SSANGYONG OM600 Service Manual
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
1B3-2 OM600 ENGINE MECHANICAL
SPECIFICA TIONS
F ASTENER TIGHTENING SPECIFICATIONS
Engine Assembly
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
Crankshaft Assembly
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
••
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
Piston
Application
Connecting Rod Bolt
Flywheel
Application
12-Sided Stretch Bolt
Cylinder Head
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
••
35 / 90°
••
N
•m
••
45 / 90°
••
N
•m
••
130
10
18
25
25
23
21
Cylinder Head
OM600 ENGINE MECHANICAL 1B3-3
Application
Camshaft Bearing Cap Bolt
Camshaft Sprocket Bolt
Exhaust Pipe Bolt& Nut
Chain Tensioner
Injection Nozzle
Intake Manifold Not
Injection Nozzle Pipe Not
Oil Dipstick Tube Bolt
Screw Plug M18 x 15
Cam Support & Shaft
Application
Stud Bolt
Exhaust Manifold Not
CamShaft Bearing Cap Bolt
12-Sided Bolt (M11)
Timing Cover
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
••
N
•m
••
25
25 / 90°
25
80
40
25
18
10
50
••
N
•m
••
12
25
25
25 / 90°
••
N
•m
••
10
10
23
32
4
23
80
23
1B3-4 OM600 ENGINE MECHANICAL
SPECIAL TOOLS
SPECIAL TOOLS TABLE
603 589 00 09 00
Serration Wrench
657 589 03 63 00
Sliding Hammer
601 589 00 66 00
Counter Sink
603 589 00 40 00
Counter Holder
000 589 77 03 00
Box Wrench Insert
602 589 00 40 00
Engine Lock
667 589 00 23 00
Height Gauge
116 589 20 33 00
Sliding Hammer
OM600 ENGINE MECHANICAL 1B3-5
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
φφ
φ
φφ
(
17) Drift
1 15 589 34 63 00
601 589 00 25 00
102 589 00 15 00
φφ
φ
φφ
(
34) Drift
617 589 10 21 00
RI Sensor
601 589 05 14 00
Assembly Cage
1B3-6 OM600 ENGINE MECHANICAL
SPECIAL TOOLS TABLE (Cont’d)
601 589 08 15 00
Drift
001 589 53 21 00
Dial Gauge
601 589 07 21 00
Depth Gauge
103 589 00 33 00
Puller
601 589 03 14 00
Sleeve
601 589 03 43 00
Oil Seal Assembler
667 589 01 21 00
Fixing Device
366 589 00 21 05
Extension
OM600 ENGINE MECHANICAL 1B3-7
SPECIAL TOOLS TABLE (Cont’ d)
363 589 02 21 00
Dial Gauge Holder
000 589 33 33 00
Counter Support
000 589 25 33 00
Internal Extractor
1 16 589 07 15 00
Drift
000 589 04 14 00
Tensioning Strap
102 589 03 40 00
Magnetic Bar
102 589 05 33 00
Puller
601 589 01 59 00
Assembling Board
1B3-8 OM600 ENGINE MECHANICAL
SPECIAL TOOLS TABLE (Cont’d)
601 589 02 59 00
Supporting Bridge
667 589 00 31 00
Press Lever
116 589 06 63 00
Magnetic Finger
667 584 02 63 00
Supporting Bar
104 589 00 37 00
Pliers
601 589 02 43 00
Drift
603 589 01 40 00
Holding Wheel
000 589 10 68 00
Cylinder Brush
OM600 ENGINE MECHANICAL 1B3-9
SPECIAL TOOLS TABLE (Cont’ d)
601 589 02 23 00
Go/No Go Gauge
105 589 03 15 00
Drift (for Intake)
103 589 02 15 00
Drift (for Exhaust)
601 589 05 15 00
Drift (for Intake)
601 589 06 15 00
Drift (for Exhaust)
000 589 10 53 00
Reamer (for Exhaust)
346 589 00 63 00
Super Cooling Box
000 589 21 53 00
Reamer (for Intake)
1B3-10 OM600 ENGINE MECHANICAL
SPECIAL TOOLS TABLE (Cont’ d)
001 589 32 21 00
Dial Gauge
001 589 53 21 00
Dial Gauge
000 589 58 43 00
Chain Assembling
Device
124 589 15 21 00
T ester
667 589 02 21 00
TDC Pulse Generator
501 589 73 21 00
Vacuum Pump
201 589 13 21 00
Vacuum Tester
617 589 04 21 00
T ester
OM600 ENGINE MECHANICAL 1B3-11
SPECIAL TOOLS TABLE (Cont’ d)
000 589 14 21 00
T ester
001 589 65 09 00
Serration Wrench
000 589 00 68 00
Cleaning Set
601 589 00 08 00
Flange
116 589 02 34 00
Thread Bolt
667 589 04 63 00
Retaining Plate
601 589 05 21 00
Looking Screw
617 589 08 21 00
Position Sensor
1B3-12 OM600 ENGINE MECHANICAL
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the skid plate.
Installation Notice
T ightening Torque 28 - 47 Nm
4. Remove the radiator drain cock and drain the coolant.
Notice
Open the coolant reservoir tank cap.
OM600 ENGINE MECHANICAL 1B3-13
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
Tightening Torque 30 Nm
7. Disconnect the lower coolant hose from the radiator.
1B3-14 OM600 ENGINE MECHANICAL
8. Disconnect the upper coolant hose from the radiator.
9. Loosen the bolt and remove the coolant pipe and cooling
fan shroud.
