1997 SSANGYONG KORANDO service

M162 ENGINE MECHANICAL 1B1 -- 47
D AEW OO M Y_2000
FLYWHEEL / DRIVEN PLATE
Preceding Work: Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces)
1st step 45+5 NSm (33+3.7 lb-ft) ...........
2nd step +90°+10°
2Plate3 Driven Plate (A/T)
4 Dowel Pin
Service Data Standard (Stretch Bolt)
Nominal SizeD--Mx1.5
Stretch Side DiameterdWhen New8.5 -- 0.2 mm
Min. Diameter8.0 mm
Bolt LengthLWhen New21.8 -- 22.2 mm
Tightening Torque1ststep45+5NSm (33 + 3.7 lb-ft), 2nd step 90°+10°

M162 ENGINE MECHANICAL 1B1 -- 83
D AEW OO M Y_2000
CONNECTING ROD
Preceding Work: Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bearing Cap Bolt
(M9 x 52, 12 m pieces)
1ststep40NSm (30 lb-ft) ..................
2nd step 90°5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 Bearing Shell Lug
9 Marking [Indication(//) or Numbers]
ServiceDataStandard
Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing
Bore Center145±0.05 mm
Width of The Connecting Rod (B) at Bearing Bore21.940 -- 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore21.940 -- 22.000 mm
Basic Bore at The Bearing Shell (D1)51.600 -- 51.614 mm
Basic Bore at The Bushing (d1)24.500 -- 24.521 mm
Bushing Inner Diameter (d)22.007 -- 22.013 mm
Clearance Between The Piston Pin and The Bushing0.007 -- 0.018 mm
Peak -- to-- valley Height of Connecting Rod Bushing on Inside0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing
Bore0.15 mm
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to
Connecting Rod Bushing Core0.07 mm
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity0.01 mm
Permissible Difference of Each Connecting Rod in Weight0.4 g

M162 ENGINE MECHANICAL 1B1 -- 107
D AEW OO M Y_2000
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 Angle60°
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

1B1 -- 108 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKCASE MATING SURFACE
ServiceDataStandard
Height of The Crankcase ‘H’ (When new)282.25 -- 282.35mm
Minimum Height After Milling281.95mm
FlatnessCrankcase Upper Mating Surface0.03mm
Crankcase Lower Mating Surface0.04mm
Permissible Deviation of Parallelism of The
UtLMtiSf
Axial Direction0.1mm
Upper to Lower Mating SurfaceTransverse Direction0.05mm
Peak -- to-- valley HeightCrankcase Upper Mating Surface0.005 -- 0.020mmyg
Crankcase Lower Mating Surface0.025mm

1B1 -- 110 M162 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.

D AEW OO M Y_2000
SECTION 1D1
M162 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 1D1 -- 2............................
General Specifications 1D1-- 2....................
Fastener Tightening Specifications 1D1 -- 2..........
Special Tools 1D1 -- 3.............................
Special Tools Table 1D1-- 3.......................
Diagnosis 1D1 -- 4.................................
System Leakage Test 1D1-- 4.....................
Maintenance and Repair 1D1 -- 5...................
On-- Vehicle Service 1D1-- 5.........................Coolant Drain and Fill Up 1D1 -- 5..................
Coolant Connection Fitting 1D1 -- 7.................
Wat er Pum p 1D1 -- 8.............................
Thermostat 1D1 -- 10.............................
Oil Cooler Pipe Line 1D1 -- 11.....................
Cooling Fan and Viscous Clutch 1D1 -- 12...........
Cooling Fan Shroud 1D1 -- 14.....................
Radiator 1D1-- 15................................

M162 ENGINE COOLING 1D1 -- 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.
4. After complete draining of the coolant, remove the
hose connector to drain plug and reinstall the drain
plug.
Installation Notice
Tightening Torque
30 NSm (22 lb-ft)
5. Tighten the radiator lower drain cock.

D AEW OO M Y_2000
SECTION 1E1
M162 ENGINE ELECTRICAL
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 1E1 -- 2............................
Generator Specifications 1E1-- 2..................
Starting Motor Specifications 1E1-- 2...............
Battery Specifications 1E1-- 2.....................
Fastener Tightening Specifications 1E1 -- 2..........
Maintenance and Repair 1E1 -- 3...................
On-- Vehicle Service 1E1-- 3.........................Generator 1E1-- 3...............................
Starting Motor 1E1--4...........................
Battery 1E1--5.................................
Spark Plug 1E1 -- 6..............................
Ignition Cable 1E1-- 8............................
Unit Repair 1E1 -- 11..............................
Battery 1E1--11.................................