PDF Service Repair Manual 1995 Koranda - 2 MB
This service and repair manual covers 1995 Koranda models.
It offers the detailed instructions needed for maintenance, troubleshooting, and complex repairs.
The document provides specifications and step-by-step procedures essential for professional mechanics and dedicated DIY enthusiasts.
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--- Page 1 ---
SECTION INDEX
SERVICE
MANUAL FRONT MATTER 0A
KORANDO GENERAL INFORMATION 0B
ENGINE 1
SUSPENSION 2
FOREWORD DRIVE LINE/AXLE 3
This manual includes procedure for mainte-
nance, adjustment, service operation and re- BRAKES 4
moval and installation of components.
All information, illustrations and specifications
contained in this manual are based on the latest TRANSMISSION 5
product information available at the time of
manual approval.
The right is reserved to make changes at any STEERING 6
time without notice.
HVAC
(HEATING, VENTILATION, 7
AND AIR CONDITIONING)
DAEWOO MOTOR CO., LTD.
RESTRAINTS 8
INCHON, KOREA
BODY AND ACCESSORIES 9
--- Page 3 ---
SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 While Operating the Vehicle . . . . . . . . . . . . . 0B-12
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . 0B-12
Vehicle Dimensions and Weights . . . . . . . . . . 0B-5 At Least Twice A Month . . . . . . . . . . . . . . . . 0B-12
Standard Bolts Specifications . . . . . . . . . . . . . 0B-6 At Least Monthly . . . . . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Repair . . . . . . . . . . . . . . . 0B-7 At Least Twice a Year . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Lubrication . . . . . . . . . . . . . 0B-7 Each Time The Oil is Changed . . . . . . . . . . . 0B-13
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . 0B-7 At Least Annually . . . . . . . . . . . . . . . . . . . . . 0B-13
Explanation of Scheduled Maintenance Recommended Fluids and Lubricants . . . . . 0B-14
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-7 General Description and System
Scheduled Maintenance Charts Operation . . . . . . . . . . . . . . . . . . . . . . . . 0B-15
(Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . 0B-8 General Repair Instructions . . . . . . . . . . . . . 0B-15
Scheduled Maintenance Charts Vehicle Identification Number System . . . . . . 0B-16
(Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . 0B-10 Vehicle Lifting Procedures . . . . . . . . . . . . . . 0B-19
Owner Inspections and Services . . . . . . . 0B-12
SPECIFICATIONS
TECHNICAL DATA
Performance-Manual Transaxle
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 140 137 148 154 165 176
Minimum Turning Radius (m) 5.8 5.8 5.8 5.8 5.8 5.8
Performance-Autumatic Transaxle
Application 661LA 662NA 662LA 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 140 137 140 160 170
Minimum Turning Radius (m) 5.8 5.8 5.8 5.8 5.8
--- Page 4 ---
GENERAL INFORMATION 0B-15
l Use genuine DAEWOO parts.
GENERAL DESCRIPTION l Discard used cotter pins, gaskets, O-rings, oil seals,
AND SYSTEM OPERATION lock washers and self-locking nuts. Prepare new ones
for installation. Normal function of these parts cannot
be maintained if these parts are reused.
GENERAL REPAIR INSTRUCTIONS
l Keep the disassembled parts neatly in groups to
l If a floor jack is used, the following precautions are facilitate proper and smooth reassembly.
recommended.
l Keep attaching bolts and nuts separated, as they
l Park the vehicle on level ground, “block” the front or vary in hardness and design depending on the
rear wheels, set the jack against the frame, raise the position of the installation.
vehicle and support it with chassis stands and then
perform the service operation. l Clean the parts before inspection or reassembly.
l Before performing the service operation, disconnect l Also clean the oil parts, etc. Use compressed air to
the negative battery cable in order to reduce the make certain they are free of restrictions.
chance of cable damaged and burning due to short- l Lubricate rotating and sliding faces of parts with oil
cir cuiting. or grease before installation.
l Use a cover on the body, the seats and the floor to l When necessary, use a sealer on gaskets to prevent
protect them against damage and contamination. leakage.
l Handle brake fluid and antifreeze solution with care l Carefully observe all specifications for bolt and nut
as they can cause paint damage. torques.
l The use of proper tools, and the recommended l When service operation is completed, make a final
essential and available tools where specified, are check to be sure service was done properly and the
important for efficient and reliable performance of problem was corrected.
the service repairs.
