1997 SSANGYONG KORANDO head

1B2 -- 78 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD GUIDE RAIL
Preceding Work: Removal of cylinder head front cover
1 Bolt (M6 X 45, 2 pieces)
9--11 NSm (80-- 97 lb-in) .....................2 Guide Rail

M161 ENGINE MECHANICAL 1B2 -- 83
D AEW OO M Y_2000
PISTON
Preceding Work: Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bolt (M9 x 52, 8 pieces)
1ststep40NSm (30 lb-ft) ..................
2nd step 90°4Piston
5 Snap Ring
6 Piston Pin

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.

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

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

1F2 -- 20 M161 ENGINE CONTROLS
D AEW OO M Y_2000
IGNITION COIL
YAA1F920
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover. The double ended coils receive
the signal for the Engine Control Module (ECM) which controls the spark advance.
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously;
T1/1: cylinder 1 and 4
T1/2: cylinder 2 and 3
The EI system ignition coil is not serviceable and must be replaced as an assembly.

1F2 -- 100 M161 ENGINE CONTROLS
D AEW OO M Y_2000
YAA1F770
Notice:Before removal, the fuel rail assembly may be
cleaned with a spray-type cleaner, following package in-
structions. Do not immerse the fuel rails in liquid clean-
ing solvent. Use care in removing the fuel rail assembly
to prevent damage to the electrical connectors and in-
jector spray tips. Prevent dirt and other contaminants
from entering open lines and passages. Fittings should
be capped and holes plugged during service.
Important:If an injector becomes separated from the
rail and remains in the cylinder head, replace the injector
O-ring seals and the retaining clip.
12. Remove the injectors and the fuel rail carefully.
13. Remove the fuel injector retainer clips.
14. Remove the fuel injectors by pulling them down and
out.
15. Discard the fuel injector O-rings.
16. Lubricate the new fuel injector O-rings with engine
oil. Install the new O-rings on the fuel injectors.
17. Perform a leak check of the fuel rail and fuel injec-
tors.
18. Installation should follow the removal procedure in
the reverse order.
YAA1F780
ENGINE COOLANT TEMPERATURE
SENSOR
Removal and Installation Procedure
1. Relieve the coolant system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the engine coolant temperature sensor
connector.
Notice:Take care when handling the engine coolant
temperature sensor. Damage to the sensor will affect
the proper operation of the fuel injection system.
4. Remove the engine coolant temperature sensor
from the pump hosing.
Installation Notice
Tightening Torque
30 NSm (22 Ib-ft)
5. Installation should follow the removal procedure in
the reverse order.