torque SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE CONTROLS 1F3 -- 25
D AEW OO M Y_2000
Tools Required
001 589 65 09 00 Serration Wrench
Removal & Installation Procedure
1. Remove the plastic clip from the injection pipe
2. Remove the fuel return hose.
3. Disconnect the injection pipes from the injection
nozzles and push them to theside.
4. Remove the fuel injection nozzle.
Serration Wrench 001 589 65 09 00
Notice
Replace the washers.
5. Installation should follow the removal procedure in
the reverse order.
Notice
Pay attention to the installation position of new
nozzle washer and tightening torque.

OM600 ENGINE CONTROLS 1F3 -- 27
D AEW OO M Y_2000
Tools Required
001 589 65 09 00 Socket Wrench Insert
000 589 00 68 00 Cleaning Set
Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove
the nozzle tensioning nut (8).
Notice
Use protective jaws for clamping.
2. Disassemble the fuel injection nozzle.
Socket Wrench Insert 001 589 65 09 00
3. Clean the nozzle needle (6) and nozzle body (7) with
an abradant.
4. Clean the nozzle seat with cleaning cutter.
Cleaning Set 000 589 00 68 00
5. Immerse nozzle needle (6) and nozzle body (7) in
filtered diesel fuel. When the nozzle body is held
vertical, the weight of the nozzle needle must cause
it to slide down toward the nozzle needle seat.
6. Assemble the injection nozzle so that the tip of the
thrust (4) pin is facing toward the nozzle holder.
Tightening Torque80 N∙m (59 lb-ft)
Notice
Nozzle needle (6) and nozzle body (7) should al-
ways be replaced as a pair.

1F3 -- 30 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Tools Required
601589000800 Flange
601 589 05 21 00 Locking Screw
116 589 20 33 00 Sliding Hammer
116 589 02 34 00 Threaded Bolt
667 589 04 63 00 Retaining Plate
Removal & Installation Procedure
1. Remove the bolts (2) and then remove the cylinder
head cover (1) and gasket (3).
Installation Notice
Tightening Torque10 N∙m(89lb-in)
Notice
Replace the gasket.
Rotate the engine 1 revolution by hand and check
TDC marking of the crankshaft and camshaft.
2. Loosen the camshaft sprocket bolt (14).
Notice
Do not remove the bolt.
Installation Notice
Tightening Torque25N∙m (18 lb-ft) + 90_
Notice
If max. length of bolt exceeds 53.6mm, replace it.
3. Loosen the bolt (11) (left -- hand thread).
Notice
Do not remove the bolt.

OM600 ENGINE CONTROLS 1F3 -- 31
D AEW OO M Y_2000
4. Position the no.1 cylinder at ATDC 15_.
Notice
Do not rotate the engine with camshaft sprocket bolt
or opposite direction of the engine rotation.
5. Remove the plug (6) and seal (5) from the fuel injec-
tion pump and collect oil in a suitable vessel.
Installation Notice
Tightening Torque30 N∙m (22 lb-ft)
Notice
Replace the seal.
6. Install the locking screw (18) into the injection pump.
Notice
Before tightening the bolts for the injection timing
device and the camshaft sprocket, always remove
the locking screw from the injection pump and rein-
stall the plug.
Locking Screw 601 589 05 21 00
7. Place alignment marks (arrow) on the timing chain
(12) and camshaft sprocket (15).

1F3 -- 32 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
8. Remove the chain tensioner (17).
Installation Notice
Tightening Torque80 N∙m (59 lb-ft)
Notice
Replace the seal (16).
9. Pull out the 12-- sided stretch bolt (14) and washer
and remove thecamshaft sprocket (12).
10. Pull out the bolt (11) and washer (10).
Notice
Be careful that the bolt is left -- hand thread.
Installation Notice
Tightening Torque46 N∙m (34 lb-ft)
11. Using special tool (24, 25), remove the locking pin
(8).
Sliding Hammer 116 589 20 33 00
Threaded Bolt 116 589 02 34 00