--- Page 5 ---
1A1-10 GENERAL ENGINE INFORMATION
Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs.
3. Place the diagram sheet to compression pressure
tester.
4. Connect the adaptor to compression pressure tester
and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using
the start motor.
6. Compare the measurements of compression
pressure tester with the specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
l Discharge the combustion residues in the cylinders
before testing the compression pressure.
l Apply the parking brake before cranking the
engine.
--- Page 6 ---
GENERAL ENGINE INFORMATION 1A2-11
Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs.
3. Place the diagram sheet to compression pressure
tester.
4. Connect the adaptor to compression pressure tester
and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using
the start motor.
6. Compare the measurements of compression
pressure tester with the specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
l Discharge the combustion residues in the cylinders
before testing the compression pressure.
l Apply the parking brake before cranking the
engine.
--- Page 7 ---
GENERAL ENGINE INFORMATION 1A3-11
COMPRESSION PRESSURE TEST
1 Test Adapter
2 Flexible Connector
3 Compression Pressure Recorder
Service Data
Normal Compression Pressure 28bar
Minimum Compression Pressure Approx.18bar
Permissible Pressure Difference Between Individual Cylinders Max. 3bar
lEngine at normal operating temperature of 80°C
Tools Required
000 589 65 09 00 Socket
001 589 73 21 00 Hand Vacuum Pump
--- Page 8 ---
1B1-10 M162 ENGINE MECHANICAL
10. Remove the upper mounting bolts of radiator and then
remove the radiator.
11. Remove the hydraulic pipe of power steering.
Notice
Completely drain the oil.
12. Discharge the refrigerant from A/C system, and disconnect
the discharge pipe and suction pipe from the compressor.
13. Remove the acceleration control cable and automatic
transmission pressure cable.
--- Page 9 ---
1B1-24 M162 ENGINE MECHANICAL
POLY V-BELT
Preceding Work : Removal of cooling fan
1 Poly V-belt 2 Belt Tensioning Pulley
Removal & Installation Procedure
1. Release the belt tension by turning the belt tensioning pulley
nut clockwise.
2. Remove the poly v-belt.
Notice
Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley
clockwise.
--- Page 10 ---
1B1-38 M162 ENGINE MECHANICAL
3. Remove the cooling fan and the viscous clutch. Unscrew
the three bolts from the cooling fan bracket and remove the
bracket (arrows).
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
4. Remove the timing gear case cover after unscrewing the
bolts (3) and (4) from the timing gear case cover and the
bolt (9) from the oil pan.
Notice
Be careful not to damage the oil pan gasket.
Installation Notice
Bolt (3,4) 22.5 - 27.5 Nm
Tightening Torque
Bolt (9) 9 - 11 Nm
l Apply the sealant after cleaning the timing gear case
cover surface.
l Be careful not to stain the oil chamber of chain tensioner
with the sealant.
5. Installation should follow the removal procedure in the
reverse order.
