engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 51
D AEW OO M Y_2000
OM661LA
49. Remove the cylinder head(2) and gasket(3).

1B3 -- 52 OM600 ENGINE MECHANICAL
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Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.
Notice
Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts.
Notice
If the max. length is exceeded, replace the bolts.
Thread Dia.Length (L)
When NewMax. Limit (L)
M1080mm82mm
M10120mm104mm
M10115 m m117mm
OM662LA4. Coat the head contact surface of bolts and thread
with oil and insert them as shown.
-- Cylinder head bolts arrangement
Bore
1M10x80......................
2 M10 x 102......................
3M10x115......................
4M8x50......................
5M8x80......................

OM600 ENGINE MECHANICAL 1B3 -- 53
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5. Tighten the cylinder head bolts to specified torque
and torque angle.
Stage 115 N∙m (11 lb-ft)
Stage 235 N∙m (26 lb-ft)
Torque angle90_
Wait f or10 minutes
Torque angle90_
OM 661LAOM 662LA
6. Install the socket bolts in the chain box.
Tightening Torque25 N∙m (18 lb-ft)
7. Connect the vacuum pipe to the thermo valve.

1B3 -- 54 OM600 ENGINE MECHANICAL
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8. Connect the vacuum lines to the vacuum pump.
9. Install the fuel filter and connect the pipe.
Tightening Torque25 N∙m (18 lb-ft)
Notice
Be careful not to be confused the connections and
hoses.
10. Connect the fuel pipe to the injection pump.
11. Install the sliding rail(24) and insert the sliding rail
pins(25, 26).
Notice
Apply sealing compound on the each collar of the
sliding rail pins.
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00

OM600 ENGINE MECHANICAL 1B3 -- 55
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12. Install the idle pulley and fit the closing cover.
Tightening Torque25 N∙m (18 lb-ft)
13. Insert the tensioning lever(31) and install the spring.
14. Install the damper.
Tightening Torque23 N∙m (17 lb-ft)
Notice
Insert the tensioning lever bolts onto the mounting
hole.
15. Insert the locking washer.
16. Inspect the valve tappet and check that the tappet
moves smoothly.

1B3 -- 56 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
17. Coat the camshaft with oil and install the camshaft
on the cylinder head to be TDC mark(arrow) up-
ward.
18. Measure the axial end play of the camshaft.
End Play0.06 -- 0.21mm
Notice
If out of standard, adjust it with the proper thickness
of locking washer.
19. Install the bearing caps on the camshaft according
to the number on the caps.
20. Tighten the bearing cap bolts according to the nu-
merical sequence.
Tightening Torque25 N∙m (18 lb-ft)
Notice
Tighten the No. 1 bolts(light arrow) first and then
tighten the No. 2 bolts(dark arrow) stage by stage.
OM662LA
OM661LA

OM600 ENGINE MECHANICAL 1B3 -- 57
D AEW OO M Y_2000
21. Position the camshaft on marking and install the
camshaft sprocket.
Notice
Align the alignment marks on the chain and sprock-
et.
22. Check the TDC position of the crankshaft.
23. Install the camshaft sprocket bolt.
Tightening Torque25 N∙m (18 lb-ft) + 90_

1B3 -- 58 OM600 ENGINE MECHANICAL
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Notice
Measure the max. length ’L’ and replace the bolt if it
exceeds 53.6mm.
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.
Tightening Torque25 N∙m (18 lb-ft)

OM600 ENGINE MECHANICAL 1B3 -- 59
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27. Replace the seal and then install the chain tension-
er.
Tightening Torque80 N∙m (59 lb-ft)
28. Remove the engine lock.
29. Insert the nozzle washer into the hole to face round
part downward.
30. Install the fuel injection nozzle.
Tightening Torque40 N∙m (30 lb-ft)
31. Connect the fuel hose.
32. Install the cable channel and connect the cables to
glow plugs.

1B3 -- 60 OM600 ENGINE MECHANICAL
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33. Replace the gasket and install the cylinder head
cover.
Tightening Torque10 N∙m(89lb-in)
34. Install the blow-- by hose.
35. Connect the wires to the coolant temperature sen-
sor and the glow plug sensor.
36. Replace the intake manifold gasket.
37. Install the intake manifold.
Tightening Torque25 N∙m (18 lb-ft)