1997 SSANGYONG KORANDO head

GENERAL ENGINE INFORMATION 1A3 -- 13
D AEW OO M Y_2000
CYLINDER PRESSURE LEAKAGE TEST
1 Connector
2 Connection Piece
3 Connection Hose
Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80_C)
At Whole EngineMax. 25 %
At Valve and Cylinder Head GasketMax. 10 %
At Piston and Piston RingMax. 20 %
Commercial Tools
Cylinder Pressure Leakage testerBOSCH, EFAW 210 A or SUN CLT 228
Connection PieceBOSCH order no. 1 687 010 016

D AEW OO M Y_2000
SECTION 1B3
OM600 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Specifications 1B3 -- 2............................
Fastener Tightening Specifications 1B3 -- 2..........
Special Tools 1B3 -- 4.............................
Special Tools Table 1B3-- 4.......................
Maintenance and Repair 1B3 -- 12..................
On-- Vehicle Service 1B3-- 12........................
Engine Assembly 1B3-- 12........................
Poly V-- Belt 1B3 -- 21.............................
Tensioning Device 1B3-- 23.......................
Poly V-- Belt Alignment & Inspection 1B3-- 26........
Prechamber 1B3-- 29............................
Milling of Prechamber Sealing Surface 1B3 -- 32.....
TDC (TDC Sensor Bracket) Setting 1B3 -- 35........
Cylinder Head 1B3-- 37...........................
Timing Case Cover 1B3 -- 63......................
Crankshaft End Cover 1B3-- 71...................
Vibration Damper and Hub 1B3-- 74...............
Crankshaft Front Radial Seal 1B3-- 80.............
Crankshaft Ball Bearing 1B3-- 82..................
Crankshaft 1B3-- 83.............................
Flywheel 1B3 -- 93...............................
Machining of Flywheel 1B3-- 97...................
Flywheel Ring Gear 1B3 -- 98......................
Hydraulic Valve Clearance Compensation
Element Check 1B3-- 101.........................
Valve Tappets 1B3-- 103..........................
Valve Spring Check 1B3-- 105.....................Valve Springs (Cylinder Head Removed) 1B3-- 106..
Valve Springs (Cylinder Head Installed) 1B3-- 109...
Valve Stem Seals 1B3-- 112......................
Check and Replacement of Valve Guides 1B3-- 116..
Valve Seat Rings 1B3-- 122.......................
Check and Machining of Valves 1B3-- 127..........
Machining of Valve Seat 1B3-- 132.................
Camshaft Timing Test 1B3-- 137...................
Camshaft 1B3-- 139.............................
Chain Tensioner 1B3-- 145........................
Timing Chain 1B3-- 147...........................
Tensioning Rail 1B3-- 151.........................
Cylinder Head Guide Rail 1B3-- 152................
Timing Case Cover Guide Rail 1B3-- 156...........
Crankshaft Sprocket 1B3-- 158....................
Piston 1B3-- 163.................................
Oil Filter 1B3-- 169...............................
Oil Pan 1B3-- 171................................
Oil Spray Nozzle 1B3-- 174.......................
Oil Pump 1B3-- 175..............................
Unit Repair 1B3 -- 177............................
Cylinder Head Pressure Leakage Test 1B3-- 177....
Facing Cylinder Head Mating Surface 1B3 -- 178.....
Replacement of Crankcase Core Plug 1B3-- 180.....
Facing Crankcase Contacting Surface 1B3 -- 182....
Oil Gallery Steel Ball 1B3-- 183....................
Cylinder Bore Measurement 1B3-- 187.............

