SSANGYONG OM600 User manual

SECTION 1B3
OM600ENGINEMECHANICAL
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
willhelppreventpersonalinjuryanddamagetothevehicle.TheignitionmustalsobeinLOCKunlessotherwise
noted.
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
TABLE OF CONTENTS
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
OilSprayNozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
OilPump . . . . . . . . . . . . . . . . . . . . . . . . . . 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

1B3-2 OM600 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N••
••
•m
28 - 47
30
3 - 7
8 - 18
20 - 34
30
70 - 80
81 - 84
50 - 75
N••
••
•m
10
23
200 / 90°
10
55 / 90°
45 / 90°
25 / 90°
25
N••
••
•m
35 / 90°
N••
••
•m
45 / 90°
Application
Skid Plate Bolt
Drain Plug Bolt
Coolong Fan Shroud Bolt
Control Linkage Nut
Clutch Linkage Cylinder Nut
Exhaust Manifold Bolt
Propeller Shaft Bolt & Nut (Axle)
Propeller Shaft Bolt & Nut (T/C)
Engine Mounting Nut
Application
Cooling Fan Belt Pulley Bolt
Socket Bolt
Tighten The Bolt
End Cover Bolt
Crankshaft Bearing Cap Bolt
Ball Bearing
Camshaft Sprocket Bolt
Oil Pump Sprocket Bolt
Application
Connecting Rod Bolt
Application
12-Sided Stretch Bolt
EngineAssembly
CrankshaftAssembly
Piston
Flywheel
CylinderHead Application
Prechamber Threaded Ring
Cylinder Head Cover Bolt
Fuel Injsction Pipe Nut
Socket Bolt
Fuel Filter Pipe Bolt
Idle Pulley Bolt
Damper Bolt
N••
••
•m
130
10
18
25
25
23
21

OM600 ENGINE MECHANICAL 1B3-3
N••
••
•m
12
25
25
25 / 90°
N••
••
•m
10
10
23
32
4
23
80
23
Application
Stud Bolt
Exhaust Manifold Not
CamShaft Bearing Cap Bolt
12-Sided Bolt (M11)
Application
Oil Pan Bolt-Socket Bolt
Oil Pan Bolt- M6
Oil Pan Bolt- M23
Belt Pulley Bolt
Guide Pulley Bolt
Guide Pulley Bracket Nut
Chain Tensioner
Tesioning Lever Bolt
CylinderHead Application
Camshaft Bearing Cap Bolt
Camshaft Sprocket Bolt
Exhaust Pipe Bolt& Nut
Chain Tensioner
InjectionNozzle
Intake Manifold Not
InjectionNozzlePipeNot
Oil Dipstick Tube Bolt
Screw Plug M18 x 15
N••
••
•m
25
25 / 90°
25
80
40
25
18
10
50
Cam Support & Shaft
TimingCover

1B3-4 OM600 ENGINE MECHANICAL
SPECIAL TOOLS
SPECIAL TOOLS TABLE
603589 00 09 00
Serration Wrench
657589 03 63 00
Sliding Hammer 000589 77 03 00 Box Wrench Insert
601589 00 66 00
Counter Sink
667589 00 23 00
Height Gauge
602589 00 40 00
EngineLock
116589 20 3300
Sliding Hammer
603589 00 40 00
CounterHolder

OM600 ENGINE MECHANICAL 1B3-5
116589 03 0700
T Type Socket Wrench
601589 00 25 00
SPECIAL TOOLS TABLE (Cont’d)
11558934 63 00
601589 00 10 00
Cylinder Head Bolt 102
102589 12 15 00
(
φφ
φφ
φ
17)Drift 102 589 00 15 00
(
φφ
φφ
φ
34)Drift
617589 10 21 00
RISensor 601 589 05 14 00 AssemblyCage

1B3-6 OM600 ENGINE MECHANICAL
601589 08 15 00
Drift
001589 53 21 00
Dial Gauge 601589 03 14 00 Sleeve
SPECIAL TOOLS TABLE (Cont’d)
103589 00 33 00
Puller
601589 07 21 00
Depth Gauge
667589 01 21 00
Fixing Device 366589 00 21 05 Extension
601589 03 43 00
Oil Seal Assembler

OM600 ENGINE MECHANICAL 1B3-7
363589 02 21 00
Dial Gauge Holder
000589 33 33 00
CounterSupport 000 589 04 14 00 Tensioning Strap
SPECIAL TOOLS TABLE (Cont’d)
11658907 15 00
Drift
000589 25 33 00
Internal Extractor
102589 05 33 00
Puller 601589 01 59 00 AssemblingBoard
102589 03 40 00
Magnetic Bar

1B3-8 OM600 ENGINE MECHANICAL
601589 02 59 00
Supporting Bridge
667589 00 31 00
PressLever 104 589 00 37 00 Pliers
SPECIAL TOOLS TABLE (Cont’d)
667584 02 63 00
SupportingBar
116589 06 6300
Magnetic Finger
603589 01 40 00
Holding Wheel 000589 10 68 00 CylinderBrush
601589 02 43 00
Drift

