engine SSANGYONG KORANDO 1997 Service Manual PDF

1B1 -- 48 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal & Installation Procedure
1. Unscrew the flywheel mounting bolt.
Installation Notice
Ti
ghteningTo rque
1st step: 45 + 5 NSm
(33+3.7lb-ft)
TighteningTorque
2nd step: 90°+10°
DReplace the bolt when the stretch side diameter (d)
of the flywheel mounting bolt is less than 8.0mm.
DFor the flywheel mounting bolt tightening, keep the
socket wrench and Tommy -- bar to be 90°and tight-
en as specified.
2. Remove the flywheel for manual transmission ve-
hicles, or the driven plate (3), and plate (2) for Auto.
transmission vehicle.
3. Installation should follow the removal procedure in
the reverse order.

M162 ENGINE MECHANICAL 1B1 -- 49
D AEW OO M Y_2000
Sectional View
1OilPan
2 Cover
3 Crankshaft Front Seal
4 Flywheel MTG Bolt
5 Crankshaft
6 Dowel Pin
7Plate8TGCC
9Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

1B1 -- 50 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CAMSHAFT ADJUSTER
Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover
1 Bolt (M6 x 16, 3 pieces)
9--11 NSm (80-- 97 lb-in) .....................
2 Magnet Assembly (2 Pin Connector)
3Bolt 35NSm (26 lb-ft) ......................
4 Armature
5RollPin
6 Nut (M20 x 1.5) 60-- 70 NSm (44-- 52 lb-ft) ......
7 Front Cover
8 Seal
9 Camshaft Position Sensor
10 Bolt (M6 x 16, 2 pieces)
9--11 NSm (80-- 97 lb-in) .....................
11 Seal12 Seal Cover
13 Camshaft Sprocket and Position Indicator (b)
14 Adjuster Piston
15 Flange bolt (M7 x 13, 3 pieces)
1ststep18--22NSm (13-- 16 lb-ft) ...........
2ndstep60°±5°
16 Flange Shaft
17 Compression Spring
18 Control Piston
19 Circlip
20 Oil Gallery
21 Pin
22 Intake Camshaft

M162 ENGINE MECHANICAL 1B1 -- 51
D AEW OO M Y_2000
Removal & Installation Procedure
1. Turn the crankshaft to the direction of engine rotation
and position the no.1 cylinder piston at TDC which the
camshaft is positioned at OT.
2. Remove the cylinder head front cover.
3. Paint the alignment marks (arrows) on the intake and
exhaust camshaft sprocket and the timing chain.
3 Bolt 13 Camshaft Sprocket
4 Amarture 18 Control Piston
6 Nut (M20 x 1.5) 22 Intake Camshaft
12 Seal Cover
4. Unscrew the bolt (3) from the armature (4) and re-
move the armature.
Installation Notice
Tightening Torque
35 NSm (26 lb-ft)
5. Unscrew the nut (6) and remove the ring and seal
cover (11).
Installation Notice
Tightening Torque
60 -- 70 NSm (44 -- 52 lb-ft)
6. Unscrew the sprocket bolt from the exhaust camshaft
and remove the sprocket.
Installation Notice
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
The sprocket bolt is designed to be used only once,
so always replace with new one.

1B1 -- 52 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
7. Remove the camshaft sprocket (13) and adjust piston
(14), and remove the flange shaft (16) from the intake
camshaft (22) after removing the bolt (15).
Installation Notice
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
The sprocket bolt is designed to be used only once,
so always replace with new one.
8. Installation should follow the removal procedure in
the reverse order.
9. Adjust the camshaft timing.
CAMSHAFT SPROCKET BOLT
Intake Flange Shaft Bolt
TighteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
Notice:The sprocket bolts are designed to be used only
once, so always replace with new one.
C. M7 x 13 Collar Bolt Torx -- T30
e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft

M162 ENGINE MECHANICAL 1B1 -- 53
D AEW OO M Y_2000
Exhaust Camshaft Sprocket Bolt
TighteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
Notice:The sprocket bolts are designed to be used only
once, so always replace with new one.
E. M7 x 13 Collar Bolt Torx -- T30
e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft

M162 ENGINE MECHANICAL 1B1 -- 59
D AEW OO M Y_2000
CAMSHAFT TIMING POSITION
Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover
1 Chain Tensioner Assembly
2 Exhaust Camshaft Sprocket
3 Upper Guide Rail4 Cylinder Head Front Cover
5 Wrench
6 Holding Pin DW110-- 120

1B1 -- 60 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
DW110 -- 120 Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turn-
ing the crankshaft.
Notice:When the OT mark on vibration damper is
aligned with timing gear case cover, the intake and ex-
haust cam of cylinderwill make the slope to the center
and will face up. In this way, the adjustment hole of the
intake and exhaust camshaftwill match in line with the
cylinder head upper end, at 3 o’clock, and 9 o’clock di-
rection each other.
2. Check the timing as below procedure;
-- Check if the camshaft adjustment hole is posi-
tioned to 3 o’clock direction at the intake side and
to 9 o’clock direction at the exhaust side, respec-
tively and align with the cylinder head mating sur-
face.
-- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear
case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30°.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole
with the cylinder head upper surface.
DIntake Side : 3 o’clock direction
DExhaust Side : 9 o’clock direction
5. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin
DW110-- 120 into the holes.
6. Secure the intake and exhaust camshaft.
7. Position the piston of No.1 cylinder at TDC (OT) by
turning the crankshaft.
8. Turn the camshaft adjuster of the intake camshaft to
the left as much as possible (cam adjuster ‘retarded’
position).
9. Install the chain to the intake camshaft sprocket.
Notice:Timing chain must be placed on the guide rail in
gear case cover.

M162 ENGINE MECHANICAL 1B1 -- 61
D AEW OO M Y_2000
10. Install the chain to the exhaust camshaft sprocket
and install it to the camshaft.
Installation Notice (Sprocket Bolt)
Ti
ghteningTo rque
1st step: 18 -- 22 NSm
(13 -- 16 lb-ft)
TighteningTorque
2nd step: 60°±5°
The sprocket bolt is designed to be used only once,
so replace with new one.
11. Install the chain tensioner.
Installation Notice
Ti
ghteningScrew Plug40 NSm
(30 lb-ft)
Tightening
TorqueTensioner
Assembly72 -- 88 NSm
(53 -- 65 lb-ft)
12. Check the camshaft timing.

1B1 -- 62 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
VALVE SPRING
Preceding Work: Removal of camshaft
Removal of spark plug
1 Valve Cotter
2 Valve Spring Retainer
3 Valve Spring
4 Valve Stem Seal
5 Lower Retainera Lever Pusher 111 589 18 61 00
b Thrust Piece 111 589 25 63 00
c Connecting Hose DW110-- 090
d Supporting Bar 111 589 01 59 00