lock SSANGYONG KORANDO 1997 Service Owner's Guide

D AEW OO M Y_2000
SECTION 1B2
M161 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other -
wise noted.
TABLE OF CONTENTS
Specifications 1B2 -- 2............................
Fastener Tightening Specifications 1B2 -- 2..........
Special Tools 1B2 -- 4.............................
Special Tools Table 1B2-- 4.......................
Maintenance and Repair 1B2 -- 7...................
On-- Vehicle Service 1B2-- 7.........................
Engine Assembly 1B2-- 7.........................
Crankcase Ventilation System 1B2-- 14.............
Generator 1B2-- 18..............................
Engine Mount 1B2-- 19...........................
Poly V-- Belt 1B2 -- 20.............................
Tensioning Device 1B2-- 22.......................
Tensioning Device Shock Absorber 1B2-- 23........
Poly V-- Belt Inspection 1B2-- 24...................
Cylinder Head Cover 1B2-- 26.....................
Cylinder Head Front Cover 1B2 -- 28...............
Cylinder Head 1B2-- 30...........................
Timing Gear Case Cover 1B2-- 34.................
Crankshaft Sealing Rear Cover 1B2-- 37...........
Belt Pulley and Vibration Damper 1B2-- 39..........
Crankshaft Front Radial Seal 1B2-- 42.............
Crankshaft Rear Radial Seal 1B2-- 44..............
Crankshaft 1B2-- 45.............................
Flywheel / Driven Plate 1B2 -- 51...................
Camshaft Adjuster 1B2-- 54.......................Camshaft Sprocket Bolt 1B2-- 57..................
Camshaft 1B2-- 58..............................
Camshaft Timing Position 1B2 -- 61................
Valve Spring 1B2 -- 63............................
Valve Stem Seal 1B2-- 67........................
Chain Tensioner 1B2-- 68.........................
Timing Chain 1B2-- 72............................
Tensioning Rail 1B2-- 77..........................
Cylinder Head Guide Rail 1B2-- 78.................
Crankcase Guide Rail 1B2-- 80....................
Crankshaft Sprocket 1B2-- 81.....................
Piston 1B2-- 83..................................
Connecting Rod 1B2-- 86.........................
Piston Ring 1B2 -- 88.............................
Oil Pan 1B2-- 90.................................
Engine Oil and Oil Filter Element 1B2-- 92..........
Oil Pump 1B2-- 95...............................
Oil Pressure Relief Valve 1B2-- 97.................
Oil Non-Return Valve 1B2-- 98....................
Oil Dipstick Guide Tube 1B2-- 99..................
Unit Repair 1B2 -- 100............................
Core Plugs in Crankcase 1B2-- 100................
Cylinder Bore 1B2-- 102..........................
Crankcase Mating Surface 1B2-- 104..............
Cylinder Head Mating Surface 1B2-- 106...........

M161 ENGINE MECHANICAL 1B2 -- 5
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Special Tools Table (Cont’d)
601 589 03 14 00
Crankshaft Front Seal
Installer
603 589 00 40 00
Fan Clutch Holder
615 589 01 33 00
Crankshaft Sprocket
Puller
601 589 03 43 00
Crankshaft Rear Seal
Installer
602 589 00 40 00
Engine Lock
617 589 00 10 00
Allen Wrench Socket
DW110 -- 090
Connecting Hose
DW110 -- 100
Valve Tappet Remover

M161 ENGINE MECHANICAL 1B2 -- 9
D AEW OO M Y_2000
7. Loosen the cylinder block drain plug and then drain
the coolant completely.
Installation Notice
Tightening Torque
30 NSm (22 lb-ft)
Notice:Replace the seal before installation of the drain
plug.
8. Remove the cooling fan shroud. Refer toSection
1D2, Engine Cooling.
9. Disconnect the each hose from radiator.
10. Remove the upper mounting bolts of radiator and
then remove the radiator.

1B2 -- 20 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
POLY V -- BELT
Preceding Work: Removal of cooling fan
1 Poly V-- belt (2,155 mm)
2 Belt Tensioning Pulley3 Belt Tensioner
Removal & Installation Procedure
1. Release the belt tension by turning the stud on the
cap with 12 sided wrench or spanner counterclock-
wise.
2. Remove the poly v -- belt.
Notice:Check the belt for damage and tensioning
pulley bearing point for wear and replace them if neces-
sary.
3. Install the belt after prying the tensioning pulley.

1B2 -- 22 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
TENSIONING DEVICE
Preceding Work: Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) +
Washer 22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) ......
2 Bolt (M8 x 25, 1 pieces) +
Washer 22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) ......3 Tensioning Device
4 Stud bolt
5 Tensioning Arm
Removal & Installation Procedure
1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in ten-
sioning arm.
3. Unscrew the bolts (1, 2) and remove the tensioning
device.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
4. Installation should follow the removal procedure in
the reverse order.

M161 ENGINE MECHANICAL 1B2 -- 41
D AEW OO M Y_2000
Tools Required
602589004000 EngineLock
Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.
2. Remove the start motor and install the engine lock
602 589 00 40 00 to the flywheel ring gear.
3. Remove the vibration damper center bolt.
Installation Notice
Ti
ghteningTo rque
1st step: 200 + 20 NSm
(148 + 15 lb-ft)
TighteningTorque
2nd step: 90°+10°
4. Remove the vibration damper assembly using the
puller.
5. Installation should follow the removal procedure in
the reverse order.
Notice:If possible, don’t separate the vibration damper
and the pulley.

M161 ENGINE MECHANICAL 1B2 -- 49
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Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt ex-
ceeds 63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly
seated on the cylinder block (arrows).
3. Measure and record the inner diameter of the crank-
shaft bearing.
Notice
DMeasure at 2 points (1, 2).
DMeasure ‘A’, ‘B’ and ‘C’ as shown. If average value of
‘B’ and ‘C’ is less than value ‘A’, then the average val-
ue of ‘B’ and ‘C’ is actual average value. If average
value of ‘B’ and ‘C’ is more than value ‘A’ is actual av-
erage value.
4. Measure and record the diameter of the crankshaft
bearing journal.
Notice
DRecord the mean value when measured at 3 points
(A,B,C).
DMeasure the inner diameter of bearing and the diam-
eter of journal and if it is out of the standard data, re-
place the bearing shell.

1B2 -- 56 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
7. Unscrew the bolt (3) from the armature (4) and re-
move the roll pin, and remove the armature.
Installation Notice
Tightening Torque
35 NSm (26 lb-ft)
8. Unscrew the nut (6) and remove the seal cover (7).
Installation Notice
Tightening Torque
60 -- 70 NSm (44 -- 52 lb-ft)
Notice:Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft
sprocket.
10. Remove the adjuster piston (9) and conical spring
(10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft.
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.
12. Installation should follow the removal procedure in
the reverse order.
13. Check and adjust the camshaft timing.

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
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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.