check engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 161
D AEW OO M Y_2000
Installation Procedure
1. Put the same alignment mark on the new crankshaft
sprocket as in the old sprocket.
Notice
Check the timing chain, camshaft sprocket, injection
pump timing sprocket, oil pump chain and oil pump
sprocket for wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a
drift (21).
Notice
Align the groove of sprocket and woodruff key (ar-
row) exactly.
Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket
(12).
Notice
Align the alignment marks (arrow) on the chain and
sprocket.
4. Install the camshaft sprocket (3).
Tightening Torque25 N∙m (18 lb-ft) + 90_
Notice
Pay attention on the alignment marks and dowel pin
(arrow).

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.

1B3 -- 166 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Installation Procedure
1. Fit the piston onto the connecting rod so that the ar-
row (15) and the locking slot (16) are facing in direc-
tion of the vehicle.
2. Coat the piston pin (15) with engine oil and insert it
by hand.
Notice
Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (ar-
row).
4. Check the piston rings (1, 2, 3) and replace them if
necessary.
5. Install and arrange the piston rings to be evenly
120_from each ends gap.

1B3 -- 168 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
12. Coat the bolts (12) with oil and then tighten the bolts.
Tightening Torque40 N∙m (30 lb-ft) + 90_
13. Rotate the crankshaft and check axial clearance be-
tween the connecting rod and crankshaft.
14. Measure clearance between the piston crown and
cylinder
StandardMax. 0.12mm
15. Position the piston at TDC and measure the dis-
tance between the piston crown and the crankcase
surface.
StandardMax. 0.965 mm
Notice
Measure at points marked.
Dial Gauge 001 589 00 53 21
Dial Gauge Holder 363 589 02 21 00

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 -- 181
D AEW OO M Y_2000
Tools Required
102589001500 Drift
102589121500 Drift
Replacement Procedure
1. Completely drain the coolant.
2. Remove any parts which impede access.
(Example : transmission, injection pump)
3. Place the screwdriver to the deepdrawn edge of the
core plug and pull forward and then rotate 90_.
4. Pull out the core plug with pliers.
5. Thoroughly clean the sealing surface and apply Loc-
tite 241.
6. Install the new core plug by using a drift.
Drift 102 589 00 15 00 (F34)
Drift 102 589 12 15 00 (F17)
7. Install the removed parts and fill the coolant.
Notice
The adhesive must be allowed to harden for about
45 minutes before filling of coolant.
8. Warm up the engine and check the coolant for leaks.

OM600 ENGINE MECHANICAL 1B3 -- 185
D AEW OO M Y_2000
Removal & Installation Procedure
1. Remove the timing case cover.
2. By inserting a round bar (6) approx. 0.7m from the
back to the front side through the oil gallery, knock
out the steel balls (1,3).
Notice
Be careful not to damage the bores of the steel
balls.
6 Shop -- made tool
3. Thoroughly clean the bores of steel balls.
4. Place the steel ball (3) onto the drift (7) with a little
grease and position to the bore and then tap until the
drift stops.
Drift 601 589 08 15 00
5. Place the steel ball (1) onto the drift (7) with a little
grease and position to the bore and then tap until the
drift stops.
Drift 601 589 08 1500
6. Warm up the engine and check the oil for leaks.

1D3 -- 4 OM600 ENGINE COOLING
D AEW OO M Y_2000
COOLING SYSTEM LEAKAGE TEST
Tools Required
124589152100Tester
Test
1. Loosen the pressure cap by 1 notch and remove the
cap after.
Notice
Do not remove radiator cap when coolant is above
90°C.
2. Add the coolant to the arrow mark of coolant reser-
voir.
3. Connect the special tool to the injector of reservoir
and apply 1.4bar pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check the hose,
pipe and leakage and, replace or retighten.

OM600 ENGINE COOLING 1D3 -- 5
D AEW OO M Y_2000
MAINTENANCE AND REPAIR
ON -- VEHICLE SERVICE
DRAIN AND FILLING OF COOLANT
Preceding Work : Removal of skid plate
Drain / Filling
1. Loosen the pressure cap of reservoir by 1 notch and
remove pressure and then loosen the cap.
Notice
Do not remove radiator cap when coolant is above
90°C.
2. Open the drain plug and drain the coolant.
Notice
Collect the coolant by using the proper bottle.
3. Remove the drain plug(1) and seal(2) of cylinder
block and drain the coolant.
4. Replace the seal to new one and tighten the drain
plug.
Installation Notice
Tightening Torque30 N∙m (22 lb-ft)
5. Tighten the drain plug of the lower radiator.
6. Fill the coolant through coolant reservoir -- tank.
Notice
DA proportion of 50% by volume of water / anticor-
rosion must be ensured.
7. After engine is running at idle speed, check the level
of coolant. If necessary, add enough specified cool-
ant.

OM600 ENGINE COOLING 1D3 -- 13
D AEW OO M Y_2000
Removal & Installation Procedure
1. Drain coolant from the radiator.
2. Remove the coolant thermoswich connector from
radiator.
3. Remove the each coolant hose.
4. Remove the auto T/M oil cooling hose and cooling
line.
Installation Notice
TighteningHose : 29-- 40N∙m (21-- 30 lb-ft)Tightening
TorqueTube : 25-- 35N∙m (18--26 lb-ft)
5. Loosen the radiator upper mounting bolt and re-
move the mounting stopper and insulator.
6. Remove the radiator.
7. Check the radiator pin for crack, leakage and bend-
ing and replace it if necessany.
8. Installation should follow the removal procedure in
the reverse order.