SSANGYONG KORANDO 1997 Service Repair Manual

M161 ENGINE MECHANICAL 1B2 -- 103
D AEW OO M Y_2000
Group Code Letter of CylinderGroup Code Letter 1)Cylinder Bore Size (mm)
Standard SizeAφ89.900 --φ89.906
E20 :φ89.9
E23φ909Xφ89.906 --φ89.912E23 :φ90.9Bφ89.912 --φ89.918
1st Repair Size
(StddSi025)
Aφ90.150 --φ90.156p
(Standard Size + 0.25)Xφ89.156 --φ90.162
Bφ90.162 --φ90.168
2nd Repair Size
(StddSi05)
Aφ90.400 --φ90.406p
(Standard Size + 0.5)Xφ90.406 --φ90.412
Bφ90.412 --φ90.418
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
ServiceDataStandard
Wear Limit in Longitudinal and Transverse Direction0.1 mm
Permissible Deviation of Cylinder Out -- of -- roundWhen new0.007 mmy
Wear limit0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)0.05 mm
Basic Peak -- to-- valley Height After Final Honing and Brushing0.003 -- 0.006 mm
Chamfer Angle75°
Honing Angle50°±10°
Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore
size in axial and transverse direction at three points
(1,2,3).
1, 2, 3 Measuring Points
A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle

1B2 -- 104 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKCASE MATING SURFACE
ServiceDataStandard
Height of The Crankcase ‘H’ (When new)289.35 -- 289.45 mm
Minimum Height After Milling289.05 mm
FlatnessCrankcase Upper Mating Surface0.03 mm
Crankcase Lower Mating Surface0.04 mm
Permissible Deviation of Parallelism of The
UtLMtiSf
Axial Direction0.1 mm
Upper to Lower Mating SurfaceTransverse Direction0.05 mm
Peak -- to-- valley HeightCrankcase Upper Mating Surface0.012 -- 0.009 mmyg
Crankcase Lower Mating Surface0.025 -- 0.020 mm

M161 ENGINE MECHANICAL 1B2 -- 105
D AEW OO M Y_2000
Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder
after finishing the chamfering with a suitable tool
(e.g., hand milling cutter).

1B2 -- 106 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD MATING SURFACE
Preceding Work: Removal of valves
ServiceDataStandard
Overall Height of Cylinder Head135.9 -- 136.0 mm
Minimum Height After Machining135.5 mm
FlatnessAxial Direction0.08 mm
Transverse Direction0.0 mm
Distance ‘T’
(BtChftBi
Standard SizeIntake24.21 -- 24.75 mm
(Between Camshaft Bearing
andValveStem)Exhaust22.21 -- 22.75 mmandValveStem)
Repair SizeIntake23.96 -- 24.51 mmp
Exhaust21.96 -- 22.51 mm
Notice:Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.

M161 ENGINE MECHANICAL 1B2 -- 107
D AEW OO M Y_2000
Measurement of Mating Surfac
1. Measure the height (H) of the cylinder head(refer to
Service data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-- measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft
bearing and the valve system(refer to Service data
standard).
7. Mill the cylinder head valve seat(refer to Service data
standard).
Universal Tool
Surface Grinding Machine
Sceledum, Type RTY
Roaro
Schio/Italy

D AEW OO M Y_2000
SECTION 1D2
M161 ENGINE COOLING
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 1D2 -- 2............................
General Specifications 1D2-- 2....................
Fastener Tightening Specifications 1D2 -- 2..........
Special Tools 1D2 -- 3.............................
Special Tools Table 1D2-- 3.......................
Diagnosis 1D2 -- 4.................................
System Leakage Test 1D2-- 4.....................
Maintenance and Repair 1D2 -- 5...................
On-- Vehicle Service 1D2-- 5.........................Coolant Drain and Fill Up 1D2 -- 5..................
Cooling Fan and Viscous Clutch 1D2 -- 7............
Wat er Pum p 1D2 -- 9.............................
Thermostat 1D2 -- 11.............................
Thermostat Housing Assembly 1D2 -- 12............
Removal and Installation of Cooling
Fan Shroud 1D2 -- 14...........................
Removal and Installation of Radiator 1D2-- 15.......

1D2 -- 2 M161 ENGINE COOLING
D AEW OO M Y_2000
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Cooling TypeWater Cooling Forced Circulation
RadiatorCirculation TypeDown Flow
Radiation61,500 kcal/h
Capability58,000 kcal/h
Dimension (Width x Height x Thickeness)680 x 415 x 25 mm(g)
680 x 415 x 28 mm
Cooling Fanφ460, 9 Blades
Anti-- Freeze AgentALUTEC-- P78, Dragon Power
Coolant A
Mixing Ratio of Anti-- Freeze Agen with Water (Anti-- Freeze Agent : Water)50 : 50
Coolant Capacity10.5 L
Reservoir Capacity3.4 L
Cap Operating Pressure (Reservoir Tank Pressure Cap)1.4 bar
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-FtLb-In
Coolant Drain Plug3022--
Engine Hanger Bracket and Coolant Outlet
Port Bolt22.5 -- 27.516.6 -- 20.3--
Thermostat Cover Bracket Bolt9--11--80 -- 97
Oil Cooler Pipe Line Bolt9--11--80 -- 97
Cooling Fan Bolt9--11--80 -- 97
Viscous Clutch40.5 -- 49.529.8 -- 36.5--
Automatic Transmission Fluid Cooler Pipe2015--
Cooling Fan Shroud Bolts3--7--27 -- 62
Water Pump Pulley Retaining Bolts9--11--80 -- 97
Water Pump Housing BoltsM69--11--80 -- 97pg
M822.5 -- 27.516.6 -- 20.3--
Radiator Bracket Mounting Bolts3--7--27 -- 62

M161 ENGINE COOLING 1D2 -- 3
D AEW OO M Y_2000
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
124 589 15 21 00
Tester
111 589 02 01 00
Open End Wrench
603 589 00 40 00
Fan Clutch Holder
111 589 00 40 00
Open End Wrench

1D2 -- 4 M161 ENGINE COOLING
D AEW OO M Y_2000
DIAGNOSIS
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test Procedure
1. Loosen the cap a little and release pressure and re-
move the cap.
Notice:For the risk of scalding, cap must not be opened
unless the coolant temperature is below 90°C.
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the special tool to the reservoir filler cap and
apply 1.4 bar of pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at
the all coolant hoses and pipes and each connec-
tions. Replace or retighten if necessary.

M161 ENGINE COOLING 1D2 -- 5
D AEW OO M Y_2000
MAINTENANCE AND REPAIR
ON -- VEHICLE SERVICE
COOLANT DRAIN AND FILL UP
Draning & Filling up Procedure
1. Loosen the cap a little and release pressure and re-
move the cap.
Notice:For the risk of scalding, the cap must not be
opened unless the coolant temperature is below 90°C.
2. Loosen the radiator lower drain cock and drain the
coolant.
Notice:Collect the coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a
hose (dia. 14mm) onto the drain bolt on the side of
crankcase (exhaust manifold) and by loosening the
plug.
Notice
DJust loosen the drain plug to drain the coolant and do
not remove the plug completely.
DCollect the coolant by using the proper container.