engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 41
D AEW OO M Y_2000
8. Remove the air cleaner cover and element and then
remove the air cleaner housing.
9. Remove the oil return hose and plug.
Notice
Cover them to prevent chips from coming into.
10. Unscrew the EGR pipe mounting bolts onto the ex-
haust manifold.
11. Remove the duct bracket from the cylinder head.
12. Unscrew the intake duct mounting bolts onto the in-
take manifold.
13. Separate the connecting rod from the control lever.

1B3 -- 42 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
14. Pull out the accelerator control linkage.
15. Remove the fuel injection line(1) from the fuel injec-
tion nozzle(12).
Box Wrench Inset 000 589 77 03 00
16. Remove the fuel injection line from the fuel injection
pump.
Box Wrench Insert 000 589 77 03 00
17. Remove the bracket mounting bolts and then re-
move the fuel injection line(1).

OM600 ENGINE MECHANICAL 1B3 -- 43
D AEW OO M Y_2000
18. Disconnect the booster hose connected to intake
manifold.
19. Remove the intake manifold and gasket.
20. Remove the cylinder head cover and gasket with the
blow-- by gas hose.
21. Disconnect the glow plug cables.

1B3 -- 44 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
22. Remove the cable channel.
23 .Disconnect the cables from the glow plug sensor
and coolant temperature sensor.
24. Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe for-
ward and then pull out the pipe.

OM600 ENGINE MECHANICAL 1B3 -- 45
D AEW OO M Y_2000
26. Disconnect the fuel lines from the fuel filter.
27. Disconnect the fuel lines from the injection pump.
28. Remove the fuel filter(35).
29. Remove the fuel injection nozzle(12) and nozzle
washer(11).
Socket Wrench Insert 001 589 65 09 00

OM600 ENGINE MECHANICAL 1B3 -- 47
D AEW OO M Y_2000
34. Remove the turbocharger.
35. Remove the exhaust manifold and gasket.
36. Remove the chain tensioner and seal.
37. Remove the bolt and separate the drive sprocket
(21).
Notice
During removal, be careful not to drop the sprocket
and chain into the timing case.
Carefully pull off the chain and then pull out the
sprocket.

1B3 -- 46 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
30. Rotate the crankshaft and set the no.1 cylinder at
TDC.
Notice
Do not rotate the crankshaft to the opposite direc-
tion of engine revolution.
31. Place alignment marks on the camshaft gear and
timing chain.
32. Ensure that the camshaft and the bearing cap mark-
ing are aligned.
33. Remove the starter motor and install the engine lock
onto the flywheel ring gear.
Engine Lock 602 589 00 40 00

1B3 -- 48 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
38. Remove the camshaft bearing cap bolts according
to the numerical sequence.
Notice
Remove the No.1 bolts first and then remove the
No. 2 bolts. Do not remove the bolts at a time com-
pletely but remove them step by step evenly or cam-
shaft can be seriously damaged.
OM662LA
OM661LA
39. Remove the bearing caps and then pull out the cam-
shaft(20) upward.
Notice
Be careful not to miss the locking washer.
40. Remove the locking washer.
Notice
Check the locking washer and replace if necessary.

OM600 ENGINE MECHANICAL 1B3 -- 49
D AEW OO M Y_2000
41. Remove the bolt(32).
42. Separate the spring and pull out the tensioning le-
ver(31).
43. Pry off the closing cover. Remove the bolt and then
remove the idle pulley.
44. Using the sliding hammer(36) and the threaded
pin(37), pull out the sliding rail pins(25, 26) and re-
move the sliding rail(24).
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00

1B3 -- 50 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
45. Remove the vacuum line from the vacuum pump.
46. Disconnect the vacuum pipe from thermo valve.
47. Remove the socket bolts(13) of the chain box.
T Type Socket Wrench 116 589 03 07 00
Magnetic Bar 102 589 03 40 00
48. Remove the cylinder head bolts in numerical se-
quence.
Cylinder Head Bolt Wrench 601 589 00 10 00
OM662LA