engine SSANGYONG KORANDO 1997 Service Repair Manual

GENERAL ENGINE INFORMATION 1A3 -- 15
D AEW OO M Y_2000
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many ma-
chined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten-- thousanths of an
inch. When any internal engine parts are serviced, care
and cleanliness are important. A liberal coating of en-
igne oil should be applied to friction areas during assem-
bly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part fo the repair proce-
dure. This is considered standard shop practice even if
not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be
installed in the same locations, and with the same mat-
ing surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnectcables may result in damage to wire harness or other
electrical parts.
ON-- ENGINE SERVICE
Caution: Disconnect the negative battery cable be -
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnect -
ing this cable will help prevent personal injury and
damage to the vehicle. The ignition must also be in
LOCK unless otherwise noted.
Notice:Any time the air cleaner is removed, the intake
opening should be covered. Thiswill protect against ac-
cidental entrance of foreign material, which could follow
the intake passage into the cylinder and cause exten-
sive damage when the engine is started.

D AEW OO M Y_2000
SECTION 1B3
OM600 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Specifications 1B3 -- 2............................
Fastener Tightening Specifications 1B3 -- 2..........
Special Tools 1B3 -- 4.............................
Special Tools Table 1B3-- 4.......................
Maintenance and Repair 1B3 -- 12..................
On-- Vehicle Service 1B3-- 12........................
Engine Assembly 1B3-- 12........................
Poly V-- Belt 1B3 -- 21.............................
Tensioning Device 1B3-- 23.......................
Poly V-- Belt Alignment & Inspection 1B3-- 26........
Prechamber 1B3-- 29............................
Milling of Prechamber Sealing Surface 1B3 -- 32.....
TDC (TDC Sensor Bracket) Setting 1B3 -- 35........
Cylinder Head 1B3-- 37...........................
Timing Case Cover 1B3 -- 63......................
Crankshaft End Cover 1B3-- 71...................
Vibration Damper and Hub 1B3-- 74...............
Crankshaft Front Radial Seal 1B3-- 80.............
Crankshaft Ball Bearing 1B3-- 82..................
Crankshaft 1B3-- 83.............................
Flywheel 1B3 -- 93...............................
Machining of Flywheel 1B3-- 97...................
Flywheel Ring Gear 1B3 -- 98......................
Hydraulic Valve Clearance Compensation
Element Check 1B3-- 101.........................
Valve Tappets 1B3-- 103..........................
Valve Spring Check 1B3-- 105.....................Valve Springs (Cylinder Head Removed) 1B3-- 106..
Valve Springs (Cylinder Head Installed) 1B3-- 109...
Valve Stem Seals 1B3-- 112......................
Check and Replacement of Valve Guides 1B3-- 116..
Valve Seat Rings 1B3-- 122.......................
Check and Machining of Valves 1B3-- 127..........
Machining of Valve Seat 1B3-- 132.................
Camshaft Timing Test 1B3-- 137...................
Camshaft 1B3-- 139.............................
Chain Tensioner 1B3-- 145........................
Timing Chain 1B3-- 147...........................
Tensioning Rail 1B3-- 151.........................
Cylinder Head Guide Rail 1B3-- 152................
Timing Case Cover Guide Rail 1B3-- 156...........
Crankshaft Sprocket 1B3-- 158....................
Piston 1B3-- 163.................................
Oil Filter 1B3-- 169...............................
Oil Pan 1B3-- 171................................
Oil Spray Nozzle 1B3-- 174.......................
Oil Pump 1B3-- 175..............................
Unit Repair 1B3 -- 177............................
Cylinder Head Pressure Leakage Test 1B3-- 177....
Facing Cylinder Head Mating Surface 1B3 -- 178.....
Replacement of Crankcase Core Plug 1B3-- 180.....
Facing Crankcase Contacting Surface 1B3 -- 182....
Oil Gallery Steel Ball 1B3-- 183....................
Cylinder Bore Measurement 1B3-- 187.............

