head SSANGYONG KORANDO 1997 Service Repair Manual

1B3 -- 152 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
CYLINDER HEAD GUIDE RAIL
Preceding Work : Removal of the cooling fan
Removal of poly V-- belt
Removal of chain tensioner
1 Cylinder Head Cover
2 Bolt 10N∙m (89 lb-in) .....................
3 Gasket Replace..........................
4 Camshaft Sprocket
5 Washer
6 12-- Sided Bolt (M11)
Inspect, 25N∙m (18 lb-ft)+90_ ..............
7 Tensioning Lever
8 Bolt 23N∙m (17 lb-ft) ......................9 Bearing Pin Sealing Compound.............
10 Guide Rail
11 Bearing Pin
12 Guide Pulley
13 Socket Bolt 23N∙m (17 lb-ft) ................
14 Closing Cover
15 Spring
16 Timing Chain

OM600 ENGINE MECHANICAL 1B3 -- 153
D AEW OO M Y_2000
Tools Required
115 589 02 34 00 Sliding Hammer
116 589 20 33 00 Threaded Pin
Removal Procedure
1. Removal the cylinder head cover.
2. Pull off the tensioning lever (7) and remove from the
spring (15).
3. Pry off the closing cover (14) and remove the bolt
(13) and then remove the guide pulley (12).
4. Place alignment marks (arrow) on the timing chain
(16) and camshaft sprocket (4).
5. Remove the camshaft sprocket.

OM600 ENGINE MECHANICAL 1B3 -- 155
D AEW OO M Y_2000
In this position, the marking on the camshaft / cam-
shaft bearing cap (arrow) must also be aligned.
5. Install the guide pulley (12).
Tightening Torque23 N∙m (17 lb-ft)
6. Attach the tensioning lever (7) to the spring (15) and
install.
7. Replace the gasket and install the cylinder head
cover.
Tightening Torque10 N∙m(89lb-in)

1B3 -- 156 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
TIMING CASE COVER GUIDE RAIL
Preceding Work : Removal of cylinder head cover
1 Bearing Pin
2 Bearing Pin
3 Guide Rail
4 Oil Pump Chain5 Crankshaft
6Spring
7 Bushing
8 Tensioning Lever

OM600 ENGINE MECHANICAL 1B3 -- 163
D AEW OO M Y_2000
PISTON
Preceding Work : Removal of cylinder head
Removal of the oil pump
1 Oil Ring
2 2nd Ring
3 Top Ring
4 Snap Ring Replace........................
5 Piston Pin
6Piston
7 Connecting Rod Bushing Check............8 Connecting Rod
9 Connecting Rod Upper Bearing Shell
10 Connecting Rod Lower Bearing Shell
11 Connecting Rod Bearing Cap
12 Connecting Rod Bolt 35N∙m (26 lb-ft)+90_ ...
13 Crankcase
14 Cylinder Bore
Notice
There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replac-
ing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If
not, there would be a unbalancing of engine.

OM600 ENGINE MECHANICAL 1B3 -- 177
D AEW OO M Y_2000
UNIT REPAIR
CYLINDER HEAD PRESSURE LEAKAGE TEST
Preceding Work : Removal of the cylinder head
Removal of the exhaust manifold
Removal of the valve
1 Feed Pipe
2Bolt
3 Return Connection
4 Gasket Replace.................................
5 Coolant Gallery Sealing..........................
6 Pressure Measuring Plate Completely tight to the cylinder head.................
7 Cylinder Head...........................
Immerse with pressure measuring plate into warm water of approx. 60_C and pressurize with compressed
air of 2 bar.
Notice
If air bubbles are seen, replace the cylinder head.
Tools Required
115 589 34 63 00 Pressure Measuring Plate
601 589 00 25 00 Suspension Device

1B3 -- 178 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
FACING CYLINDER HEAD MATING SURFACE
Preceding Work : Removal of prechamber
Cylinder head pressure leakage test
1Valve
2 Cylinder Head
3 Prechamber
A Height of Cylinder HeadB Longitudinal Direction
C Transverse Direction
a Valve Arrears
b Prechamber Protrusion
Service Data
Height ’A’
(cylinder head surface -- cylinder head cover surface)142.9 -- 143.1 mm
Minimum height after machining142.5 mm
PermissibleunevennessofpartingsurfaceIn longitudinal direction0.08 mmPermissible unevenness of parting surfaceIn transverse direction0.0 mm
Permissible variation of parallelism (longitud. Direction)Max. 0.1 mm
Peak -- to-- valley height0.0017 mm
Vl’’Intake valve0.1 -- 0.7 mmValve arrears ’a’Exhaust valve0.1 -- 0.7 mm
Prechamber protrusion7.6 -- 8.1 mm

OM600 ENGINE MECHANICAL 1B3 -- 179
D AEW OO M Y_2000
Measurement Procedure
1. Measure height ’A’.
Limit142.5 mm
Notice
If the height is less than 142.5mm, replace the cylin-
der head.
2. Insert the valve (1) and measure valve arrears ’a’.
Valve Arrears ’a’0.1 -- 0.7 mm
Notice
If out of standard, machine the valve seat.
3. Install the prechamber and measure protrusion ’C’.
Protrusion ’C’7.6 -- 8.1mm
4. Assemble the engine and check the valve timing.

OM600 ENGINE MECHANICAL 1B3 -- 3
D AEW OO M Y_2000
Cylinder Head
ApplicationNSmLb-- FtLb-- In
Prechamber Threaded Ring13096--
Cylinder Head Cover Bolt10--89
Fuel Injsction Pipe Nut1813--
Socket Bolt2518--
Fuel Filter Pipe Bolt2518--
Idle Pulley Bolt2317--
Damper Bolt2115--
Camshaft Bearing Cap Bolt2518--
Camshaft Sprocket Bolt25 / 90_18 / 90_--
Exhaust Pipe Bolt& Nut2518--
Chain Tensioner8059--
Injection Nozzle4030--
Intake Manifold Not2518--
Injection Nozzle Pipe Not1813--
Oil Dipstick Tube Bolt10--89
Screw Plug M18 x 155037--
Cam Support & Shaft
ApplicationNSmLb-- FtLb-- In
Stud Bolt12--106
Exhaust Manifold Not2518--
CamShaft Bearing Cap Bolt2518--
12-- Sided Bolt (M11)25 / 90_18 / 90_--
Timing Cover
ApplicationNSmLb-- FtLb-- In
Oil Pan Bolt -- Socket Bolt10--89
Oil Pan Bolt--M610--89
Oil Pan Bolt--M232317--
Belt Pulley Bolt3224--
Guide Pulley Bolt4--35
Guide Pulley Bracket Nut2317--
Chain Tensioner8059--
Tesioning Lever Bolt2317--

OM600 ENGINE CONTROLS 1F3 -- 29
D AEW OO M Y_2000
REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE
Preceding Work : Removal of vacuum pump
1 Cylinder Head Cover
2 Bolt 10N∙m (89 lb-in) .....................
3 Gasket Replace..........................
4 Fuel Injection Pump
5 Seal Replace.............................
6 Screw Plug 30N∙m (22 lb-ft) ................
7OilPan
8 Locking Pin
9 Injection Timing Device10 Washer
11 Bolt (Left -- Hand Thread) 46N∙m (34 lb-ft) ....
12 Camshaft Sprocket
13 Washer
14 12-- Sided Stretch Bolt
Check, 25N∙m (18 lb-ft) +90_ ..............
15 Timing Chain
16 Seal
17 Chain Tensioner 80N∙m (59 lb-ft) ............