SSANGYONG KORANDO 1997 Service Repair Manual

1B2 -- 58 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CAMSHAFT
Preceding Work: Removal of cylinder head cover
Removal of camshaft adjust actuator and cylinder head front cover
1 Bolt (M7 X 13, 3 pieces)
1stStep18--22NSm (13-- 16 lb-ft) ..........
2nd Step 60°±5°Rotation Added
2 Exhaust Camshaft Sprocket
3 Timing Chain
4a Intake Camshaft Spocket (E20)4b Camshaft Adjuster and Camshaft
Sprocket (E23)
5 Bearing Cap Bolt (20 pieces)
22.5-- 27.5 NSm (16.6--20.3 lb-ft) .............
6 Camshaft Bearing Cap
7 Wrench

M161 ENGINE MECHANICAL 1B2 -- 59
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Removal & Installation Procedure
1. Turn the crankshaft and position the no.1 cylinder pis-
ton at ATDC20°.
2. Put the alignment marks (arrows) on the camshaft
sprocket and the timing chain.
3. Remove the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
To r q u eTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)
4. Remove the exhaust camshaft sprocket.
Notice
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
Notice:The sprocket bolt is designed to be used only
once, so always replace with new one.
5. Take off the timing chain from intake camshaft
sprocket, and secure it not to fall down into the timing
gear case.
6. Using the wrench (7), turn the camshaft until there is
no resistence in camshaft bearing area.

1B2 -- 60 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
7. Remove the bearing cap, and remove the intake
and the exhaust camshaft.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
Notice:Check the numbers on the bearing cap not to be
mixed up.
8. Apply the engine oil on the valve tappet and cam-
shaft bearing.
9. Installation should follow the removal procedure in
the reverse order.
Notice:
DBase circle of cam should cantact with the valve tap-
pet.
DInstall the camshaft bearing caps according to the
numbers on the cylinder head cast and bearing cap.
10. Check the camshaft timing position.

M161 ENGINE MECHANICAL 1B2 -- 61
D AEW OO M Y_2000
CAMSHAFT TIMING POSITION
Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover
1 Holding Pin 111 589 03 15 00
2 Intake Camshaft Sprocket
3 Camshaft Bearing Cap
4 Timing Chain
5 Exhaust Camshaft Sprocket6 Bolt (M7 X 13, 3 pieces)
1ststep18--22NSm (13-- 16 lb-ft) ...........
2ndstep60°±5°rotation added
7StratePin

1B2 -- 62 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
111 589 03 15 00 Holding Pin
Inspection Procedure
1. Position the NO.1 cylinder piston to ATDC 20°by
turning the crankshaft.
Notice:When the ATDC 20°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 insert hole in NO.1 and
NO.4 camshaft bearing capwill match in line with the
flange hole for camshaft sprocket.
2. Check the timing as below procedure;
-- Check if the holding pin 111 589 03 15 00 can be
inserted into the NO.1 and NO.4 bearing cap hole.
-- At this condition, check if the ATDC 20°mark on
vibration damper aligns with the marker on the tim-
ing gear case.
Adjustment Procedure
1. Position the NO.1 cylinder to ATDC 20°.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Adjust the timing position with inserting the holding
pin 111 589 03 15 00 into the NO.1 and NO.4 cam-
shaft bearing cap hole and flange hole while rotating
the camshaft by using wrench.
5. Install the chain to the intake camshaft sprocket.
6. Install the chain to the exhaust camshaft sprocket
and tighten the bolt.
Installation Notice
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.
7. Install the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
TorqueTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)
8. Check the camshaft timing.

M161 ENGINE MECHANICAL 1B2 -- 63
D AEW OO M Y_2000
VALVE SPRING
Preceding Work: Removal of camshaft
Removal of spark plug
1 Valve Cotter
2 Valve Spring Retainer
3 Valve Spring
4 Valve Stem Seal
5 Lower Retainera Lever Pusher 111 589 18 61 00
b Thrust Piece 111 589 25 63 00
c Connecting Hose DW110-- 090
d Supporting Bar 111 589 01 59 00

1B2 -- 64 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
111 589 01 59 00 Supporting Bar
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece
602589004000 EngineLock
DW110-- 090 Connecting Hose
DW110-- 100 Valve Tappet Remover
Removal & Installation Procedure
1. Place the supporting bar 111 589 01 59 00 (a) at the
camshaft bearing cap and tighten them with the bear-
ing cap bolt.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
2. Turn the crankshaft to position the each cylinder pis-
ton at TDC.
Mark on The Vibration Damper
Cylinder
OT1, 4
UT2, 3
Notice
DRemove the valve spring only at TDC.
DAlways rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and
for smooth rotation.
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.

M161 ENGINE MECHANICAL 1B2 -- 65
D AEW OO M Y_2000
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.
14. Installation should follow the removal procedure in
the reverse order.

1B2 -- 66 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Test (Upper and Lower Valve Tappet and
Valve Cotter)
DUpper Valve Spring Retainer
Size(mm)(d)8.5Size(mm)(D)12.3
DLower Valve Spring Retainer
Thickness (mm)
(a)0.8 -- 1.0
DValve Cotter
Size(mm)(B)9.0Size(mm)(H)9.2 -- 9.8

M161 ENGINE MECHANICAL 1B2 -- 67
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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.