1997 SSANGYONG KORANDO engine

OM600 ENGINE MECHANICAL 1B3 -- 157
D AEW OO M Y_2000
Removal Procedure
1. Pull out the tensioning lever (8) together with the
spring (6) and guide rail (3) far enough until the ten-
sioning lever has moved passed the oil pump chain
(4) and is resting against the crankshaft (5)
2. Pull the tensioning lever (8) off the bearing pin (2)
and carefully remove the spring (6). Remove the
tensioning lever (8) together with the spring (6) and
bushing (7).
3. Remove the guide rail (3).
Installation Procedure
1. Install the guide rail (3). Attach the spring (6) to the
guide rail and to the tensioning lever (8).
Notice
Ensure that the spring is correctly located in the
guide rail (arrow).
2. Push the guide rail, spring, bushing and tensioning
lever together onto the bearing pin (1, 2).

1B3 -- 158 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of timing case cover
1 12-- Sided Stretch Bolt (M11)
Check, 25N∙m (18 lb-ft)+90_ ...............
2 Washer
3 Camshaft Sprocket
4 Timing Chain
5 Bearing Pin
6 Bearing Pin
7OilPump
8 Oil Pump Sprocket
9 Oil Pump Chain10 Washer
11 Bolt 25N∙m (18 lb-ft) ......................
12 Crankshaft Sprocket
13 Crankshaft
15 Key
16 Guide Rail
17 Spring
18 Bushing
19 Tensioning Lever

OM600 ENGINE MECHANICAL 1B3 -- 159
D AEW OO M Y_2000
Special Tools
116 589 07 15 00 Drift
102589053300 Puller
Removal Procedure
1. Pull out the tensioning lever (19) together with the
spring (17) and guide rail (16) far enough until the
tensioning lever has passed the oil pump chain (9)
and is resting against the crankshaft (13).
2. Pull out tensioning lever (19), spring (17) and bush-
ing (18) from the bearing pin (6).
3. Pull out the guide rail (16).
4. Remove the bolt(11) and then remove the washer
(10), oil pump chin (9) and sprocket (8).

1B3 -- 160 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
5. Place alignment marks (arrow) on the timing chain
(4) and crankshaft sprocket (12).
6. Remove the woodruff key(15).
7. Place alignment marks (arrow) on the timing chain
(4) and camshaft sprocket (3).
8. Remove the chain tensioner.
9. Remove the bolt (1) and then remove the washer (2)
and camshaft sprocket (3).
10. Remove the crankshaft sprocket (12) by using a
puller (20).
Puller 102 589 05 33 00

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).

1B3 -- 162 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
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
D AEW OO M Y_2000
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