engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 31
D AEW OO M Y_2000
Assembly Procedure
Notice
In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and
fire is broken, it can not be used.
1. Clean the sealing surface of the prechamber.
2. Insert the prechamber into the cylinder head at the
same time aligning the cam on the collar of the pre-
chambers with the slots in the cylinder head.
Notice
If the spacer rings are fitted to the prechambers, the
spacer rings should be replaced with rings of the
same thickness.
Thickness of Spacer
Ring0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the
ring by using the serration wrench.
Tightening Torque130 N∙m (96 lb-ft)

1B3 -- 32 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
MILLING OF PRECHAMBER SEALING SURFACE
1Drift
2 Sleeve
3 Milling Cutter4 Counter Sink (Special Tool -- 601 589 00 66)
5 Cylinder Head
Tools Required
601589006600 CounterSink
667 589 00 23 00 Height Gauge
Milling of the Prechamber Sealing Surface
Notice
The prechamber sealing surface may only be rema-
chined once with the cylinder head fitted. It is essen-
tial to adhere to the specified projection ’C’ of the
prechamber of 7.6 -- 8.1mm.
This ensures that the required clearance exists be-
tween prechamber and piston crown with the piston
in TDC. For this reason, spacer rings should be in-
serted on remachined sealing surfaces.
Thickness of spacers0.3, 0.6, 1.0 mm
If a spacer ring is already fitted, or a marking is
made on the cylinder head, the cylinder head must
be removed and size ’C’ measured if further rema-
chining is necessary on a prechamber sealing sur-
face.

OM600 ENGINE MECHANICAL 1B3 -- 33
D AEW OO M Y_2000
1. Remove the injection nozzle.
2. Remove the prechamber.
3. Cover the prechamber bore to avoid any chips drop-
ping into the combustion chamber.
4. Remove the protective sleeve from the countersink
and rotate the countersink into the prechamber bore
to be machined as far as the stop.
Counter Sink 601 589 00 66 00
5. Maintain size ’X’ from the top edge of mandrel to the
top edge of the sleeve with the gauge.
Height Gauge 667 589 00 23 00
6. Measure the ’X’ by using a vernier caliper.
7. Mount the turning tool onto the countersink tool and
rotate to the right approx. 5 revolutions by applying
slight pressure.

1B3 -- 34 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
8. Remeasure size ’X’ and compare it with the first
measurement and determine the thickness of
spacer ring.
Ex
Size before machining25.7 mm
Size after machining25.5 mm
The spacer ring should be selected so that it is at
least 0.1mm and not more than 0.3mm thicker than
the measured on the sealing surface. In this exam-
ple, the necessary thickness of spacer ring should
be within 0.3 ~ 0.5mm and the thickness of spacer
ring to be installed is 0.3mm.
9. Remove the countersink tool and clean the chips.
Notice
If the sealing surface is not completely flat, rema-
chine the sealing surface.
10. Remove rag from the prechamber bore and crank
the engine with starter motor to threw out any chips
which may have got into the combustion chamber.
11. Insert the proper spacer ring into the prechamber
sealing surface.
12. Punch a mark on the cylinder head above the pre-
chamber sealing surface which has been machined.
13. Install the prechambers.
Notice
If the cylinder head is removed, the projection ’C’ is
measured in place of size ’X’ and the appropriate
size of spacer ring selected.
Normal Projection (c)7.6 -- 8.1mm

OM600 ENGINE MECHANICAL 1B3 -- 35
D AEW OO M Y_2000
TDC (TDC SENSOR BRACKET) SETTING
Preceding Work : Removal of No.1 cylinder prechamber
1 Measuring Device
2 Dial Gauge
3 Cylinder Head
4 Piston Set at TDC........................
Tools Service
001589322100 DialGauge
601 589 07 21 00 Depth Gauge
667589012100 FixingDevice
Notice
DThe TDC sensor bracket must be adjusted in case
of followings.
DWhen replacing the TDC sensor bracket.
DWhen replacing the crankshaft, the hub or the
vibration damper.
DlWhen replacing or installing the timing case cover.
DAfter engine overhauling.
* If the cylinder head is removed, the measuring pin of
the dial gauge can be positioned on the piston
crown.
This is done by placing the magnetic dial holder on
the mating surface of the crankcase.

