1997 SSANGYONG KORANDO head

OM600 ENGINE MECHANICAL 1B3 -- 107
D AEW OO M Y_2000
Tools Required
102 589 03 40 00 Magnetic Bar
116 589 06 63 00 Magnetic Finger
601589015900AssemblingBoard
601 589 02 59 00 Supporting Bridge
667589003100PressLever
Removal & Installation Procedure
1. Remove the nuts (8) uniformly and then remove the
washer (7), exhaust manifold (9) and gasket.
Installation Notice
Check the stud bolt (6) for damage and replace if
necessary.
Tightening Torque12 N∙m (106 lb-in)
Replace the gasket and tighten the nuts (8).
Tightening Torque25 N∙m (18 lb-ft)
2. Install the assembling board (11) to the cylinder
head with 4 cylinder head blots (10).
Assembling Board 601 589 01 59 00
3. Pull out the valve tappet (1) with magnetic bar (12).
Notice
Place the valve tappets upside down (open end up-
ward).
Magnetic Bar 102 589 03 40 00
4. Install the supporting bridge (13) on the cylinder
head (5).
Supporting Bridge 601 589 02 59 00

OM600 ENGINE MECHANICAL 1B3 -- 109
D AEW OO M Y_2000
VALVE SPRINGS (CYLINDER HEAD INSTALLED)
Preceding Work : Removal of camshaft
1 Valve Tappet
2 Valve Cotters
3 Spring Retainer4 Valve Spring Check, replace if necessary....
5 Timing Chain
6 Cylinder Head
Notice
Remove the valve springs only when the piston is at
TDC.
Tools Required
102 589 03 40 00 Magnetic Bar
116 589 06 63 00 Magnetic Finger
603 589 01 40 00 Holding Wheel
667 589 00 31 00 Press Lever
667 589 02 63 00 Supporting Bar

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
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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

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

1B3 -- 122 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
VALVE SEAT RINGS
Preceding Work : Removal of valve
Checking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head
2 Valve Seat Ring
3 Valve Guide
A Height (Cylinder Head Upper / Lower Surface)
B Height (cylinder Head Cover Surface -- Seat of
Valve Seat Ring)D Valve Seat Ring Outer Diameter
D1 Valve Seat Ring Inner Diameter
D2 Basic Bore Diameter
H Height of Valve Seat Ring
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Intake







































































































































































































































































Exhaust
D240.000 -- 40.016 mm37.000 -- 37.016 mm
D40.084 -- 40.100 mm37.084 -- 37.100 mm
D133.400 -- 33.600 mm30.400 -- 30.600 mm
H6.955 -- 7.045 mm6.955 -- 7.045 mm
Overlap U=D-- D20.068 -- 0.100 mm0.068 -- 0.100 mm
B133.4 mm133.4 mm
A142.5 mm142.5 mm

OM600 ENGINE MECHANICAL 1B3 -- 123
D AEW OO M Y_2000
Commercial Tools
Cylinder Head Clamping DeviceHunger
D-- 8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning ToolHunger
D-- 8000 München 70
Ty p e VDS 1 A
Order No. 236 03 308
Ring Seat Turning ToolHunger
D-- 8000 München 70
Type RDS 1
Order No. 219 00 100
Pneumatic Removal / Installation Device
(Drift : 8mm, 9mm, 14mm)Hunger
D-- 8000 München 70
Type PVM 1
Tensioning HeadHunger
D-- 8000 München 70
Order No. 250 15 250
Cutting Tool for Recessing GroovesHunger
D-- 8000 München 70
Order No. 217 93 601
Test Set for ValvesHunger
D-- 8000 München 70
Order No. 216 69 210
Internal Dial Gauge (Range : 25 -- 60mm)Mahr
D-- 7300 Esslingen
Order No. 844
External Micrometer (Range : 25 -- 60mm)Mahr
D-- 7300 Esslingen
Order No. 40 S
Electrically Heated Water TankOtto Dürr
D-- 7123 Sachsenherm -- Ochsenbach