engine SSANGYONG KORANDO 1997 Service Repair Manual

GENERAL ENGINE INFORMATION 1A3 -- 5
D AEW OO M Y_2000
OM661LA ENGINE
Front View

1A3 -- 6 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
Side View

GENERAL ENGINE INFORMATION 1A3 -- 7
D AEW OO M Y_2000
PERFORMANCE CURVE
OM662LA ENGINE

1A3 -- 8 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
OM661LA ENGINE

GENERAL ENGINE INFORMATION 1A3 -- 9
D AEW OO M Y_2000
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01
Torque Wrench
001 589 76 21 00
Compression Pressure
Tester
601 589 65 09 00
Socket
001 589 73 21 00
Hand Vacuum Pump

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.

GENERAL ENGINE INFORMATION 1A3 -- 11
D AEW OO M Y_2000
COMPRESSION PRESSURE TEST
1 Test Adapter
2 Flexible Connector
3 Compression Pressure Recorder
Service Data
Normal Compression Pressure28bar
Minimum Compression PressureApprox.18bar
Permissible Pressure Difference Between Individual CylindersMax. 3bar
DEngine at normal operating temperature of 80_C
Tools Required
000 589 65 09 00 Socket
001 589 73 21 00 Hand Vacuum Pump

1A3 -- 12 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
Compression Pressure Measurement
Notice
Ensure that no gear is engaged and that the vehicle
is protected from rolling.
1. Run the engine to be the coolant temperature 80_C.
2. Remove the fuel injection nozzle.
Socket Wrench Insert 001 589 65 09 00
3. Install the test adapter (1) and connect the flexible
connector (2) to the compression pressure recorder.
Compression Pressure Recorder 001 589 76 21 00
4. Disconnect the vacuum line from the stop unit and
connect the hand vacuum pump to the stop unit.
5. Pump the hand vacuum pump and make the fuel in-
jection pump in stop position.
Operating PressureApprox. 500bar
Hand Vacuum Pump 001 589 73 21 00
6. Using a starter motor, crank the engine 8 revolu-
tions.
7. Measure the remaining cylinder compression pres-
sure in the same manner and compare it with ser-
vice data.
Notice
If out of standard, do cylinder pressure leakage test.
8. Remove the compression pressure recorder.
9. Install the fuel injection nozzle.

GENERAL ENGINE INFORMATION 1A3 -- 13
D AEW OO M Y_2000
CYLINDER PRESSURE LEAKAGE TEST
1 Connector
2 Connection Piece
3 Connection Hose
Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80_C)
At Whole EngineMax. 25 %
At Valve and Cylinder Head GasketMax. 10 %
At Piston and Piston RingMax. 20 %
Commercial Tools
Cylinder Pressure Leakage testerBOSCH, EFAW 210 A or SUN CLT 228
Connection PieceBOSCH order no. 1 687 010 016

1A3 -- 14 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
Leakage Test
1. Run the engine to be the coolant temperature 80_C.
2. Remove the fuel injection nozzle.
3. Open the coolant subtank cap.
4. Check the coolant level and replenish if necessary.
5. Open the oil filler cap.
6. Remove the air cleaner cover and element.
7. Position the piston at TDC.
8. Install the connector (1) and connection piece (2).
9. Calibrate the tester and connect the connection
hose (3)
10. Pressurize with compressed air and compare the
pressure changes with permissible pressure leak-
age.
11. If permissible pressure leakage is out of standard,
check followings :
-- Intake and exhaust lines.
-- Sounds in oil filler area.
-- Air bubbles in radiator coolant.
12. Do pressure leakage test for the remaining cylinders
according to the firing order.
DOM 662LA Engine : 1-- 2-- 4-- 5-- 3
DOM 661LA Engine : 1-- 3-- 4-- 2
13. Remove the tester.
14. Close the coolant pressure cap and oil filler cap.
15. Install the air cleaner element and cover.
16. Install the fuel injection nozzle.