Tightening Torque 3 -7 Nm
10. Remove the hoses (air intake to intercooler, intercooler to
intake duct).
11. Remove the pipes connected to intercooler.
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.
OM600 ENGINE MECHANICAL 1B3-15
14 . Disconnect the coolant hose from the water inlet.
15 . Remove the air-conditioner lines from the compressor.
Notice
Evacuate the refrigerant before removal.
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.
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.
OM600 ENGINE MECHANICAL 1B3-17
24 . Disconnect the ground cable.
25 . Disconnect the alternator wires.
26. Disconnect the starter motor wires and remove the starter
motor.
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 the connection of control pressure cable (an arrow)
used in auto transmission.
31 . Separate the exhaust pipe flange from the turbo charger.
Installation Notice
Tightening Torque 30 Nm
32 . Loosen the installing bolt of clutch release cylinder and
remove the clutch release cylinder.
Installation Notice
Tightening Torque 20 - 34 Nm
OM600 ENGINE MECHANICAL 1B3-19
33. Disconnect the exhaust pipe flange from the exhaust
manifold.
Installation Notice
Tightening Torque 30 Nm
34 . Remove the propeller shaft from the transmission.
Installation Notice
Tightening Torque
35 . Remove the shift control cable.
36 . Remove the transmission.
Axle 70 ~ 80 Nm
T/C 81 ~ 89 Nm
1B3-20 OM600 ENGINE MECHANICAL
37 . Loosen the engine mounting bracket nut.
Installation Notice
Tightening Torque 50 - 75 Nm
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.
POLY V-BELT
OM600 ENGINE MECHANICAL 1B3-21
1 Nut............................................................. 23Nm
2 Tensioning Lever
3 Bolt
4 Spring
5 Tensioning Lever
6 Poly V-Belt
1B3-22 OM600 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the nut.
2. Push the tensioning lever in direction of arrow with a rod
(F12 ´ 180mm) and pull out the bolt to the rear.
3. Push back the tensioning lever (arrow direction) to release
the spring tension and remove the belt.
4. Install the poly V-belt beginning at the tensioning pulley (7).
7 Tensioning Pulley
8 Crankshaft
9 Alternator
10 Coolant Pump
11 Guide Pulley
12 Power Steering Pump
13 Aircon. Compressor
Lengthe of Belt
With Air Conditioner
2,100 mm
Length (L)
Without Air Conditioner
2,040 mm
TENSIONING DEVICE
Preceding Work : Removal of cooling fan
OM600 ENGINE MECHANICAL 1B3-23
1 Bolt ............................................................ 21Nm
2 Damper
3 Nut............................................................. 21Nm
4 Tensioning Lever
5 Guide Rail Pin
6 Bolt
7 Poly V-Belt
8 Belt Pulley
9 Bolt ............................................................ 10Nm
10 Tensioning Pulley
11 Socket Bolt ................................................ 29Nm
12 Closing Cover
13 Washer
14 Tensioning Lever
15 Fit Bolt ..................................................... 100Nm
16 Closing Cover
17 Spring
18 Bolt ............................................................ 20Nm
1B3-24 OM600 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the nut.
Installation Notice
Tightening Torque 10 Nm
2. Push the tensioning lever in direction of arrow with a rod
( F12 ´ 180mm ) and push out the bolt to the rear.
3. Push back the tensioning lever to release the spring tension
and remove the belt.
4. Remove the bolt (9) and then remove the belt pulley (8).
5. Remove the bolt (1, 18) and take off the damper (2).
Notice
Pay attention to installation position of the damper.
6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).
Installation Notice
Insert spring (17) with color coding (blue/violet) facing up.
8. Pry off the closing cover (12) and remove the socket bolt
(11) and then remove the tensioning pulley (10).
Installation Notice
Tightening Torque 29 Nm
OM600 ENGINE MECHANICAL 1B3-25
9. Pry off the closing cover (16) and remove the fit bolt (15).
10 . Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice
Apply Loctite on thread of fit bolt.
Tightening Torque 100 Nm
12. Installation should follow the removal procedure in the
reverse order.
1B3-26 OM600 ENGINE MECHANICAL
POLY V-BELT ALIGNMENT & INSPECTION
Without Air Conditioner
With Air Conditioner
Inspection Procedure
l Mark poly V-belt at a clearly visible point with chalk.
l Rotate the engine and check the belt.
Notice
If one of the following types of damage is found, replace
the belt.
1. Rubber lumps in the base of rips.
2. Dirt or grit ingrained.
OM600 ENGINE MECHANICAL 1B3-27
3. Pointed rips.
4. Belt cord visible in the base of rips.
5. Cord torn out at the side.
6. Outer cords frayed.
1B3-28 OM600 ENGINE MECHANICAL
7. Belt detached from the base of rip.
8. Splits across the rips.
9. Sections of rip torn out.
10 . Splits across several rips.
11. Splits across the back.
PRECHAMBER
Preceding Work : Removal of glow plug
Removal of fuel injection nozzle
OM600 ENGINE MECHANICAL 1B3-29
1 Threaded Ring ........................................ 130 Nm
2 Prechamber
3 Cylinder Head
1B3-30 OM600 ENGINE MECHANICAL
Tools Required
603 589 00 09 00 Serration Wrench
667 589 03 63 00 Sliding Hammer
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 sealing surfaces in
the cylinder head must be remachined.
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