedjAccelerationjDeceleration
jA/C switch ON/OFFjOther

1A3 -- 10 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair. The following procedures may
help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate loca-
tion of the leak by the drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-- type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil fill
tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid willappear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a gas-
ket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. Thebent flange must be
repaired also. Before attempting to repair a leak, check
for the following conditions and correct them as they
may cause a leak.
Gaskets
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe fasteners are tightened improperly or the threads
are dirty or damaged.
DThe flanges or the sealing surface is warped.
DThere are scratches, burrs or other damage to the
sealing surface.
DThe gasket is damaged or worn.
DThere is cracking or porosity of the component.
DAn improper seal was used (where applicable).
Seals
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe seal bore is damaged (scratched, burred or
nicked).
DThe seal is damaged or worn.
DImproper installation is evident.
DThere are cracks in the components.
DThe shaft surface is scratched, nicked or damaged.
DA loose or worn bearing is causing excess seal wear.

1B3 -- 16 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
16. Remove the power steering pump lines.
Notice
Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the
feed pump on injection pump.
18. Vehicle with automatic transmission.
Remove the hydraulic lines (19, 20) from oil cooler
(2).
19. Disconnect the engine harness.
20. Disconnect the preheating time relay cable.