engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE MECHANICAL 1B3 -- 161
D AEW OO M Y_2000
Installation Procedure
1. Put the same alignment mark on the new crankshaft
sprocket as in the old sprocket.
Notice
Check the timing chain, camshaft sprocket, injection
pump timing sprocket, oil pump chain and oil pump
sprocket for wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a
drift (21).
Notice
Align the groove of sprocket and woodruff key (ar-
row) exactly.
Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket
(12).
Notice
Align the alignment marks (arrow) on the chain and
sprocket.
4. Install the camshaft sprocket (3).
Tightening Torque25 N∙m (18 lb-ft) + 90_
Notice
Pay attention on the alignment marks and dowel pin
(arrow).

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Notice
If the max. length ’L’ of the stretch bolt exceeds
53.6mm, replace it.
5. Fit the oil pump chain (9) on the crankshaft sprocket
(12) and insert the oil pump sprocket (8) into the oil
pump chain and then install it on the oil pump.
Notice
The curved side of the oil pump sprocket should
face the oil pump.
6. Insert the woodruff key (15).
7. Install the guide rail (16). Attach the spring (17) to
guide rail and to tensioning lever together onto the
bearing pins (5,6).
Notice
Ensure that the spring is correctly located in the
guide rail (arrow).

OM600 ENGINE MECHANICAL 1B3 -- 163
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PISTON
Preceding Work : Removal of cylinder head
Removal of the oil pump
1 Oil Ring
2 2nd Ring
3 Top Ring
4 Snap Ring Replace........................
5 Piston Pin
6Piston
7 Connecting Rod Bushing Check............8 Connecting Rod
9 Connecting Rod Upper Bearing Shell
10 Connecting Rod Lower Bearing Shell
11 Connecting Rod Bearing Cap
12 Connecting Rod Bolt 35N∙m (26 lb-ft)+90_ ...
13 Crankcase
14 Cylinder Bore
Notice
There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replac-
ing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If
not, there would be a unbalancing of engine.

1B3 -- 164 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Service Data
Piston clearanceMax. 0.12 mm
Piston crown protrusion in TDC position0.735 -- 0.965 mm
Connecting rod bushing diameter26.012 -- 26.018 mm
Connecting Rod Bolt Dimensions
ThreadM9 x 1
Stretch shaft(C) diameter (new)7.4-0.1mm
Minimum stretch shaft diameter (C)7.1 mm
Length(L)(new)52-0.3mm
Tools Required
000 589 04 14 00 Tensioning Strap
001 589 53 21 00 Dial Gauge
363 589 02 21 00 Dial Gauge Holder

OM600 ENGINE MECHANICAL 1B3 -- 165
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Removal Procedure
1. Remove combustion residues from the cylinder
bores.
2. Remove the connecting rod bolts (12) and then re-
move the connecting rod bearing caps(11).
3. Remove the connecting rod bearing shells (9, 10).
Notice
Be careful not mix the bearing caps and shells each
other.
4. Remove the piston (6) and connecting rod (8).
5. Remove the snap ring (4) and pull out the piston pin
(5).
6. Separate the piston and connecting rod.

1B3 -- 166 OM600 ENGINE MECHANICAL
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Installation Procedure
1. Fit the piston onto the connecting rod so that the ar-
row (15) and the locking slot (16) are facing in direc-
tion of the vehicle.
2. Coat the piston pin (15) with engine oil and insert it
by hand.
Notice
Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (ar-
row).
4. Check the piston rings (1, 2, 3) and replace them if
necessary.
5. Install and arrange the piston rings to be evenly
120_from each ends gap.

OM600 ENGINE MECHANICAL 1B3 -- 167
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6. Coat the cylinder bore, connecting rod bearing jour-
nal, connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap
(7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a
wooden stick (18).
Notice
The arrow on the piston crown must point toward the
front of vehicle.
9. Insert the connecting rod bearing shells (9, 10).
Notice
Be careful of the difference in upper and lower bear-
ing shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice
Position so that the retaining lugs are on the same
side of the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connect-
ing rod bolts.
Limit ’C’7.1mm

1B3 -- 168 OM600 ENGINE MECHANICAL
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12. Coat the bolts (12) with oil and then tighten the bolts.
Tightening Torque40 N∙m (30 lb-ft) + 90_
13. Rotate the crankshaft and check axial clearance be-
tween the connecting rod and crankshaft.
14. Measure clearance between the piston crown and
cylinder
StandardMax. 0.12mm
15. Position the piston at TDC and measure the dis-
tance between the piston crown and the crankcase
surface.
StandardMax. 0.965 mm
Notice
Measure at points marked.
Dial Gauge 001 589 00 53 21
Dial Gauge Holder 363 589 02 21 00

OM600 ENGINE MECHANICAL 1B3 -- 169
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OIL FILTER
1 Nut 25 N∙m (18 lb-ft) ......................
2 Oil Filter Cover...........................
3 O -- Ring Replace..........................
4 Oil Filter Element Replace If necessary.....
5 Oil Filter Housing6 Bolt (M8) 10 N∙m(89lb-in) ................
7 Oil Pressure Switch
8 Gasket
9Bolt 25N∙m (18 lb-ft) .....................

1B3 -- 170 OM600 ENGINE MECHANICAL
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Remeval & Installation Procedure
1. Remove the oil filter cover and then drain the oil.
2. Remove the oil pressure switch line.
3. Remove the oil filter housing.
4. Clean the sealing surface.
5. Installation should follow the removal procedure in
the reverse order.