SsangYong Korando III (2010 year). Manual — part 323
02-14
Measure how the piston is protruded from the
upper side of the cylinder block.
(3) Piston protrusion check
Specified value
0.475 to 0.745mm
Measure it at both end positions in the axial
direction of the crankshaft.
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02-15
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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.
02-16
5. 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.
02-17
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Electrical equipment
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Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. there could be poor engine performance, incomplete
combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)
terminal.
When replacing the electric device, use only genuine part and check the conditions of connections
and grounds. Loosened connection or ground make cause a fire and personal injury.
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Fuel and lubrication system
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Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking
should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and nuts
should be tightened as specified.
After removal/installation works, be sure to check whether there is leak on the connecting section.
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages in HP
pump and injectors. Thus, be sure to plug the inlets of removed fuel line components with cap and
protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual while working
on DI engine fuel system)
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