head SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 119
D AEW OO M Y_2000
4. Reaming basic bore in cylinder head (repair size).
-- Thoroughly remove carbon deposits in cylinder
head.
Notice
Particularly remove the insides of the valve seat
rings.
-- Remove the elevation (arrow) of intake valve seat
rings.
-- Select correct broaching tool and guide sleeve
(refer to the table).
Notice
Before broaching work, the broaching tool must be
cleared of swarf with a stiff plastic brush.
-- Lubricate the basic bore, guide sleeve and
broaching tool with petroleum.
-- Push broaching tool (6) in broaching direction (ar-
row) into the guide sleeve (7) far enough so that
the first cut of the broaching tool is positioned in
the basic bore when guide sleeve is fitted onto
the valve seat ring (3).
6. Broaching tool
7. Guide sleeve
See the ’standard data’
-- Center the guide sleeve (7) in the valve seat ring
(3) by turning.
-- Knock through the broaching tool (6) with a plas-
tic hammer (approx. 25g). and aluminum drift.

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5. Heat the cylinder head (1) in a wear tank to approx.
80_C.
6. Cool down the new valve guide (2) with liquid nitro-
gen.
Notice
Do not touch the cooled valve guide by hand.
Super Cooling box 346 589 00 63 00
7. Drive in new valve guide with drift (8) until the wire
ring makes contact.
Notice
Thevalveguidemustbedriveninfromthecylinder
head cover.
Drift (for Intake) 601 589 05 15 00
Drift (for Exhaust) 601 589 06 15 00
8. Check the valve guide bore with GO / NO GO gauge
(9).
The GO side (marked ’0’) should just still drop. If the
GO side cannot be inserted, the bore of valve guide
should be reamed.
Notice
Perform the check only on cooled down cylinder
head.
GO / NO GO Gauge (for Intake) 102 589 00 23 00
GO / NO GO Gauge (for Exhaust) 117 589 03 23 00

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VALVE SEAT RINGS
Preceding Work : Removal of valve
Checking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head
2 Valve Seat Ring
3 Valve Guide
A Height (Cylinder Head Upper / Lower Surface)
B Height (cylinder Head Cover Surface -- Seat of
Valve Seat Ring)D Valve Seat Ring Outer Diameter
D1 Valve Seat Ring Inner Diameter
D2 Basic Bore Diameter
H Height of Valve Seat Ring
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Exhaust
D240.000 -- 40.016 mm37.000 -- 37.016 mm
D40.084 -- 40.100 mm37.084 -- 37.100 mm
D133.400 -- 33.600 mm30.400 -- 30.600 mm
H6.955 -- 7.045 mm6.955 -- 7.045 mm
Overlap U=D-- D20.068 -- 0.100 mm0.068 -- 0.100 mm
B133.4 mm133.4 mm
A142.5 mm142.5 mm

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Commercial Tools
Cylinder Head Clamping DeviceHunger
D-- 8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning ToolHunger
D-- 8000 München 70
Ty p e VDS 1 A
Order No. 236 03 308
Ring Seat Turning ToolHunger
D-- 8000 München 70
Type RDS 1
Order No. 219 00 100
Pneumatic Removal / Installation Device
(Drift : 8mm, 9mm, 14mm)Hunger
D-- 8000 München 70
Type PVM 1
Tensioning HeadHunger
D-- 8000 München 70
Order No. 250 15 250
Cutting Tool for Recessing GroovesHunger
D-- 8000 München 70
Order No. 217 93 601
Test Set for ValvesHunger
D-- 8000 München 70
Order No. 216 69 210
Internal Dial Gauge (Range : 25 -- 60mm)Mahr
D-- 7300 Esslingen
Order No. 844
External Micrometer (Range : 25 -- 60mm)Mahr
D-- 7300 Esslingen
Order No. 40 S
Electrically Heated Water TankOtto Dürr
D-- 7123 Sachsenherm -- Ochsenbach

