torque SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 107
D AEW OO M Y_2000
Tools Required
102 589 03 40 00 Magnetic Bar
116 589 06 63 00 Magnetic Finger
601589015900AssemblingBoard
601 589 02 59 00 Supporting Bridge
667589003100PressLever
Removal & Installation Procedure
1. Remove the nuts (8) uniformly and then remove the
washer (7), exhaust manifold (9) and gasket.
Installation Notice
Check the stud bolt (6) for damage and replace if
necessary.
Tightening Torque12 N∙m (106 lb-in)
Replace the gasket and tighten the nuts (8).
Tightening Torque25 N∙m (18 lb-ft)
2. Install the assembling board (11) to the cylinder
head with 4 cylinder head blots (10).
Assembling Board 601 589 01 59 00
3. Pull out the valve tappet (1) with magnetic bar (12).
Notice
Place the valve tappets upside down (open end up-
ward).
Magnetic Bar 102 589 03 40 00
4. Install the supporting bridge (13) on the cylinder
head (5).
Supporting Bridge 601 589 02 59 00

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Tools Required
001589532100 DialGauge
363 589 02 21 00 Dial Gauge Holder
366589002105 Extension
Measurement Procedure
1. Remove the cylinder head cover.
2. Rotate the engine in the direction of engine rotation
until the intake valve of NO.1 cylinder is completely
closed. The cam lobe faces up (arrow).
Notice
Do not rotate the engine at the bolt of the crankshaft
sprocket. Do not rotate the engine in the opposite di-
rection of engine rotation. If do, thiswill cause seri-
ous measuring errors.
3. Install the dial gauge holder and dial gauge (7) with
the extension (8) to the cylinder head and position
the tracer pin (9) onto the valve tappet (intake valve
of cylinder NO.1) with a preload of min. 3mm.
Notice
The tracer pin should be positioned exactly vertical.
Dial gauge Holder 363 589 02 21 00
Dial Gauge 001 589 53 21 00
Extension 366 589 00 21 05
4. Set the dial gauge to ’0’.
5. Rotate the engine further in direction of rotation until
the dial gauge has moved back by 2mm (valve lift) to
1mm.
6. Check the timing.
NewAT DC 11 . 3 3_
After approx. 20,000kmAT DC 1 2_
Notice
If timing is out standard, the camshaft should be
checked for wear and the timing chain for stretch. If
adifferenceofmorethan4_exists, the timing chain
should be replaced.
7. Replace the gasket and install the cylinder head
cover.
Tightening Torque10 N∙m(89lb-in)

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5. Tighten the camshaft bearing cap bolts acccording
to installation order.
Tightening Torque25 N∙m (18 lb-ft)
Notice
Tighten the No. 1 bolts (light arrow) by one revolu-
tion in stages first and then tighten the No.2 bolts
(dark arrow).
OM 662LA
OM 661LA
6. Install the camshaft sprocket to be aligned the mark-
ings of the camshaft / camshaft bearing cap (arrow).
Notice
Align the alignment marks on the timing chain and
sprocket.
7. Tighten the camshaft sprocket bolt.
Tightening Torque25 N∙m (18 lb-ft) + 90_

1B3 -- 144 OM600 ENGINE MECHANICAL
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Notice
If max. length ’L’ of the 12-- sided bolt exceeds
53.6mm, replace it.
8. Install the chain tensioner.
Tightening Torque80 N∙m (59 lb-ft)
Notice
Replace the seal.
Before installation, by pumping in the oil approx. 10
times, fill the oil.
9. Remove the engine lock.
10. Check the TDC marking of OT on the crankshaft.

1B3 -- 150 OM600 ENGINE MECHANICAL
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11. Place the fitting tool (8) onto the chain link and rivet
the chain pins one by one.
Tightening Torque35-- 40 N∙m (26-- 30 lb-ft)
12. Check the riveting of chain pins and re-- rivet if nec-
essary.
13. Remove the wire.
14. Position the no.1 cylinder at TDC.
In this position, the marking on camshaft / camshaft
bearing cap (arrow) must also be aligned. If the
markings are not aligned, the timing chain must be
re-- set and the injection pump timing has to be set.

1B3 -- 154 OM600 ENGINE MECHANICAL
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6. Pull out the bearing pins (9, 11) with sliding hammer
and remove the guide rail 10.
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00
Installation Procedure
1. Apply collar of both bearing pins with sealing com-
pound.
2. Position the guide rail and insert the bearing pins.
3. Install the camshaft sprocket.
Tightening Torque10 N∙m(89lb-in)
Notice
If the max. length ’L’ of the 12-- sided bolt exceeds
53.6mm, replace it.
4. Position the no. 1 cylinder at the TDC of OT.

OM600 ENGINE MECHANICAL 1B3 -- 155
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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)

OM600 ENGINE MECHANICAL 1B3 -- 161
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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).

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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

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3. Unscrew the oil strainer bracket bolt.
Tightening Torque10 N∙m(89lb-in)
4. Remove the oil pump.
5. Unscrew the screw plug and remove the relief valve.
6. Installation should follow the removal procedure in
the reverse order.