transmission SSANGYONG KORANDO 1997 Service Owner's Guide

1A3 -- 10 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair. The following procedures may
help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate loca-
tion of the leak by the drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-- type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil fill
tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid willappear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a gas-
ket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. Thebent flange must be
repaired also. Before attempting to repair a leak, check
for the following conditions and correct them as they
may cause a leak.
Gaskets
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe fasteners are tightened improperly or the threads
are dirty or damaged.
DThe flanges or the sealing surface is warped.
DThere are scratches, burrs or other damage to the
sealing surface.
DThe gasket is damaged or worn.
DThere is cracking or porosity of the component.
DAn improper seal was used (where applicable).
Seals
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe seal bore is damaged (scratched, burred or
nicked).
DThe seal is damaged or worn.
DImproper installation is evident.
DThere are cracks in the components.
DThe shaft surface is scratched, nicked or damaged.
DA loose or worn bearing is causing excess seal wear.

1B3 -- 16 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
16. Remove the power steering pump lines.
Notice
Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the
feed pump on injection pump.
18. Vehicle with automatic transmission.
Remove the hydraulic lines (19, 20) from oil cooler
(2).
19. Disconnect the engine harness.
20. Disconnect the preheating time relay cable.

OM600 ENGINE MECHANICAL 1B3 -- 19
D AEW OO M Y_2000
31. Separate the exhaust pipe flange from the turbo
charger.
Installation Notice
Tightening Torque30 N∙m (22 lb-ft)
32. Loosen the installing bolt of clutch release cylinder
and remove the clutch release cylinder.
Installation Notice
Tightening Torque20-- 34 N∙m (15-- 25 lb-ft)
33. Disconnect the exhaust pipe flange from the ex-
haust manifold.
Installation Notice
Tightening Torque30 N∙m (22 lb-ft)
34. Remove the propeller shaft from the transmission.
Installation Notice
TighteningTorque
Axle 70-- 80 N∙m
(52--59 lb-ft)
TighteningTorqueT/C 81 -- 89 N∙m
(60--66 lb-ft)
35. Remove the shift control cable.
36. Remove the transmission.

1B3 -- 82 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKSHAFT BALL BEARING
1 Spacer
2 Cover Replace............................3 Ball Bearing
4 Bolt 45N∙m (33 lb-ft)+ 90_ ................
Notice
Manual transmission only.
Tools Required
000 589 33 33 00 Counter Support
000 589 25 33 00 Internal Extractor
Removal & Installation Procedure
1. Remove the manual transmission.
2. Using a puller, pull out the locking ring and ball bear-
ing together.
Counter Support 000 589 33 33 00
Internal Extractor 000 589 25 33 00
3. Apply Loctite 241 on the new ball bearing and then
insert the ball bearing to be stopped at the spacer
ring by using a proper mandrel.

OM600 ENGINE MECHANICAL 1B3 -- 93
D AEW OO M Y_2000
FLYWHEEL
Preceding Work : Removal of transmission
Removal of the clutch
1OilPan
2 Straight Pin
3 Flywheel4 12-- Sided Stretch Bolt
Check, 45N∙m (33 lb-ft)+90_ ...............
5 Drive Plate (Automatic Transmission)
6 Flywheel (Automatic Transmission)

1B3 -- 94 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
OM662LA OM661LA
DManual transmission flywheel
DAutomatic transmission flywheel

OM600 ENGINE MECHANICAL 1B3 -- 95
D AEW OO M Y_2000
Tools Required
602 589 00 40 00 Engine Lock
Removal & Installation Procedure
1. Install the engine lock.
Engine Lock 602 589 02 40 00
2. Remove the 12-- sided stretch bolts (4).
Installation Notice
Tightening Torque45 N∙m (33 lb-ft) + 90_
Notice
If the length ’L’ of bolts exceeds 22.5mm, replace
the bolts.
3. Remove the flywheel (3), if equipped with manual
transmission.
Installation Notice
Correctly align the position of dowel pin (2).

1B3 -- 96 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
4. Remove the flywheel (6) and driven plate (5), if
equipped with automatic transmission.
Installation Notice
Correctly align the position of dowel pin (2).
5. Installation should follow the removal procedure in
the reverse order.

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.

1F3 -- 46 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Removal Procedure
1. Position then no.1 cylinder at 15_ATDC.
Notice
Do not rotate the engine in opposition direction of
engine rotation.
2. Remove the connecting rod (9).
3. Disconnect the vacuum lines (13, 14).
4. Remove the accelerator control damper (10).
(Manual transmission vehicle)
5. Remove the suction line (16) and pressure line (4).
6. Remove the banjo bolt (1) and then remove the seal
(2) and fuel line (3).
7. Remove the plastic clip (8) on the injection line.
8. Disconnect the injection lines (15) from the injection
pump (25).
9. Remove the banjo bolt (1) and then remove the seal
(7) and return line (5).