1B3 -- 124 OM600 ENGINE MECHANICAL
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Removal Procedure
1. Measure dimension ’A’.
Limit142.5 mm
2. Clamp the cylinder head with clamping device.
3. Cut groove into the valve seat ring so that dimension
’C’ is approx. 2mm and dimension ’E’ is approx.
6mm.
4. Remove the cylinder head from the clamping device
and place it onto wooden blocks.
5. Remove the valve guide (3).
Drift (Intake) 8mm
Drift (Exhaust) 9mm
6. Insert the tensioning head (4) and extracted wedges
(arrow) by turning the bolt (5).
Notice
Carefully tighten the bolt (5) otherwise the valve
seat ring in the cylinder headwill be excessively ten-
sioned.
7. Lock the bolt (5) with nut (6).

OM600 ENGINE MECHANICAL 1B3 -- 125
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8. Turn over the cylinder head.
9. Remove the tensioning head (4) and valve seat ring
(2) with drift (14mm) and removal tool.
10. Clean the basic bore of valve seat ring.
11. Measure the basic bore diameter (D2) and outer di-
ameter (D) of the new valve seat ring (standard
size).
12. Calculate the overlap value ’U’ (D -- D2).
Overlap Value ’U’0.068 -- 0.100 mm
Example) Measured value D = 37.100mm
Measured value D2 = 37.010mm
——————————————
Overlap value ’U’ = 0.090mm
If overlap value ’U’ is out of standard, machine the
basic bore for the valve seat ring.
13. Clamp the cylinder head with clamping device.
14. Machining basic bore for valve seat ring (repair
size).
Notice
Maintain minimum value of ’B’.
-- Machine the basic bore.
Limit
MaxD2Intake40.516 mmMax.D2Exhaust37.516 mm
Min.B133.4 mm
-- Measure machined basic bore and outer diame-
ter ’D’ of valve seat ring (repair size).
-- Measure the overlap ’U’.
Overlap ’U’ (D-- D2)0.068 -- 0.100 mm
Example) Measured value D = 37.600mm
Measured value D2 = 37.480mm
——————————————
Overlap value ’U’ = 0.120mm
The basic diameter D2 must be machined by
0.020mm in order to get the required overlap value.

1B3 -- 126 OM600 ENGINE MECHANICAL
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15. Hang the cylinder head (1) to the lifting device and
heat in a water tank to approx. 80_C.
16. Cool down new valve seat ring (2) into the cooling
box with liquidnitrogen.
Notice
Do not touch the cooled valve seat rings with hand.
Super Cooling Box 345 589 00 63 00
17. Drive in new valve seat ring (2) with a proper wood-
en drift.
18. Install the valve guide (3) with a proper drift and as-
sembling tool.
Notice
Thevalveguidemustbedriveninfromthecylinder
head cover.
Drift (Intake) 8mm
Drift (Exhaust) 9mm
19. Machine the valve seats.

OM600 ENGINE MECHANICAL 1B3 -- 127
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CHECK AND MACHINING OF VALVES
Preceding Work : Removal of cylinder head
Removal of the vale spring
Removal of the valve
I Valve Length
W Camshaft Cam Basic Diameter
X Distance (Camshaft Basic Bore -- Valve Stem)Y Half Camshaft Basic Bore Diameter
Z Distance (Cylinder Head Cover Parting Surface
-- V a l v e S t e m )

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5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve
guide.
7. Insert the valves (1) into the valve guides according
to marking.
8. Measure amount by which the valve arrears ’a’.
Arrears ’a’0.1 -- 0.7 mm
Notice
If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
Diameter ’w’38±0.2 mm
or 37.6±0.2 mm
10. Measure distance ’z’ (cylinder head cover parting
surface -- valve stem).

1B3 -- 132 OM600 ENGINE MECHANICAL
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MACHINING OF VALVE SEAT
Preceding Work : Removal of prechamber
Removal and inspection of valve, replace if necessary
Inspection of valve guide, replace if necessary
1Valve
2 Valve Seat Ring
3 Cylinder Head
4 Valve Guidea Valve Seat Angle
b Valve Seat Free Angle