OM600 ENGINE MECHANICAL 1B3 -- 3
D AEW OO M Y_2000
Cylinder Head
ApplicationNSmLb-- FtLb-- In
Prechamber Threaded Ring13096--
Cylinder Head Cover Bolt10--89
Fuel Injsction Pipe Nut1813--
Socket Bolt2518--
Fuel Filter Pipe Bolt2518--
Idle Pulley Bolt2317--
Damper Bolt2115--
Camshaft Bearing Cap Bolt2518--
Camshaft Sprocket Bolt25 / 90_18 / 90_--
Exhaust Pipe Bolt& Nut2518--
Chain Tensioner8059--
Injection Nozzle4030--
Intake Manifold Not2518--
Injection Nozzle Pipe Not1813--
Oil Dipstick Tube Bolt10--89
Screw Plug M18 x 155037--
Cam Support & Shaft
ApplicationNSmLb-- FtLb-- In
Stud Bolt12--106
Exhaust Manifold Not2518--
CamShaft Bearing Cap Bolt2518--
12-- Sided Bolt (M11)25 / 90_18 / 90_--
Timing Cover
ApplicationNSmLb-- FtLb-- In
Oil Pan Bolt -- Socket Bolt10--89
Oil Pan Bolt--M610--89
Oil Pan Bolt--M232317--
Belt Pulley Bolt3224--
Guide Pulley Bolt4--35
Guide Pulley Bracket Nut2317--
Chain Tensioner8059--
Tesioning Lever Bolt2317--

OM600 ENGINE MECHANICAL 1B3 -- 5
D AEW OO M Y_2000
SPECIAL TOOLS TABLE (Cont’d)
116 589 03 07 00
T Type Socket Wrench
601 589 00 10 00
Cylinder Head Bolt 102
102 589 12 15 00
(φ17) Drift
617 589 10 21 00
RI Sensor
115 589 34 63 00
602 589 00 25 00
102 589 00 15 00
(φ34) Drift
601 589 05 14 00
Assembly Cage

OM600 ENGINE MECHANICAL 1B3 -- 29
D AEW OO M Y_2000
PRECHAMBER
Preceding Work : Removal of glow plug
Removal of fuel injection nozzle
1 Threaded Ring 130 N∙m (96 lb-ft) ...........
2 Prechamber3 Cylinder Head

1B3 -- 30 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
603 589 00 09 00 Serration Wrench
667589036300 SlidingHammer
Removal & Installation Procedure
1. Using the serration wrench (4), remove the threaded
ring (1).
Serration Wrench 603 589 00 09 00
2. Install the sliding hammer into the prechamber.
Sliding Hammer 667 589 03 63 00
3. Remove the perchamber (2).
Notice
After removing the prechamber, cover over the
bores with clean rag.
4. Inspect the prechamber.
Notice
If the prechamber seats in the cylinder head are
leaking or if the prechambers are replaced, the seal-
ing surfaces in the cylinder head must be rema-
chined.

OM600 ENGINE MECHANICAL 1B3 -- 31
D AEW OO M Y_2000
Assembly Procedure
Notice
In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and
fire is broken, it can not be used.
1. Clean the sealing surface of the prechamber.
2. Insert the prechamber into the cylinder head at the
same time aligning the cam on the collar of the pre-
chambers with the slots in the cylinder head.
Notice
If the spacer rings are fitted to the prechambers, the
spacer rings should be replaced with rings of the
same thickness.
Thickness of Spacer
Ring0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the
ring by using the serration wrench.
Tightening Torque130 N∙m (96 lb-ft)

1B3 -- 32 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
MILLING OF PRECHAMBER SEALING SURFACE
1Drift
2 Sleeve
3 Milling Cutter4 Counter Sink (Special Tool -- 601 589 00 66)
5 Cylinder Head
Tools Required
601589006600 CounterSink
667 589 00 23 00 Height Gauge
Milling of the Prechamber Sealing Surface
Notice
The prechamber sealing surface may only be rema-
chined once with the cylinder head fitted. It is essen-
tial to adhere to the specified projection ’C’ of the
prechamber of 7.6 -- 8.1mm.
This ensures that the required clearance exists be-
tween prechamber and piston crown with the piston
in TDC. For this reason, spacer rings should be in-
serted on remachined sealing surfaces.
Thickness of spacers0.3, 0.6, 1.0 mm
If a spacer ring is already fitted, or a marking is
made on the cylinder head, the cylinder head must
be removed and size ’C’ measured if further rema-
chining is necessary on a prechamber sealing sur-
face.