1F3 -- 40 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Tools Required
617 589 09 21 00 Rl Sensor
617589102100 TimingTester
667589002100 TDCPulseGenerator
Commercial Tools
ItemTools
Digigal TesterWith Pulse GeneratorBosch, MOT 001.03gg
Hartmann & Braun, EOMT3
Without Pulse GeneratorBosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel -- Tester 875
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in
a suitable vessel.
2. Install the Rl sensor into the governor housing of in-
jection pump (1).
Rl Sensor 617 589 10 21 00
3. Connect the digital tester and TDC pulse sender unit
according to connection diagram.
4. Run the engine at idle speed and check the Rl value
on the digital tester
Rl valueAT DC 1 4_-- 1 6_
Notice
If out of standard, adjust the start of delivery.
5. Stop the engine.
6. Remove the Rl sensor, digital tester and TDC pulse
sender unit.
7. Replace the seal and tighten the plug.
8. Check engine oil level and adjust if necessary.
Tightening Torque30 N∙m (22 lb-ft)

1F3 -- 42 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Tools Required
617 589 08 21 00 Position Sensor
Adjustment Procedure
1. Position the No. 1 cylinder at ATDC 15_
Notice
Do not rotate the engine in opposite direction of en-
gine rotation.
2. Remove the bolt (2) at the supporting bracket.
3. Remove the bolt (4).
4. Turn the adjusting screw (1) until both lamps ’A’ + ’B’
on the position sensor light up.
To t h e r i g h tStart of delivery retarded
To t h e l e f tStart of delivery advanced
Notice
If the adjustment range is not adequate, remove the
injection pump and reinstall.
Position Sensor 617 589 08 21 00
5. After adjusting, retighten all the bolt to the specified
torque.

OM600 ENGINE CONTROLS 1F3 -- 49
D AEW OO M Y_2000
5. Coat the new seal (23) with engine oil and install it.
6. Insert the fuel injection pump (25) and tighten the
bolts (22).
Tightening Torque23 N∙m (17 lb-ft)
7. Remove the locking screw (32).
8. Tighten the bolt(12).
Tightening Torque23 N∙m (17 lb-ft)
9. Insert the washer (21) and tighten the bolts (20) and
then remove the assembly cage (29).
Tightening Torque46 N∙m (34 lb-ft)
10. Connect the fuel pipes.
Return Line46 N∙m (34 lb-ft)
Fuel Injection Line18 N∙m (13 lb-ft)
Fuel feed Line13 N∙m (10 lb-ft)
Suction and Pressure Line13 N∙m (10 lb-ft)
Notice
Replace the seal.
Box Wrench Insert 000 589 77 03 00

WHEEL ALIGNMENT 2B-7
SSANGYONG MY2002
VEHICLE HEIGHT
Adjustment Procedure
1. Check the tire for proper inflation.
2. Measure ‘A’ from the center of the lower arm
rear mounting bolt end to the ground.
KAA2B050
3. Measure ‘B’ from the center of the steering
knuckle shaft to the ground.
KAA2B060
4. If the difference between ‘A’ and ‘B’ is not
within specification, adjust vehicle height using
torsion bar height control bolt.
Adjustment Notice
Specification31 - 36 mm
(1.22 - 1.42 inch)B - A
Notice: Before wheel alignment, adjust vehicle
height adjustment first.
KAA2B070
FRONT TOE-IN ADJUSTMENT
Adjustment Procedure
1. Disconnect the outer tie rods from the knuckle as-
semblies. Refer to Section 6C, Power Steering
Gear.
2. Loosen the front toe adjusting nut.
Notice: In this adjustment, the right and the left tie
rods must be equal in length, or the tires will wear
unevenly.
3. Turn the right and the left outer tie rods to align the
toe to the proper specifications. Refer to “Wheel
Alignment Specifications” in this section.
KAA2B080
4. Hold the outer tie rod and tighten the front toe adjust-
ing nut.
Adjustment Notice
Tightening Torque 73 Nm (54 lb-ft)
5. Reconnect the outer tie rods to the knuckle assem-
blies. Refer to Section 6C, Power Steering Gear.

FRONT SUSPENSION 2C-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURES
BALL JOINT INSPECTION
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front
suspension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in-and-out motion.
4. Look for any horizontal movement of the knuckle
relative to the control arm.
5. Ball joints must be replaced under the following
conditions:
•The joint is loose.
The ball seal is cut.
The ball stud is disconnected from the knuckle.
The ball stud is loose at the knuckle.
The ball stud can be twisted in its socket with
finger pressure.
Ball Stud Inspection
Make sure to check the tightness of the ball stud in the
knuckle boss during each inspection of the ball joint.
One way to inspect the ball stud for wear is to shake
the wheel and feel for movement of the stud end at the
knuckle boss.
Another way to inspect the ball stud for wear is to check
the fastener torque at the pinch nut. A loose nut can
indicate a stressed stud orahole in theknuckle boss.
Worn of damaged ball joints and knuckles must be re-
placed.