engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 111
D AEW OO M Y_2000
6. Remove the spring retainer(3) and spring (4).
7. Check the valve spring and replace if necessary.
8. Insert valve spring (4) with the color coding (arrow)
facing down and insert valve spring Retainer(3).
9. By press the spring retainer(3) with press lever (90),
install the valve cotters with magnetic finger (10).
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00
10. Remove the supporting bar.
11. Remove the holding wheel (7) from the timing chain
(5).
Holding Wheel 603 589 01 40 00
13. Coat the valve tappet with oil and install it.
Magnetic Bar 102 589 03 40 00

1B3 -- 112 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
VALVE STEM SEALS
Preceding Work : Removal of camshaft
1 Valve Tappet
2 Valve Cotters
3 Spring Retainer4 Valve Spring Check, replace if necessary....
5 Valve Stem Seal
6Valve
Notice
Remove the valve stem seals when the piston is posi-
tioned at TDC.

OM600 ENGINE MECHANICAL 1B3 -- 113
D AEW OO M Y_2000
Tools Required
667 589 00 31 00 Press Lever
104 589 00 37 00 Pliers
102 589 03 40 00 Magnetic Lifter
603 589 01 40 00 Holding Wheel
601 589 02 43 00 Drift
116 589 06 63 00 Magnetic Finger
667 589 02 63 00 Supporting Bar
A: Intake valve stem seal B: Exhaust valve stem seal



















































































































































































































































































































































































































































































































































Intake valve stem seal
































































































































































































































































Exhaust valve stem seal
ChamferOffsetAll round
Inner diameter ’d’7.3 mm8.2 mm
ColorBrownGreen
Wire ringBlackYellow

1B3 -- 114 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Replacement Procedure
1. Remove the valve tappet (1) with magnetic lifter.
Notice
Place the valve tappets upside down (open end up-
ward).
Magnetic Lifter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain
(11).
Holding Wheel 603 589 01 40 00
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
Supporting Bar 667 589 02 63 00
5. Using press lever (9), press the spring retainer(3)
downward and remove the valve collets with mag-
netic finger (10).
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00

OM600 ENGINE MECHANICAL 1B3 -- 115
D AEW OO M Y_2000
6. Remove the spring retainer(3) and valve spring (4).
7. Remove the valve stem seal (5).
Pliers 104 589 00 37 00
8. Insert the cap (12) onto the valve (6) and install the
new valve stem seal (5) and then remover the cap.
Drift 601 589 02 43 00
9. By pressing the spring seat with press lever (9),
install the valve cotters(2) with magnetic finger (10).
Notice
Be careful not to damage guide bore of the valve
tappet.
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00

1B3 -- 116 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
CHECK AND REPLACEMENT OF VALVE GUIDES
Preceding Work : Removal of cylinder head
Removal of valve spring
Removal of valve
1 Cylinder Head
2 Valve Guide3 Valve Seat Ring
a Basic Bore Diameter
Service Ddata




















































































































































































Item








































































































































Outer Diameter
’D’




































































































Color Code




























































































































Basic Bore
Diameter ’a’





















































































Overlap
’D’ -- ’a’































































































































Valve Guide
InnerDiameter’A’



































































Length
’L’
IntakeRepair size 114.251Red14.200 -- 14.2110.029 --80008030395IntakeRepair size 214.440 -- 14.451White14.400 -- 14.411
0.029--
0.0518.000 -- 8.03039.5
ExhaustRepair size 114.240 -- 14. 251Red14.200 -- 14.2110.029 --90009050377ExhaustRepair size 214.440-- 14.451White14.400 -- 14.411
0.029--
0.0519.000 -- 9.05037.7

OM600 ENGINE MECHANICAL 1B3 -- 117
D AEW OO M Y_2000
Notice
Measure center (arrow) of the valve guide and if the
inner diameter ’A’ exceeds standard value, replace
the guide.
Tools Required
000 589 10 53 00 Reamer (for Exhaust)
000589106800CylinderBrush
000 589 21 53 00 Reamer (for Intake)
102 589 00 23 00 GO / NO GO Gauge (for Intake)
103589021500Drift(forExhaust)
103589031500Drift(forIntake)
117 589 03 25 00 GO / NO GO Gauge (for Exhaust)
346 589 00 63 00 Super Cooling Box
601 589 02 23 00 GO/NO GO Gauge
601589051500Drift(forIntake)
601589061500Drift(forExhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves






































































































































































































Valve Seat







































































































































































































Broaching Tool No.




































































































































































































Guide Sleeve Tool No.







































































































































































































Guide Sleeve Side
Intake115 589 00 53 00102 589 00 63 00B
Exhaust
115589005300
(14.2 mm)
102589006300
102 589 08 63 00B
Intake115 589 01 53 00601589156300A
Exhaust
115589015300
(14.4 mm)601 589 15 63 00B

1B3 -- 118 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Checking
1. Thoroughly clean the valve guide bore using a cylin-
der brush.
Cylinder Brush 000 589 10 68 00
2. Insert the GO/NO GOgauge into the valve guide
bore. If the NO GO side is inserted fully, replace the
valve guide (Intake 8mm, Exhaust 9mm).
GO/NO GO Gauge 601 589 02 23 00
Replacement Procedure
1. Drive out the valve guide (2) by using a drift (5).
Notice
The valve guide must be driven out upward of the
cylinder head.
Drift (for Intake) 103 589 03 15 00
Drift (for Exhaust) 103 589 02 15 00
2. Thoroughly clean the basic bore by using a cylinder
brush.
Cylinder Brush 000 589 10 68 00
3. Check the basic bore in cylinder head for scoring
marks and ream to next repair size if necessary.

OM600 ENGINE MECHANICAL 1B3 -- 119
D AEW OO M Y_2000
4. Reaming basic bore in cylinder head (repair size).
-- Thoroughly remove carbon deposits in cylinder
head.
Notice
Particularly remove the insides of the valve seat
rings.
-- Remove the elevation (arrow) of intake valve seat
rings.
-- Select correct broaching tool and guide sleeve
(refer to the table).
Notice
Before broaching work, the broaching tool must be
cleared of swarf with a stiff plastic brush.
-- Lubricate the basic bore, guide sleeve and
broaching tool with petroleum.
-- Push broaching tool (6) in broaching direction (ar-
row) into the guide sleeve (7) far enough so that
the first cut of the broaching tool is positioned in
the basic bore when guide sleeve is fitted onto
the valve seat ring (3).
6. Broaching tool
7. Guide sleeve
See the ’standard data’
-- Center the guide sleeve (7) in the valve seat ring
(3) by turning.
-- Knock through the broaching tool (6) with a plas-
tic hammer (approx. 25g). and aluminum drift.

1B3 -- 120 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
5. Heat the cylinder head (1) in a wear tank to approx.
80_C.
6. Cool down the new valve guide (2) with liquid nitro-
gen.
Notice
Do not touch the cooled valve guide by hand.
Super Cooling box 346 589 00 63 00
7. Drive in new valve guide with drift (8) until the wire
ring makes contact.
Notice
Thevalveguidemustbedriveninfromthecylinder
head cover.
Drift (for Intake) 601 589 05 15 00
Drift (for Exhaust) 601 589 06 15 00
8. Check the valve guide bore with GO / NO GO gauge
(9).
The GO side (marked ’0’) should just still drop. If the
GO side cannot be inserted, the bore of valve guide
should be reamed.
Notice
Perform the check only on cooled down cylinder
head.
GO / NO GO Gauge (for Intake) 102 589 00 23 00
GO / NO GO Gauge (for Exhaust) 117 589 03 23 00