SSANGYONG KORANDO 1997 Service Repair Manual

1B2 -- 68 M161 ENGINE MECHANICAL
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 number 1 cylinder to ATDC 20°.
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
snap ring doesn’t return to the original position and the
tension gets exceeded.

M161 ENGINE MECHANICAL 1B2 -- 69
D AEW OO M Y_2000
4. Carefully unscrew the screw plug (1), and remove the
seal (2).
Notice
DFor the removal of screw plug, be careful that it can
be jumped out due to the force of compression
spring.
DRemove the screw plug only when the seal and com-
pression spring are damaged.
5. Carefully remove the filler pin (3), compression spring
(4), snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal
(8).
Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the
chain tensioner housing (7).
Notice:When connecting the thrust pin, push in the
thrust pin far enough so that it doesn’t protrude at the
chain tensioner housing.
2. Install the chain tensioner housing (7), thrust pin (6),
snap ring (5), and the seal (8).
Installation Notice
Tightening Torque
72 -- 88 NSm (53 -- 65 lb-ft)
3. Insert the compression spring (4) with the filler pin (3)
into chain tensioner housing.

1B2 -- 70 M161 ENGINE MECHANICAL
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.

M161 ENGINE MECHANICAL 1B2 -- 71
D AEW OO M Y_2000
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

1B2 -- 72 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
TIMING CHAIN
Preceding Work: Removal of cylinder head cover
Removal of spark plug
1Pin
2 New Timing Chain
3 Timing Chain (Used)
4 Wedge5Link
6 Center Plate
7 Outer Plate

M161 ENGINE MECHANICAL 1B2 -- 73
D AEW OO M Y_2000
Tools Required
000589584300 ChainAssembly
111 589 03 15 00 Holding Pin
Replacement Procedure
1. Position the NO.1 cylinder to ATDC 20°.
2. Insert the holding pin 111 589 03 15 00 to the intake
and exhaust camshaft flange not to rotate camshaft.
3. Remove the chain tensioner.
4. Mount the wedges to both sides of the camshaft
sprocket as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind
off the timing chain pin from the intake camshaft
sprocket with the grinder.

1B2 -- 74 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
6. Remove the outer plate (7) with the screw driver and
remove the link (5).
7. Connect the new timing chain (2) to the used timing
chain (3) with the link (5), center plate (6, thickness
1.6mm), and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revo-
lution by pressing the new timing chain against the
exhaust camshaft sprocket to prevent it to be
tangled.
Notice:Be sure to remove the wedge before cranking
the engine.
9. Take out the used timing chain out from the chain
housing.
10. Connect both separators of the new timing chain
with the link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the as-
sembly tool as shown in the figures.

M161 ENGINE MECHANICAL 1B2 -- 75
D AEW OO M Y_2000
12. Place the outer plate (7, thickness 1.2mm) inside
the thrust piece (b).
13. Install the chain assembly 000 589 58 43 00 above
the link and tighten the spindle (c) until a block is felt.
14. Place the chain assembly 000 589 58 43 00.
15. Replace the thrust piece (b) as shown in the figure.
16. Install the chain assembly 000 589 58 43 00 to the
link pin and tighten the spindle (c).
Installation Notice
Tightening Torque
30 NSm (22 lb-ft)

1B2 -- 76 M161 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.

M161 ENGINE MECHANICAL 1B2 -- 77
D AEW OO M Y_2000
TENSIONING RAIL
Preceding Work: Removal of cylinder head
1 Sliding Rail Pin
2 Sliding Rail3 Timing Gear Case Cover
Removal & Installation Procedure
1. Remove the timing gear case cover (3).
Notice:Be careful not to damage the gasket.
2. Remove the sliding rail (1) from the sliding rail pin (2).
Notice
DReplace the plastic guide (2) if it is damaged.
DFor installation, exactly align the plastic guide (2) with
the sliding rail (1).
3. Installation should follow the removal procedure in
the reverse order.