head SSANGYONG KORANDO 1997 Service Service Manual

M161 ENGINE MECHANICAL 1B2 -- 27
D AEW OO M Y_2000
Removal & Installation Procedure
1. Remove the intake air duct.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
2. Remove the spark plug cover.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
Notice:Release 3 screws from the spark plug cover and
remove the cover for M161 Engine coil.
3. Remove the spark plug connector and ignition cable.
4. Unscrew the bolts (3) and remove the head cover and
the gasket.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
Notice:Replace the gasket with a new one if necessary.
5. Installation should follow the removal procedure in
the reverse order.
6. Check for oil leaks by operating the engine.

1B2 -- 28 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD FRONT COVER
Preceding Work: Removal of cylinder head cover
Removal of thermostat housing assembly
Removal of engine hanger bracket
1 Bolt (M6 X 16, 3 pieces)
9--11 NSm (80-- 97 lb-in) .....................
2 Camshaft Adjuster
3 Bolt (M8 X 35, 2 pieces)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............
4 Bolt (M6 X 22, 6 pieces)
9--11 NSm (80-- 97 lb-in) .....................5 Front Cover (E23 : M161.973)
6 Front Cover (E20 : M161.943)
7 Sleeve
8 O -- ring Replace............................
9 Thermostat Housing

M161 ENGINE MECHANICAL 1B2 -- 29
D AEW OO M Y_2000
Removal & Installation Procedure
1. Disconnect the camshaft adjuster connector and re-
move the camshaft adjuster (E23 engine only).
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
2. Remove the cylinder head front cover.
Installation Notice
Tightening
Torque (3)
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
Tightening
Torque (4)9--11NSm
(80 -- 97 lb-in)
Apply the sealant at the mating surface of the cylinder
head and the front cover.
3. Remove the O -- ring.
Installation Notice
Replace the O -- ring with new one and apply the seal-
ant.
4. Installation should follow the removal procedure in
the reverse order.

1B2 -- 30 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD
Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover
Removal of intake manifold
Removal of cylinder head lower line (intake manifold side)
1 Cylinder Head Bolt (M12 X 100, 10 pieces)
1ststep55NSm (41 lb-ft) ...................
2nd step 90°rotation added
3rdstep90°rotation added
3 Bolt (M8 X 35, 4 pieces)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............4 Camshaft Bearing cap
5 Cylinder Head
6 Gasket Replace...........................
7 Dowel Sleeve Note........................

M161 ENGINE MECHANICAL 1B2 -- 33
D AEW OO M Y_2000
10. Remove the cylinder head bolts in the reverse order
of the numerics (No.10→No.1) using allen wrench
socket617589001000.
Installation Notice
Tighten the bolts as numerical order with specified
torque (No.1→No.10).
1st step: 55 NSm (41 lb-ft)
Tightening Torque2nd step: + 90°ggq
3rd step: + 90°
Notice:Operate during engine cooling.
11. Remove the No. 1 bearing cap of the exhaust cam-
shaft.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
12. Carefully remove the cylinder head.
13. Check the cylinder head mating surface and clean
the crankcase head bolt mounting hole.
14. Replace the cylinder head gasket with new one.
15. Check the length of the cylinder head bolt.
Installation Notice
Length(L)When New 100 mmLength(L)Max. Length 105 mm
Notice:Replace the bolt if the measured length exceed
the max. length.
16. Installation should follow the removal procedure in
the reverse order.

1B2 -- 34 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
TIMING GEAR CASE COVER
Preceding Work: Removal of viscous clutch
Removal of cylinder head front cover
Removal of tensioning device
Removal of water pump
Removal of oil filter element
Removal of oil pan
Removal of generator bracket
1 Bolt (M8 X 60, 3 pieces)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............
2 Bolt (M8 X 75, 1 piece)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............3Seal
4 Timing gear case cover
5O--ring
6 Sleeve

1B2 -- 36 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
8. Unscrew the bolts (A).
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
9. Remove the belt pulley and vibration damper.
Installation Notice (Center Bolt)
Ti
ghteningTo rque
1st step: 200 + 20NSm
(148 + 15 lb-ft)
TighteningTorque
2nd step: 90°+10°
10. Unscrew the bolts (1, 2) on timing gear case cover
and remove the timing gear case cover.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
Notice:Be careful not to damage the cylinder head gas-
ket.
11. Remove the radial shaft seal.
Notice:Installation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase
sealing surface.
13. Replace the O -- ring with new one and apply the
sealant on the sealing surface.
Notice:Be careful not to stain the oil chamber of chain
tensioner with the sealant.
14. Installation should follow the removal precedure in
the reverse order.
15. Warm up the engine and check for oil leaks.

M161 ENGINE MECHANICAL 1B2 -- 45
D AEW OO M Y_2000
CRANKSHAFT
Preceding Work: Removal of engine
Removal of cylinder head
Removal of timing gear case cover
Removal of crankcase sealing rear cover
Removal of oil pan
Removal of baffle plate
Removal of oil pump
1 Bearing Cap Bolt (M8 X 55 -- 10 pieces)
1ststep55NSm (41 lb-ft) .................
2nd step 90°rotation added
2 Bearing Cap
3 Upper Main Bearing4 Lower Main Bearing
5 Upper Thrust Bearing
6 Lower Thrust Bearing
8 Crankshaft

1B2 -- 54 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CAMSHAFT ADJUSTER
1 Bolt (M6 X 16, 3 pieces)
9--11 NSm (80-- 97 lb-in) ....................
2 Cylinder Head Front Cover
3Bolt 35NSm (26 lb-ft) ......................
4 Armature
5RollPin
6 Nut (M20 X 1.5) 60-- 70 NSm (44-- 52 lb-ft) .....
7 Seal Cover
8 Camshaft Sprocket
9 Adjust Piston
10 Conical Spring11 Flange Bolt (M7 X 13, 3 pieces)
1stStep18--22NSm (13--16 lb-ft) ...........
2nd Step 60°±5°Rotation Added
12 Flange Shaft
13 Compression Spring
14 Control Piston
15 Circlip
16 Oil Gallery
17 Straight Pin
18 Intake Camshaft
Y49 Magnetic Actuator (2-- pin connector)

M161 ENGINE MECHANICAL 1B2 -- 55
D AEW OO M Y_2000
Removal & Installation Procedure
1. Turn the crankshaft and position the no.1 cylinder pis-
ton at ATDC 20°.
Notice:Turn the crankshaft in the direction of engine
rotation.
2. Remove the cylinder head front cover.
3. Put the alignment marks (arrows) on the camshaft
sprocket and the timing chain.
4. Insert the holding pin 111 589 03 15 00 into the no.1
and no.6 bearing cap hole on camshaft to secure in-
take and exhaust camshaft.
5. Remove the chain tensioner.
6. Unscrew the exhaust sprocket bolt and remove the
exhaust camshaft sprocket.
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.