OM600 ENGINE MECHANICAL 1B3-9
601589 02 23 00
Go/No Go Gauge
105589 03 15 00
Drift(for Intake) 6015890615 00 Drift(forExhaust)
SPECIAL TOOLS TABLE (Cont’d)
601589 05 15 00
Drift(for Intake)
103589 02 15 00
Drift(forExhaust)
346589 00 63 00
Super Cooling Box 000589 21 53 00 Reamer (for Intake)
000589 10 53 00
Reamer(for Exhaust)

1B3-10 OM600 ENGINE MECHANICAL
001589 32 21 00
Dial Gauge
001589 53 21 00
Dial Gauge 667589 02 21 00 TDC Pulse Generator
SPECIAL TOOLS TABLE (Cont’d)
124589 15 21 00
Tester
000589 58 43 00
ChainAssembling
Device
201589 13 21 00
Vacuum Tester 617589 04 21 00 Tester
501589 73 21 00
Vacuum Pump

OM600 ENGINE MECHANICAL 1B3-11
000589 14 21 00
Tester
001589 65 09 00
Serration Wrench 116589 02 3400 Thread Bolt
SPECIAL TOOLS TABLE (Cont’d)
000589 00 68 00
Cleaning Set
601589 05 21 00
Looking Screw 617589 08 21 00 PositionSensor
667589 04 63 00
Retaining Plate
601589 00 08 00
Flange

1B3-12 OM600 ENGINE MECHANICAL
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ENGINE ASSEMBLY

OM600 ENGINE MECHANICAL 1B3-13
4. Remove the radiator drain cock and drain the coolant.
Notice
Open the coolant reservoir tank cap.
3. Remove the skid plate.
Installation Notice
Tightening Torque 28 - 47 Nm
5. Remove the drain plug (1) and seal (2) from the cylinder
block and drain the coolant completely.
6. After draining, replace the seal and reinstall the drain plug.
Installation Notice
7. Disconnect the lower coolant hose from the radiator.
Tightening Torque 30Nm
Removal&InstallationProcedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.

1B3-14 OM600 ENGINE MECHANICAL
9. Loosen the bolt and remove the coolant pipe and cooling
fan shroud.
10. Remove the hoses (air intake to intercooler, intercooler to
intake duct).
8. Disconnect the upper coolant hose from the radiator.
Tightening Torque 3 -7 Nm
11. Remove the pipes connected to intercooler.

OM600 ENGINE MECHANICAL 1B3-15
15. Remove the air-conditioner lines from the compressor.
Notice
Evacuate the refrigerant before removal.
12. Remove the hose(air cleaner to turbocharger) with blow
by hose.
13. Disconnect the air cleaner intake hose and remove the air
cleaner cover and element.
14. Disconnect the coolant hose from the water inlet.

1B3-16 OM600 ENGINE MECHANICAL
16. Remove the power steering pump lines.
Notice
Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the feed
pump on injection pump.
18. Vehicle with automatic transmission.
Remove the hydraulic lines (19, 20) from oil cooler (2).
19. Disconnect the engine harness.
20. Disconnect the preheating time relay cable.

OM600 ENGINE MECHANICAL 1B3-17
26. Disconnect the starter motor wires and remove the starter
motor.
21. Remove the fuel lines from the fuel filter and cover the
filter with plug.
22. Disconnect the brake booster hose from vacuum pump.
23. Disconnect the other vacuum lines.
24. Disconnect the ground cable.
25. Disconnect the alternator wires.

1B3-18 OM600 ENGINE MECHANICAL
27. Disconnect the preheating time relay sensor plug.
28. Disconnect the coolant temperature sensor plug.
29. Disconnect the accelerator cable from the control linkage.
Installation Notice
Tightening Torque 8 - 18 Nm
30. Loosen theconnectionofcontrolpressurecable (anarrow)
used in auto transmission.

OM600 ENGINE MECHANICAL 1B3-19
33. Disconnect the exhaust pipe flange from the exhaust
manifold.
Installation Notice
35. Remove the shift control cable.
36. Remove the transmission.
Tightening Torque Axle 70 ~ 80 Nm
T/C 81 ~ 89 Nm
Tightening Torque 20 - 34 Nm
31. Separate the exhaust pipe flange from the turbo charger.
Installation Notice
32. Loosen the installing bolt of clutch release cylinder and
remove the clutch release cylinder.
Installation Notice
Tightening Torque 30Nm
Tightening Torque 30Nm
34. Remove the propeller shaft from the transmission.
Installation Notice

1B3-20 OM600 ENGINE MECHANICAL
37. Loosen the engine mounting bracket nut.
Installation Notice
38. Remove the engine assembly from the vehicle by using a
hoist or crane.
39. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 50 - 75 Nm