engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 81
D AEW OO M Y_2000
Notice
The sealing lip of the repair radial seal is offset to the
inside by 2mm to ensure that is does not run in any
groove which the standard radial seal may have left
on the crankshaft flange.
A Standard Radial Seal
B Repair Radial Seal
Replacement Procedure
1. Pull out the radial seal (1) and be careful not to dam-
age the sealing surface of timing case cover.
2. Thoroughly clean the mounting bore of the radial
seal.
3. Coat a little oil on the sealing lip of new radial (1) and
contact surface.
Notice
Don’t use grease.
4. Install the radial seal (1) by using a sleeve (4).
Notice
Align the groove of sleeve and woodruff key(arrow).
Sleeve 601 589 03 14 00

1B3 -- 82 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKSHAFT BALL BEARING
1 Spacer
2 Cover Replace............................3 Ball Bearing
4 Bolt 45N∙m (33 lb-ft)+ 90_ ................
Notice
Manual transmission only.
Tools Required
000 589 33 33 00 Counter Support
000 589 25 33 00 Internal Extractor
Removal & Installation Procedure
1. Remove the manual transmission.
2. Using a puller, pull out the locking ring and ball bear-
ing together.
Counter Support 000 589 33 33 00
Internal Extractor 000 589 25 33 00
3. Apply Loctite 241 on the new ball bearing and then
insert the ball bearing to be stopped at the spacer
ring by using a proper mandrel.

OM600 ENGINE MECHANICAL 1B3 -- 83
D AEW OO M Y_2000
CRANKSHAFT
Preceding Work : Removal of the end cover
Removal of the piston
Removal of the crankshaft sprocket
3 Crankshaft Main Bearing Shells (Upper)
4 Trust Bearings (Upper)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)7 Thrust Bearings (Lower)
8 Crankshaft Bearing Cap
9 Crankshaft Bearing Cap (Fit Bearing)
10 12-- sided Stretch Bolts : 55N∙m (41 lb-ft)+90_
Tools Required
001589532100 DialGauge
363 589 02 21 00 Dial Gauge Holder
366589002105 Extension

1B3 -- 84 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Thrust Washer and Bearing Arrangement
OM662LA Engine
3 Crankshaft Main Bearing Shells (Upper)
4 Thrust Bearings (Upper)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)A Radial Bearings
B Radial and Axial Bearings (Thrust Bearing)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.

OM600 ENGINE MECHANICAL 1B3 -- 85
D AEW OO M Y_2000
OM661LA Engine
3 Crankshaft Main Bearing Shells (Upper)
4 Thrust Bearings (Upper)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)A Radial Bearings
B Radial and Axial Bearings (Thrust Bearing)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.

1B3 -- 86 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Crankshaft Standard and Repair Sizes
mm
Crankshaft bearing journal
diameterThrust bearing
journal widthThrust bearing
journal diameter
Standardsize509505796524.500 -- 24.5334795047965Standardsize50.950 -- 57.96524.600 -- 24.63347.950 -- 47.965
Repair size 157.500 -- 57.71524.700 -- 24.73347.700 -- 47.715
Repair size 257.450 -- 57.46524.900 -- 24.93347.450 -- 47.650
Repair size 357.200 -- 57.21525.000 -- 25.03347.200 -- 47.215
Repair size 456.950 -- 56.965--46.950 -- 46.965
Bearing Clearances
mm
Thrust bearingCrankshaft bearing
RadialclearanceNew0.027 -- 0.0510.026 -- 0.068RadialclearanceLimitMax. 0.070Max. 0.080
AxialclearancesNew0.100-- 0.254--AxialclearancesLimitMax. 0.300--
Matching Fit Bearing Journal Width to Thrust Bearings
mm
Fit bearing journal widthThrust bearing thickness
24.500 -- 24.5332.15
24.600 -- 24.6332.20
24.700 -- 24.7332.25
24.900 -- 24.9332.35
25.000 -- 25.0332.40
Notice
DMeasure crankshaft axial clearance and adjust with proper thrust Bearing.
DThe same thickness of washer must be installed on both sides of the fit bearing.

OM600 ENGINE MECHANICAL 1B3 -- 87
D AEW OO M Y_2000
Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Marking of basic bearing bore in lower
parting surfaceColor code of relevant crankshaft
bearing shell
1 punch mark or blueBlue or white -- blue
2 punch marks or yellowYellow or white -- yellow
3 punch marks or redRed or white -- red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft
Marking of bearing journals on crank websColor code of relevant crankshaft
bearing shell
Blue or white -- blueBlue or white -- blue
Yellow or white-- blueYellow or white -- yellow
Red or white-- blueRed or white -- red

1B3 -- 88 OM600 ENGINE MECHANICAL
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Removal & Installation Procedure
1. Remove the bearing cab bolt.
2. Remove the bearing caps (8).
Notice
The crankshaft bearing caps are marked with
stamped numbers. Remove the bearing cap from
the vibration damper side.
3. Remove the crankshaft bearing caps (9) and lower
thrust bearings (7).
4. Remove the lower thrust bearings (6) from the bear-
ing cap (9).
5. Remove the crankshaft (5).
6. Remove the upper thrust bearings(4).
7. Remove the upper bearing shells (3) from crank-
case.

OM600 ENGINE MECHANICAL 1B3 -- 89
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8. Thoroughly clean the oil gallery.
9. Select a proper new bearing shells with reference to
table.
10. Coat the new bearing shells with oil and insert into
the crankcase and into the crankshaft bearing caps.
Notice
Do not mix up upper and lower crankshaft bearing
shells.
11. Install the bearing caps according to marking and
tighten the 12--sided stretch bolts.
Tightening Torque35-- 40 N∙m (26-- 30 lb-ft)
Notice
No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E).
Extension 366 589 00 21 05
13. Measure at 3 points (A, B and C) and if the average
value of B and C is less than A’s value, the average
value of B and C is the mean value and if more than
A’s value, A’s value is the mean value.
14. Measure crankshaft bearing journal diameter (F).
Notice
When measured in A and B, the runout should not
exceed 0.010mm.

1B3 -- 90 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
15. Measure radial clearance of crankshaft bearing (G).
Clearance ’G’0.027 -- 0.051mm
Notice
If ’G’ is out of standard, replace the bearing shells
and adjust the radial clearance of crankshaft bear-
ing.
Example) Measured value ’E’ = 57.700mm
Measured value ’F’ = 57.659mm
——————————————
Clearance ’G’ = 0.041mm
16. Remove the crankshaft bearing cap.
17. Measure width of thrust bearing journal (H) and ad-
just with proper thrust bearings (see table).
Notice
The same thickness of thrust washers should be
installed on both sides of the thrust bearing.
18. Coat the upper thrust bearing (4) with oil and insert
into the crankcase so that the oil grooves are facing
the crank webs (arrow).
19. Coat the lower thrust bearing (7) with oil and insert
into the crankshaft bearing cap so that the oil
grooves are facing the crank webs (arrow).
Notice
The retaining lugs should be positioned in the
grooves (arrow).