1997 SSANGYONG KORANDO engine

M161 ENGINE MECHANICAL 1B2 -- 85
D AEW OO M Y_2000
1. Check the piston ring gap and apply the engine oil to
the piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by press-
ing in the piston pin (6) and install the snap ring to the
groove.
3. Clean the cylinder bore, connecting rod bearing jour-
nal, connecting rod bearing shell and the piston and
coat them with engine oil.
4. Install the piston ring.
5. Install the piston so that the arrow on the piston head
faces to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap
mark (// or a number), tighten the bolts.
Installation Notice
TighteningTorque1st step: 40 NSm (30 lb-ft)TighteningTorque2nd step: 90°
Apply the engine oil to the bearing cap upper and low-
er bearing shells.
7. Check if the crankshaft rotates without any trouble by
rotating it.

1B2 -- 86 M161 ENGINE MECHANICAL
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, 8 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 to Bushing Bore CenterE20 : 154 mm
E23 : 149±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
Bore0.1/100 mm
Permissible Deviation of Axial Paralleism of Connecting Rod
Bearing Bore to Connecting Rod Bushing Bore0.045/100 mm
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from
Concentricity0.01 mm
Permissible Difference of Each Connecting Rod in Weight0.4 g

M161 ENGINE MECHANICAL 1B2 -- 87
D AEW OO M Y_2000
Inspection
1. Measure the basic bore of the connecting rod bear-
ing.
Notice:If the basic bore exceeds the value of
51.614mm, replace the bearing or check the connecting
rod.
2. Check connecting rod bolts.
Length When New (L)
51.7 -- 52 mm
Max. Length (L)52.9 mm
TighteningTo rque
1st step: 40 NSm
(30 lb-ft)
TighteningTorque
2nd step: 90°
Notice:If the length exceeds max. length, replace it.
3. Check the assembly mark (indication//or number:ar-
row) of the connecting rods and the bearing cap when
installing.
Notice
DMake sure it doesn’t exceed over 4g with other con-
necting rods when replacing the connecting rods.
DCheck if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.

1B2 -- 88 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
PISTON RING
Preceding Work: Removal of piston
1 Piston Compression Ring (Top Ring)
2 Piston Compression Ring (2nd Ring)
3 Piston Oil Ring4--
5 Spacer
6SideRail

M161 ENGINE MECHANICAL 1B2 -- 89
D AEW OO M Y_2000
Replacement Procedure
1. Measure the piston ring’s gap.
EdGfTh
Groove 1 0.20 -- 0.40 mm
End Gap of The
PistonRingGroove 2 0.20 -- 0.40 mmPistonRing
Groove 3 0.20 -- 0.45 mm
GapBetweenGroove 1 0.028 -- 0.060 mmGapBetween
ThePistonand
ThPitRi
Groove 2 0.010 -- 0.045 mm
The Piston RingGroove 3 0.010 -- 0.045 mm
Notice:If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
3. For installation, position the piston ring to be the
‘TOP’ mark on the piston ring upward and arrange the
piston ring ends to be 120°apart.
4. Adjust the hook spring joint in the oil ring 180°away
from the ring end.

1B2 -- 90 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
OIL PAN
1Bolt
2Bolt
3Bolt
4Bolt5Bolt
6OilPan
7 Gasket
Removal & Installation Procedure
1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket.
Notice:Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then
apply the sealant.
4. Replace the gasket with new one.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine.

M161 ENGINE MECHANICAL 1B2 -- 91
D AEW OO M Y_2000
Oil Circulation
1 Oil Strainer
2OilPump
3OilPan
4 Oil Non-- Return Valve
5 Oil Filter
6 Oil Filter Bypass Valve
7 Main Oil Gallery
8 Closing Ball (φ15mm)
9 Crankshaft
10 Connecting Rod Bearing
11 Crankshaft Bearing
12 Connecting Rod
13 Piston
14 Oil Spray (Piston Crown Area)
15 Non-- Return Valve (Crankcase)16 Oil Supply (To Chain Tensioner)
17 Camshaft
18 Cam Bearing
19 Valve
20 Oil Gallery (Supply Oil to Intake Tappet)
21 Oil Gallery (Supply Oil to Exhaust Tappet)
22 Ball (φ8mm)
23 Camshaft Plug
24 Seal
25 Screw Plug
26 Oil Return Gallery
(Cylinder Head and Crankcase)
27 Oil Return Gallery (Crankcase)
28 End Cover (φ20mm)
29 Oil Return Pipe

M161 ENGINE MECHANICAL 1B2 -- 97
D AEW OO M Y_2000
OIL PRESSURE RELIEF VALVE
Preceding Work: Removal of oil pan
1 Screw Plug 50 NSm (37 lb-ft) ................
2 Compression Spring3 Guide Pin
4Piston
Removal & Installation Procedure
1. Remove the screw plug (1).
Installation Notice
Tightening Torque
50 NSm (37 lb-ft)
2. Remove the spring (2), guide pin (3) and the piston
(4).
3. Installation should follow the removal procedure in
the reverse order.
Notice:Don’t use the seal for the screw plug.