SSANGYONG KORANDO 1997 Service Repair Manual

1B2 -- 88 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
PISTON RING
Preceding Work: Removal of piston
1 Piston Compression Ring (Top Ring)
2 Piston Compression Ring (2nd Ring)
3 Piston Oil Ring4--
5 Spacer
6SideRail

M161 ENGINE MECHANICAL 1B2 -- 89
D AEW OO M Y_2000
Replacement Procedure
1. Measure the piston ring’s gap.
EdGfTh
Groove 1 0.20 -- 0.40 mm
End Gap of The
PistonRingGroove 2 0.20 -- 0.40 mmPistonRing
Groove 3 0.20 -- 0.45 mm
GapBetweenGroove 1 0.028 -- 0.060 mmGapBetween
ThePistonand
ThPitRi
Groove 2 0.010 -- 0.045 mm
The Piston RingGroove 3 0.010 -- 0.045 mm
Notice:If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
3. For installation, position the piston ring to be the
‘TOP’ mark on the piston ring upward and arrange the
piston ring ends to be 120°apart.
4. Adjust the hook spring joint in the oil ring 180°away
from the ring end.

1B2 -- 90 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
OIL PAN
1Bolt
2Bolt
3Bolt
4Bolt5Bolt
6OilPan
7 Gasket
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.

M161 ENGINE MECHANICAL 1B2 -- 91
D AEW OO M Y_2000
Oil Circulation
1 Oil Strainer
2OilPump
3OilPan
4 Oil Non-- Return Valve
5 Oil Filter
6 Oil Filter Bypass Valve
7 Main Oil Gallery
8 Closing Ball (φ15mm)
9 Crankshaft
10 Connecting Rod Bearing
11 Crankshaft Bearing
12 Connecting Rod
13 Piston
14 Oil Spray (Piston Crown Area)
15 Non-- Return Valve (Crankcase)16 Oil Supply (To Chain Tensioner)
17 Camshaft
18 Cam Bearing
19 Valve
20 Oil Gallery (Supply Oil to Intake Tappet)
21 Oil Gallery (Supply Oil to Exhaust Tappet)
22 Ball (φ8mm)
23 Camshaft Plug
24 Seal
25 Screw Plug
26 Oil Return Gallery
(Cylinder Head and Crankcase)
27 Oil Return Gallery (Crankcase)
28 End Cover (φ20mm)
29 Oil Return Pipe

M161 ENGINE MECHANICAL 1B2 -- 97
D AEW OO M Y_2000
OIL PRESSURE RELIEF VALVE
Preceding Work: Removal of oil pan
1 Screw Plug 50 NSm (37 lb-ft) ................
2 Compression Spring3 Guide Pin
4Piston
Removal & Installation Procedure
1. Remove the screw plug (1).
Installation Notice
Tightening Torque
50 NSm (37 lb-ft)
2. Remove the spring (2), guide pin (3) and the piston
(4).
3. Installation should follow the removal procedure in
the reverse order.
Notice:Don’t use the seal for the screw plug.

1B2 -- 98 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
OIL NON-- RETURN VALVE
Preceding Work: Removal of timing gear case cover
1 Oil Non-- return Valve
Functions
The non -- return valve prevents the oil in the chain ten-
sioner from drying up. In other words, it stops oil-- return-
ing in order to prevent the oil in the chain tensioner from
getting dry. As a result, the chain tensioner can be acti-
vated with oil in itself.
Replacement Procedure
1. Remove the non--return valve using a pliers.
2. Insert new non-- return valve with hand.

M161 ENGINE MECHANICAL 1B2 -- 99
D AEW OO M Y_2000
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge
2 Oil Dipstick Guide Tube
3O--ring4 Bolt (M6 X 16, 1 piece)
9--11 NSm (80-- 97 lb-in) ....................
5 Clamp
Removal & Installation Procedure
1. Pull out the oil dipstick level gauge (1).
2. Unscrew the bolt (4) and remove the oil dipstick guide
tube (2).
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
It is very hard to remove the oil dipstick guide tube
without special tool. If it is not necessary, do not re-
move the guide tube.
3. Installation should follow the removal procedure in
the reverse order.
4. Check for leaks by starting the engine.

1B2 -- 100 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
UNIT REPAIR
CORE PLUGS IN CRANKCASE
Preceding Work: Draining of the coolant
1 Core Plug Replace.........................

M161 ENGINE MECHANICAL 1B2 -- 101
D AEW OO M Y_2000
Tools Required
102589001500 Drift
Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side
comes out using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.
Notice:Wait for about 45minutes before filling the cool-
ant so that the Loctite 241 hardens.
6. Warm up the engine and check the coolant for leaks.

1B2 -- 102 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER BORE
Group Code Letter and Cylinder Bore Size
EngineGroup Code Letter of CylinderPiston Type to be UsedCylinder Bore Size (mm)
AAorXφ90.906 --φ90.912
XA, X or Bφ90.906 --φ90.912
E23BXorBφ90.912 --φ90.918
X+5X+5φ90.950 --φ90.968
X+10X+10φ91.000 --φ91.018
AAorXφ89.900 --φ90.906
XA, X or Bφ89.906 --φ89.912
E20BXorBφ89.912 --φ89.918
X+5X+5φ89.950 --φ89.968
X+10X+10φ90.000 --φ90.018