SsangYong Korando III (2010 year). Manual — part 30

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3. CHECK AND INSPECTION

1) Cylinder

(1) Compression pressure test

Specified value

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Compression ratio

16.5 : 1

Test condition

at normal operating temperature (80˚C)

Compression pressure

Standard

32 bar

Minimum

18 bar

Differential limit between cylinders

Maximum 3 bar

The compression pressure test is to check the conditions of internal components (piston, piston ring,

intake and exhaust vale, cylinder head gasket). This test provides current engine operating status.

Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from

moving components of engine (e.g., belt and cooling fan).

Park the vehicle on the level ground and apply the parking brake.

Do not allow anybody to be in front of the vehicle.

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(2) Cylinder pressure leakage test

If the measured value of the compression pressure test is not within the specifications, perform the

cylinder pressure leakage test.

Specified value

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Perform this test in the sequence of firing order.

Do not test the cylinder pressure leakage with wet type test procedure. (do not

inject the engine oil into the combustion chamber)

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Test condition: normal engine operating

temperature (80˚C)

Specified value

Whole engine

below 25%

at valve and cylinder head gasket

below 10%

at piston ring

below 20%

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Position the piston at TDC and measure the piston

protrusion from crank case mating surface.

(3) Piston protrusion check

Specified value

0.475 to 0.745mm

Measure it at both ends of crankshaft.

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2) Cylinder Head

(1) Cylinder head mating surface check

Specified value

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Total height "A"

131.9 to 132.1 mm

Minimum height after machining

131.9mm

Flatness

Longitudinal direction

0.1 / 150

Transverse direction

0.15

Parallel deviation of cylinder head

below 0.1 mm

Peak-to valley of surface

Rmax7

Rz6.3

valve recess "a"

Intake valve

0.6 to 1.0 mm

Exhaust valve

Measure the cylinder head height "A".

1.

If the height is less than the limit, the cylinder

head must be replaced.

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Insert the valves into the valve guides and

measure the recesses.

2.

If the measured value is out of the specified

range, machine the valve seat as much as

necessary until the specified value is

achieved.

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Valve recess “a"

0.6 to 1.0 mm

(2) Cylinder head pressure Leak test

Immerse the cylinder head with the pressure plate into warm water (approx. 60°C) and pressurize

with compressed air to 2 bar.

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4. GUIDELINES ON ENGINE SERVICE

To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and

unit inspection/repair and to secure optimum engine performance and safety after service works, basic

cautions and service work guidelines that can be easily forgotten during engine service works are

described in.

Cautions before service works

For safe and correct works, you must observe the working procedures and instructions in this

manual. And, use the designated tools as follow:

Engine stand / Heavy duty engine jack

To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while

servicing in engine compartment.

Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)

terminal.

Before service works, be sure to prepare the works by cleaning and aligning work areas.

Do not allow the foreign material get into the fuel injection system.

When removing the engine, use only the safety hook on engine and engine hanger. Do not support

the bottom of oil pan with a jack.

Engine and accessories

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Completely drain the engine oil, coolant and fuel from engine before removal.

Before disassembling/assembling the engine components, carefully read the working procedures in

this manual.

Make sure to keep the specified tightening torques during installation.

Clean and properly lubricate the parts before reassembly.

Carefully check that there are not any interference while servicing.

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Engine has a lot of precise portions so tightening torque should be correct during disassembly/assembly

and removal/installation and service work should be done in clean ways during disassembly/assembly.

Maintaining working area clean and cautious service administration is essential element of service works

while working on the engine and each section of the vehicle. So the mechanics should well aware of it.