1B3 -- 2 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Engine Assembly
ApplicationNSmLb-- FtLb-- In
Skid Plate Bolt28 -- 4721 -- 35--
Drain Plug Bolt3022--
Coolong Fan Shroud Bolt3--7--27 -- 62
Control Linkage Nut8--186--13--
Clutch Linkage Cylinder Nut20 -- 3415 -- 25--
Exhaust Manifold Bolt3022--
Propeller Shaft Bolt & Nut (Axle)70 -- 8052 -- 59--
Propeller Shaft Bolt & Nut (T/C)81 -- 8960 -- 66--
Engine Mounting Nut50 -- 7537 -- 55--
Crankshaft Assembly
ApplicationNSmLb-- FtLb-- In
Cooling Fan Belt Pulley Bolt10--89
Socket Bolt2317--
Tighten The Bolt200 / 90_148 / 90_--
End Cover Bolt10--89
Crankshaft Bearing Cap Bolt55 / 90_41 / 90_--
Ball Bearing45 / 90_33 / 90_--
Camshaft Sprocket Bolt25 / 90_18 / 90_--
Oil Pump Sprocket Bolt2518--
Piston
ApplicationNSmLb-- FtLb-- In
Connecting Rod Bolt35 / 90_26 / 90_--
Flywheel
ApplicationNSmLb-- FtLb-- In
12-- Sided Stretch Bolt45 / 90_33 / 90_--

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 MECHANICAL 1B3 -- 5
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
116 589 03 07 00
T Type Socket Wrench
601 589 00 10 00
Cylinder Head Bolt 102
102 589 12 15 00
(φ17) Drift
617 589 10 21 00
RI Sensor
115 589 34 63 00
602 589 00 25 00
102 589 00 15 00
(φ34) Drift
601 589 05 14 00
Assembly Cage

1B3 -- 6 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
601 589 08 15 00
Drift
001 589 53 21 00
Dial Gauge
601 589 07 21 00
Depth Gauge
667 589 01 21 00
Fixing Device
103 589 00 33 00
Puller
601 589 03 14 00
Sleeve
601 589 03 43 00
Oil Seal Assembler
366 589 00 21 05
Extension

OM600 ENGINE MECHANICAL 1B3 -- 7
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
363 589 02 21 00
Dial Gauge Holder
000 589 33 33 00
Counter Support
000 589 25 33 00
Internal Extractor
102 589 05 33 00
Puller
116 589 07 15 00
Drift
000 589 04 14 00
Tensioning Strap
102 589 03 40 00
Magnetic Bar
601 589 01 59 00
Assembling Board

1B3 -- 8 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
601 589 02 59 00
Supporting Bridge
667 589 00 31 00
Press Lever
116 589 06 63 00
Magnetic Finger
603 589 01 40 00
Holding Wheel
667 584 02 63 00
Supporting Bar
104 589 00 37 00
Pliers
601 589 02 43 00
Drift
000 589 10 68 00
Cylinder Brush

OM600 ENGINE MECHANICAL 1B3 -- 9
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
601 589 02 23 00
Go/No Go Gauge
105 589 03 15 00
Drift (for Intake)
103 589 02 15 00
Drift (for Exhaust)
346 589 00 63 00
Super Cooling Box
601 589 05 15 00
Drift (for Intake)
601 589 06 15 00
Drift (for Exhaust)
000 589 10 53 00
Reamer (for Exhaust)
000 589 21 53 00
Reamer (for Intake)

1B3 -- 10 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
001 589 32 21 00
Dial Gauge
001 589 53 21 00
Dial Gauge
000 589 58 43 00
Chain Assembling
Device
201 589 13 21 00
Vacuum Tester
124 589 15 21 00
Te s t e r
667 589 02 21 00
TDC Pulse Generator
501 589 73 21 00
Vacuum Pump
617 589 04 21 00
Te s t e r