1997 SSANGYONG KORANDO service

GENERAL ENGINE INFORMATION 1A3 -- 11
D AEW OO M Y_2000
COMPRESSION PRESSURE TEST
1 Test Adapter
2 Flexible Connector
3 Compression Pressure Recorder
Service Data
Normal Compression Pressure28bar
Minimum Compression PressureApprox.18bar
Permissible Pressure Difference Between Individual CylindersMax. 3bar
DEngine at normal operating temperature of 80_C
Tools Required
000 589 65 09 00 Socket
001 589 73 21 00 Hand Vacuum Pump

GENERAL ENGINE INFORMATION 1A3 -- 15
D AEW OO M Y_2000
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many ma-
chined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten-- thousanths of an
inch. When any internal engine parts are serviced, care
and cleanliness are important. A liberal coating of en-
igne oil should be applied to friction areas during assem-
bly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part fo the repair proce-
dure. This is considered standard shop practice even if
not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be
installed in the same locations, and with the same mat-
ing surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnectcables may result in damage to wire harness or other
electrical parts.
ON-- ENGINE SERVICE
Caution: Disconnect the negative battery cable be -
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnect -
ing this cable will help prevent personal injury and
damage to the vehicle. The ignition must also be in
LOCK unless otherwise noted.
Notice:Any time the air cleaner is removed, the intake
opening should be covered. Thiswill protect against ac-
cidental entrance of foreign material, which could follow
the intake passage into the cylinder and cause exten-
sive damage when the engine is started.

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.............

1B3 -- 12 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
MAINTENANCE AND REPAIR
ON -- VEHICLE SERVICE
ENGINE ASSEMBLY

OM600 ENGINE MECHANICAL 1B3 -- 35
D AEW OO M Y_2000
TDC (TDC SENSOR BRACKET) SETTING
Preceding Work : Removal of No.1 cylinder prechamber
1 Measuring Device
2 Dial Gauge
3 Cylinder Head
4 Piston Set at TDC........................
Tools Service
001589322100 DialGauge
601 589 07 21 00 Depth Gauge
667589012100 FixingDevice
Notice
DThe TDC sensor bracket must be adjusted in case
of followings.
DWhen replacing the TDC sensor bracket.
DWhen replacing the crankshaft, the hub or the
vibration damper.
DlWhen replacing or installing the timing case cover.
DAfter engine overhauling.
* If the cylinder head is removed, the measuring pin of
the dial gauge can be positioned on the piston
crown.
This is done by placing the magnetic dial holder on
the mating surface of the crankcase.

1B3 -- 84 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Thrust Washer and Bearing Arrangement
OM662LA Engine
3 Crankshaft Main Bearing Shells (Upper)
4 Thrust Bearings (Upper)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)A Radial Bearings
B Radial and Axial Bearings (Thrust Bearing)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.

OM600 ENGINE MECHANICAL 1B3 -- 85
D AEW OO M Y_2000
OM661LA Engine
3 Crankshaft Main Bearing Shells (Upper)
4 Thrust Bearings (Upper)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)A Radial Bearings
B Radial and Axial Bearings (Thrust Bearing)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.

OM600 ENGINE MECHANICAL 1B3 -- 105
D AEW OO M Y_2000
VALVE SPRINGS CHECK
Preceding Work : Removal of valve spring
1 Valve Spring2 Spring Scale
Service Data
OuterdiameterWirediameterFreelengthAt preloadedOuterdiameterWirediameterFreelengthLengthTension (new)Limit
33.1 mm4.20 mm50.0 mm27 mm680 -- 740 N612 N