SSANGYONG KORANDO 1997 Service Repair Manual

1B2 -- 78 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD GUIDE RAIL
Preceding Work: Removal of cylinder head front cover
1 Bolt (M6 X 45, 2 pieces)
9--11 NSm (80-- 97 lb-in) .....................2 Guide Rail

M161 ENGINE MECHANICAL 1B2 -- 79
D AEW OO M Y_2000
Tools Required
111 589 03 15 00 Holding Pin
Removal & Installation Procedure
1. Position the number 1 cylinder to ATDC20°guide rail.
2. Install the holding pin 111 589 03 15 00 into the no.1
and no.6 bearing cap hole.
3. Remove the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
TorqueTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)
4. Unscrew the bolt (1) and remove the guide rail.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
5. Installation should follow the removal procedure in
the reverse order.

1B2 -- 80 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKCASE GUIDE RAIL
Preceding Work: Removal of timing gear case cover
1 Guide Rail Pin
2 Guide Rail3 Timing Gear Case Cover
Removal & Installation Procedure
1. Remove the timing gear case cover (3).
Notice:Be careful not to damage the gasket when re-
moving/installing the timing gear case cover.
2. Remove the guide rail (2) from the guide rail pin (1).
Notice:
DReplace the plastic guide (2) if damaged.
DConnect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
3. Installation should follow the removal procedure in
the reverse order.

M161 ENGINE MECHANICAL 1B2 -- 81
D AEW OO M Y_2000
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
1 Oil Pump Chain Tensioner
2 Oil Pump Chain Bushing
3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5Key6 Bolt (M8 x 20, 1 piece) / Washer
29-- 35 NSm (21-- 26 lb-ft) ...................
7 Oil Pump Sprocket
8OilPump
9 Oil Pump Roller Chain
10 Timing Chain

1B2 -- 82 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
615 589 01 33 00 Crankshaft Sprocket Puller
Removal & Installation Procedure
1. Put the assembly mark at the crankshaft sprocket (4)
and the timing chain (10) with the paint (arrow).
Installation Notice
Align the assembly marks on crankshaft sprocket and
timing chain. Also, align the assembly marks on cam-
shaft sprocket and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprock-
et (7) from the oil pump.
Installation Notice
Tightening Torque
29 -- 35 NSm (21 -- 26 lb-ft)
3. Remove the oil pump roller chain (9).
4. Remove the oil pump chain tensioner (1), oil pump
chain bushing (3), and the oil pump chain spring (2).
5. Remove the crankshaft sprocket (4) using crankshaft
sprocketpuller615589013300.
Notice:
DMake sure not to lose the crankshaft pulley key (5)
when removing.
DInstall the crankshaft sprocket (4) after warming it up.
6. Installation should follow the removal procedure in
the reverse order.

M161 ENGINE MECHANICAL 1B2 -- 83
D AEW OO M Y_2000
PISTON
Preceding Work: Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bolt (M9 x 52, 8 pieces)
1ststep40NSm (30 lb-ft) ..................
2nd step 90°4Piston
5 Snap Ring
6 Piston Pin

1B2 -- 84 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the
cap.
2. Remove the connecting rod and the piston upward.
Notice:Make sure that the bearing cap and shell are not
changed each other.
3. Removethesnapring(5) andpulloutthepistonpin
(6).
Notice:Remove the snap ring using a clean cloth as
shown in the right picture so that the piston, piston ring,
and the snap ring don’t get damaged.
Installation Procedure

M161 ENGINE MECHANICAL 1B2 -- 85
D AEW OO M Y_2000
1. Check the piston ring gap and apply the engine oil to
the piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by press-
ing in the piston pin (6) and install the snap ring to the
groove.
3. Clean the cylinder bore, connecting rod bearing jour-
nal, connecting rod bearing shell and the piston and
coat them with engine oil.
4. Install the piston ring.
5. Install the piston so that the arrow on the piston head
faces to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap
mark (// or a number), tighten the bolts.
Installation Notice
TighteningTorque1st step: 40 NSm (30 lb-ft)TighteningTorque2nd step: 90°
Apply the engine oil to the bearing cap upper and low-
er bearing shells.
7. Check if the crankshaft rotates without any trouble by
rotating it.

1B2 -- 86 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CONNECTING ROD
Preceding Work: Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bearing Cap Bolt
(M9 x 52, 8 pieces)
1ststep40NSm (30 lb-ft) ..................
2nd step 90°5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 Bearing Shell Lug
9 Marking [Indication (//) or Numbers]
ServiceDataStandard
Distance (L) from The Connecting Rod Bearing to Bushing Bore CenterE20 : 154 mm
E23 : 149±0.05 mm
Width of The Connecting Rod (B) at Bearing Bore21.940 -- 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore21.940 -- 22.000 mm
Basic Bore at The Bearing Shell (D1)51.600 -- 51.614 mm
Basic Bore at The Bushing (d1)24.500 -- 24.521 mm
Bushing Inner Diameter (d)22.007 -- 22.013 mm
Clearance Between The Piston Pin and The Bushing0.007 -- 0.018 mm
Peak -- to-- valley Height of Connecting Rod Bushing on Inside0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing
Bore0.1/100 mm
Permissible Deviation of Axial Paralleism of Connecting Rod
Bearing Bore to Connecting Rod Bushing Bore0.045/100 mm
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from
Concentricity0.01 mm
Permissible Difference of Each Connecting Rod in Weight0.4 g

M161 ENGINE MECHANICAL 1B2 -- 87
D AEW OO M Y_2000
Inspection
1. Measure the basic bore of the connecting rod bear-
ing.
Notice:If the basic bore exceeds the value of
51.614mm, replace the bearing or check the connecting
rod.
2. Check connecting rod bolts.
Length When New (L)
51.7 -- 52 mm
Max. Length (L)52.9 mm
TighteningTo rque
1st step: 40 NSm
(30 lb-ft)
TighteningTorque
2nd step: 90°
Notice:If the length exceeds max. length, replace it.
3. Check the assembly mark (indication//or number:ar-
row) of the connecting rods and the bearing cap when
installing.
Notice
DMake sure it doesn’t exceed over 4g with other con-
necting rods when replacing the connecting rods.
DCheck if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.