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SSANGYONG OM600 - User Manual

SSANGYONG OM600
186 pages
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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.
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
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
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SSANGYONG OM600 Specifications

General IconGeneral
BrandSSANGYONG
ModelOM600
CategoryEngine
LanguageEnglish

Summary

Specifications

Fastener Tightening Specifications

Torque specifications for various engine components and fasteners.

Cylinder Head

Details related to cylinder head fasteners and components.

Cam Support & Shaft

Specifications for camshaft support and shaft components.

Timing Cover

Specifications related to the timing case cover and its associated bolts.

Special Tools

Special Tools Table

A comprehensive list of specialized tools required for engine service, with part numbers.

Maintenance and Repair

On-Vehicle Service

Procedures for servicing the engine while it is installed in the vehicle.

Engine Assembly

Details on the assembly process of the engine components.

Poly V-Belt

Information and procedures related to the removal and installation of the Poly V-belt.

Tensioning Device

Detailed explanation of the V-belt tensioning device and its components.

Poly V-Belt Alignment & Inspection

Guidelines for inspecting and aligning the Poly V-belt for proper function.

Prechamber

Procedures for the removal, inspection, and installation of the prechamber.

Milling of Prechamber Sealing Surface

Steps for remachining the prechamber sealing surface on the cylinder head.

TDC (TDC Sensor Bracket) Setting

Procedures for setting the Top Dead Center sensor bracket for engine timing.

Cylinder Head

Comprehensive section covering cylinder head removal, installation, and related procedures.

Timing Case Cover

Instructions for removing and installing the timing case cover and its related parts.

Crankshaft End Cover

Procedures for removing and installing the crankshaft end cover and radial seal.

Vibration Damper and Hub

Steps for removing and installing the vibration damper and hub assembly.

Crankshaft Front Radial Seal

Procedures for replacing the crankshaft front radial seal.

Crankshaft Ball Bearing

Details on removing and installing the crankshaft ball bearing.

Crankshaft

Section covering crankshaft removal, bearing replacement, and measurements.

Flywheel

Procedures for removing, installing, and machining the engine flywheel.

Machining of Flywheel

Guidelines for machining the flywheel clutch surface and checking runout.

Flywheel Ring Gear

Steps for replacing the flywheel ring gear.

Hydraulic Valve Clearance Compensation Element Check

Procedure for checking the hydraulic valve clearance compensation elements.

Valve Tappets

Information on removing, inspecting, and installing valve tappets.

Valve Spring Check

Service data and procedures for checking valve springs.

Valve Springs (Cylinder Head Removed)

Steps for removing and installing valve springs with the cylinder head off.

Valve Springs (Cylinder Head Installed)

Procedures for removing and installing valve springs with the cylinder head in place.

Valve Stem Seals

Detailed instructions for removing and replacing valve stem seals.

Check and Replacement of Valve Guides

Procedures for checking and replacing valve guides.

Valve Seat Rings

Service data and procedures for checking and replacing valve seat rings.

Check and Machining of Valves

Guidelines for checking valve dimensions and machining them.

Machining of Valve Seat

Procedures for machining the valve seat angles and width.

Camshaft Timing Test

Method for testing and verifying camshaft timing.

Camshaft

Procedures for removing and installing the camshaft, including bearing caps.

Chain Tensioner

Information on the chain tensioner and its installation.

Timing Chain

Steps for replacing the engine timing chain.

Tensioning Rail

Details on the tensioning rail and its plastic coating.

Cylinder Head Guide Rail

Procedures for removing and installing the cylinder head guide rail.

Crankshaft Sprocket

Instructions for removing and installing the crankshaft sprocket.

Piston

Section covering piston removal, installation, and related measurements.

Oil Filter

Procedures for removing and installing the oil filter and its housing.

Oil Pan

Steps for removing and installing the engine oil pan.

Oil Spray Nozzle

Details on the oil spray nozzle and its removal.

Oil Pump

Procedures for removing and installing the engine oil pump.

Unit Repair

Various repair procedures for engine components.

Cylinder Head Pressure Leakage Test

Method for testing the cylinder head for pressure leaks.

Facing Cylinder Head Mating Surface

Procedures for machining the cylinder head mating surface.

Replacement of Crankcase Core Plug

Instructions for replacing the crankcase core plugs.

Facing Crankcase Contacting Surface

Procedures for machining the crankcase contacting surfaces.

Oil Gallery Steel Ball

Procedures for installing and checking the oil gallery steel balls.

Cylinder Bore Measurement

How to measure cylinder bore diameter and check for wear.

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