SsangYong Korando II (1996-2006 year). Manual — part 8
1A1 -- 10 GENERAL ENGINE INFORMATION
DAEWOO MY_2000
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap
4 Vibration Damper
6 Cylinder Pressure Leakage Tester with
Connecting Hose
Permissible Pressure Leakage
At Whole Engine
Max. 25 %
At Valve and Cylinder Head Gasket
Max. 10 %
At Piston and Piston Ring
Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC Mark
OT (TDC)
a (120°)
b (240°)
Cylinder Number
1, 6
2, 5
3, 4
Universal Tool
Cylinder Pressure Leakage Tester
Bosch, EFAW 210A
Sun, CLT 228
GENERAL ENGINE INFORMATION 1A1 -- 11
DAEWOO MY_2000
Leakage Test
1. Warm the engine up to normal operating tempera-
ture.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant
surge tank cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the
scale of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotat-
ing the crankshaft.
9. Connect the connecting hose to tester and measure
the leakage volume after blowing up compressed
air.
Notice: Measure the leakage volume in the completely
opening condition of throttle valve by pulling the accel-
eration cable.
10. Perform the pressure test according to the firing or-
der.
Notice:
Firing Order : 1 -- 5 -- 3 -- 6 -- 2 -- 4
11. Compare the leakage pressure with the specifica-
tions.
1A1 -- 12 GENERAL ENGINE INFORMATION
DAEWOO MY_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-thousandths of an
inch. When any internal engine parts are serviced, care
and cleanliness are important. A liberal coating of enigne
oil should be applied to friction areas during assembly, to
protect and lubricate the surfaces on initial operation.
Proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure. This is con-
sidered 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 mating
surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables 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. This will 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.
DAEWOO MY_2000
SECTION 1B1
M162 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 other-
wise noted.
TABLE OF CONTENTS
Specifications
1B1--2
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications
1B1--2
. . . . . . . . . .
Special Tools
1B1--4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table
1B1--4
. . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Repair
1B1--7
. . . . . . . . . . . . . . . . . . .
On--Vehicle Service
1B1--7
. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly
1B1--7
. . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation System
1B1--14
. . . . . . . . . . . . .
Generator
1B1--16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount
1B1--17
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Poly V--Belt
1B1--18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioning Device
1B1--20
. . . . . . . . . . . . . . . . . . . . . . .
Poly V--Belt Inspection
1B1--21
. . . . . . . . . . . . . . . . . . .
Cylinder Head Cover
1B1--24
. . . . . . . . . . . . . . . . . . . . .
Cylinder Head Front Cover
1B1--26
. . . . . . . . . . . . . . .
Cylinder Head
1B1--28
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Gear Case Cover
1B1--31
. . . . . . . . . . . . . . . . .
Crankshaft Sealing Rear Cover
1B1--33
. . . . . . . . . . .
Belt Pulley and Vibration Damper
1B1--35
. . . . . . . . . .
Crankshaft Front Radial Seal
1B1--38
. . . . . . . . . . . . .
Crankshaft Rear Radial Seal
1B1--40
. . . . . . . . . . . . . .
Crankshaft
1B1--41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel / Driven Plate
1B1--47
. . . . . . . . . . . . . . . . . . .
Camshaft Adjuster
1B1--50
. . . . . . . . . . . . . . . . . . . . . . .
Camshaft Sprocket Bolt
1B1--52
. . . . . . . . . . . . . . . . . .
Camshaft
1B1--54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Timing Position
1B1--59
. . . . . . . . . . . . . . . .
Valve Spring
1B1--62
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Seal
1B1--66
. . . . . . . . . . . . . . . . . . . . . . . .
Chain Tensioner
1B1--67
. . . . . . . . . . . . . . . . . . . . . . . . .
Timing Chain
1B1--70
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioning Rail
1B1--75
. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Guide Rail
1B1--76
. . . . . . . . . . . . . . . . .
Crankcase Guide Rail
1B1--77
. . . . . . . . . . . . . . . . . . . .
Crankshaft Sprocket
1B1--78
. . . . . . . . . . . . . . . . . . . . .
Piston
1B1--80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod
1B1--83
. . . . . . . . . . . . . . . . . . . . . . . . .
Piston Ring
1B1--85
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Specification
1B1--87
. . . . . . . . . . . . . . . . . .
Oil Pan
1B1--88
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil and Oil Filter Element
1B1--90
. . . . . . . . . .
Oil Filter
1B1--92
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump
1B1--94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Relief Valve
1B1--96
. . . . . . . . . . . . . . . . .
Oil Non-Return Valve
1B1--97
. . . . . . . . . . . . . . . . . . . .
Oil Dipstick Guide Tube
1B1--98
. . . . . . . . . . . . . . . . . .
Unit Repair
1B1--99
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Gallery in Crankcase
1B1--99
. . . . . . . . . . . . . . . . . .
Oil Gallery in Cylinder Head
1B1--101
. . . . . . . . . . . . . .
Core Plugs in Crankcase
1B1--104
. . . . . . . . . . . . . . . .
Cylinder Bore
1B1--106
. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Mating Surface
1B1--108
. . . . . . . . . . . . . .
Cylinder Head Mating Surface
1B1--110
. . . . . . . . . . .
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