1B3 -- 36 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber
bore and position the dial gauge with a preload of
5mm.
Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of en-
gine rotation until the large pointer on the dial gauge
stops (TDC position).
Notice
The position of TDC is when the large pointer on the
dial gauge is stopped before moving back.
5. Remove the reinstall the measuring device and
position the dial gauge scale at ’0’.
6. Slowly rotate the crankshaft in the direction of en-
gine rotation until the dial gauge has moved back
(counterclockwise) by 3.65mm.
7. Insert fixing device into the sensor bracket.
Notice
The pin on the vibration damper must engage into
the slot of the fixing device.
Fixing Device 667 589 01 21 00
8. If the pin does not engage, adjust the setting of the
sensor bracket by removing and tightening of the
sensor bracket bolts.
Tightening Torque10 N∙m(89lb-in)
Notice
The timing mark on the damper must be positioned
at ATDC 20.

OM600 ENGINE MECHANICAL 1B3 -- 37
D AEW OO M Y_2000
CYLINDER HEAD
1 Fuel Injection Pipe 18N∙m (13 lb-ft) ..........
2 Cylinder Head
3 Gasket Replace..........................
4 Bolt 25N∙m (18 lb-ft) ......................
5 Washer
6 Clamp
7 Heater Feed Pipe
8Bolt
9 Washer
10 Bolt
11 Nozzle Washer Replace...................
12 Fuel Injection Nozzle 35 -- 40 N∙m(26--30 lb-ft)
13 Hexagon Socket Bolt 25 N∙m (18 lb-ft) ......
14 Washer
15 Bolt 25 N∙m (18 lb-ft) .....................
16 Cylinder Head Bolt See Table..............
17 Cylinder Head Cover
18 Bolt 10 N∙m (89 lb-in) .....................
19 Gasket
20 Camshaft21 Camshaft Drive Sprocket Replace...........
22 Washer
23 Bolt(12-- Sided) 25N∙m (18 lb-ft) + 90_ .......
24 Sliding Rail
25 Sliding Rail Pin
26 Sliding Rail Pin
27 Chain Tensioner 80 N∙m (59 lb-ft) ...........
28 Gasket Replace..........................
29 Cooling Fan Check.......................
30 Hexagon Socket Bolt 45 N∙m (33 lb-ft) ......
31 Tensioning Lever
32 Bolt 25 N∙m (18 lb-ft) .....................
33 Bolt
34 Nut 23 N∙m (17 lb-ft) ......................
35 Fuel Filter
36 Turbo Charger
37 Intake Duct
38 Gasket Replace..........................
39 Intake Manifold

1B3 -- 38 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Tightening Torque
Cylinder Bolts (12-- sided socket head)stage 110 N∙m(89lb-in)y()
(Engine cold)stage 235 N∙m (26 lb-ft)
stage 3180_
M8 Cylinder Head Bolts25 N∙m (18 lb-ft)
Tools Required
000 589 77 03 00 Box Wrench Insert
001589650900SocketWrenchInsert
102 589 03 40 00 Magnetic Bar
116 589 02 34 00 Threaded Pin
116 589 03 07 00 T Type Socket Wrench
116 589 20 33 00 Sliding Hammer
601589001000CylinderHeadBoltWrench
602 589 00 40 00 Engine Lock
603 589 00 40 00 Counter Holder
Tightening Sequence for Cylinder Head
Bolts
OM 662LA Engine
OM 661LA Engine

OM600 ENGINE MECHANICAL 1B3 -- 39
D AEW OO M Y_2000
Notice
The cylinder head may only be removed when the
engine has cooled down. The cylinder head is re-
moved together with the exhaust manifold. As the
cylinder head bolts undergo a permanent tightening.
They require to be replaced if they exceed the maxi-
mum lengthes indicated in the table.
Thread DiaLength(L)
When NewMax. Length(L)
M1080mm82mm
M10120mm104mm
M10115mm117 m m
The twelve -- sided socket head bolts are tightened
with each stages of torque and torque angle.
It is not necessary to retighten the cylinder head
bolts at the 1000~1500km inspection or after
1000~1500km of repairs.

1B3 -- 40 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Disassembly Procedure
1. Completely drain the coolant from the radiator and
cylinder block.
2. Remove the cooling fan shroud.
3. Hold the fan with counter holder and remove the bolt
and then remove the cooling fan.
Notice
Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
4. Remove the bracket oil dipstick tube.
5. Remove the nut.
6. Remove the nut on the tensioning lever and insert
the rod(F12’ 180mm). By pushing the rod to the ar-
row direction, pull back the bolt.
7. Push the tensioning lever to the opposite direction to
release the spring tension and remove the poly V--
belt.