6. Warm up the engine and check for oil leaks.
--- Page 11 ---
1B1-52 M162 ENGINE MECHANICAL
FLYWHEEL / DRIVEN PLATE
Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T)
............................................... 1st step 45+5 Nm 4 Dowel Pin
2nd step +90° +10°
2 Plate
Service Data Standard (Stretch Bolt)
Nominal Size D - M x 1.5
Stretch Side Diameter d When New 8.5 - 0.2 mm
Min. Diameter 8.0 mm
Bolt Length L When New 21.8 - 22.2 mm
Tightening Torque 1st step 50 Nm, 2nd step 90°
--- Page 12 ---
1B1-66 M162 ENGINE MECHANICAL
VALVE SPRING
Preceding Work : Removal of camshaft
Removal of spark plug
1 Valve Tappet Assembly 7 Connecting Hose
2 Valve Cotter 8 Thrust Piece
3 Upper Retainer 9 Slide
4 Valve Spring .......... Check, Replace if necessary 10 Adjust Bolt
5 Valve Stem Seal 11 Lever Pusher
6 Lower Retainer 12 Supporting Bar
--- Page 13 ---
1B1-80 M162 ENGINE MECHANICAL
CYLINDER HEAD GUIDE RAIL
Preceding Work : Removal of cylinder head cover
1 Chain Tensioner
2 Upper Guide Rail
3 Upper Guide Rail Pin
4 Wrench (Special Tool)
Tools Required
104 589 01 01 00 Spanner
Removal & Installation Procedure
1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating direction
using the wrench (4) and loosen the timing chain at upper
guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of
rotation using the wrench (4, special tool : 104 589 01 01
00).
5. Check for damages at the upper sliding rail and replace it if
necessary. Install the upper guide rail pin.
6. Install the chain tensioner.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
Tensioner Assembly 72 - 88 Nm
--- Page 14 ---
1B1-94 M162 ENGINE MECHANICAL
9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.
3 Oil Filler Cap
4 Dipstick Gauge
--- Page 15 ---
1B1-108 M162 ENGINE MECHANICAL
Tools Required
102 589 00 15 00 Drift
Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.
Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 240 hardens.
6. Warm up the engine and check the coolant for leaks.
--- Page 16 ---
1B2-8 M161 ENGINE MECHANICAL
SPECIAL TOOLS TABLE (Cont’d)
617 589 00 10 00 116 589 01 34 00
Wrench Socket Threaded Bolt
104 589 00 40 00 111 589 03 15 00
Holder Insert Pin
--- Page 17 ---
1B2-22 M161 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the belt pulley after removal of poly v-belt.
Installation Notice
Tightening Torque 40.5 - 49.5 Nm
Notice
Pull the tensioning pulley counterclockwise as shown in the
figure.
2. Disconnect the hydraulic pipe of the power steering pump
and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
4. Remove the compressor after disconnecting the wiring
connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the pipes.
--- Page 18 ---
1B2-36 M161 ENGINE MECHANICAL
CYLINDER HEAD FRONT COVER
Preceding Work : Removal of cylinder head cover
Removal of thermostat housing assembly
Removal of engine hanger bracket
1 Bolt (M6 X 16, 3 pieces) ......................... 9-11 Nm 6 Front Cover (E20 : M161.940)
2 Camshaft Adjuster 7 Sleeve
3 Bolt (M8 X 35, 2 pieces) ................. 22.5-27.5 Nm 8 O-ring .................................................... Replace
4 Bolt (M6 X 22, 6 pieces) ......................... 9-11 Nm 9 Thermostat Housing
5 Front Cover (E23 : M161.970)
Removal & Installation Procedure
1. Disconnect the camshaft adjuster connector and remove
the camshaft adjuster (E23 engine only).
Installation Notice
Tightening Torque 9 - 11 Nm
--- Page 19 ---
1B2-50 M161 ENGINE MECHANICAL
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
Tightening Torque 1st step 180 - 220 Nm
2nd step + 90°
Engine Lock 602 589 00 40 00
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in the
reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.
--- Page 20 ---
1B2-64 M161 ENGINE MECHANICAL
CAMSHAFT SPROCKET BOLT
Intake Flange Shaft Bolt
1st step 20 Nm
Tightening Torque
2nd step + 90°
Notice
The sprocket bolts are designed to be used only once, so
always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
Exhaust Camshaft Sprocket Bolt
1st step 20 Nm
Tightening Torque
2nd step + 90°
Notice
The sprocket bolts are designed to be used only once, so
always replace with new one.
E. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
--- Page 21 ---
1B2-78 M161 ENGINE MECHANICAL
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
Tightening Torque 40 Nm
5. Check for leaks by operating the engine.
Sectional View
1 Screw Plug 13 Chain Tensioner Housing
2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve) A Oil Supply Hole
11 Compression Spring B Chain Tensioner Oil Storage Hole
12 Thrust Piece
--- Page 22 ---
1B2-92 M161 ENGINE MECHANICAL
CONNECTING ROD
Preceding Work : Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 8 pieces) ............ 1st step 40 Nm
2nd step 90°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]
Service Data Standard
Distance (L) from The Connecting Rod Bearing to Bushing Bore Center E20 : 154 mm
E23 : 149 ± 0.05 mm
Width of The Connecting Rod (B) at Bearing Bore 21.940 - 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore 21.940 - 22.000 mm
Basic Bore at The Bearing Shell (D1) 51.600 - 51.614 mm
Basic Bore at The Bushing (d1) 24.500 - 24.571 mm
Bushing Inner Diameter (d) 22.007 - 22.013 mm
Clearance Between The Piston Pin and The Bushing 0.007 - 0.018 mm
Peak-to-valley Height of Connecting Rod Bushing on Inside 0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to 0.1/100 mm
Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod 0.045/100 mm
Bearing Bore to Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from 0.01 mm
Concentricity
Permissible Difference of Each Connecting Rod in Weight 0.4 g
--- Page 23 ---
1B2-106 M161 ENGINE MECHANICAL
Tools Required
102 589 00 15 00 Drift
Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.
Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 241 hardens.
6. Warm up the engine and check the coolant for leaks.
--- Page 24 ---
1B3-8 OM600 ENGINE MECHANICAL
SPECIAL TOOLS TABLE (Cont’d)
601 589 02 59 00 667 584 02 63 00
Supporting Bridge Supporting Bar
667 589 00 31 00 104 589 00 37 00
Press Lever Pliers
116 589 06 63 00 601 589 02 43 00
Magnetic Finger Drift
603 589 01 40 00 000 589 10 68 00
Holding Wheel Cylinder Brush
--- Page 25 ---
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
--- Page 26 ---
1B3-36 OM600 ENGINE MECHANICAL
Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber bore and
position the dial gauge with a preload of 5mm.
Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of engine rotation
until the large pointer on the dial gauge stops (TDC position).
Notice
The position of TDC is when the large pointer on the dial
gauge is stopped before moving back.
5. remove the reinstall the measuring device and position the
dial gauge scale at ‘0’.
6. Slowly rotate the crankshaft in the direction of engine rotation
until the dial gauge has moved back (counterclockwise) by
3.65mm.
7. Insert fixing device into the sensor bracket.
Notice
The pin on the vibration damper must engage into the slot
of the fixing device.
Fixing Device 667 589 01 21 00
8. If the pin does not engage, adjust the setting of the sensor
bracket by removing and tightening of the sensor bracket
bolts.Tightening Torque 10 Nm
Notice
The timing mark on the damper must be positioned at ATDC
20.
--- Page 27 ---
1B3-50 OM600 ENGINE MECHANICAL
45. Remove the vacuum line from the vacuum pump.
46. Disconnect the vacuum pipe from thermo valve.
47. Remove the socket bolts(13) of the chain box.
T Type Socket Wrench 116 589 03 07 00
Magnetic Bar 102 589 03 40 00
48. Remove the cylinder head bolts in numerical se-quence.
Cylinder Head Bolt Wrench 601 589 00 10 00
OM 662LA
--- Page 28 ---
1B3-64 OM600 ENGINE MECHANICAL
Tools Required
116 589 03 07 00 Socket Wrench
Removal Procedure
1. Remove the fan clutch and cooling fan belt pulley.
2. Drain the engine oil completely.
3. Remove the oil dipstick tube bracket bolts.
4. Remove the crankshaft pulley.
5. Loosen the bolt (1) and then remove the cylinder head cover
(2) and gasket.
6. Remove the vacuum pump.
7. Detach the closing cover (20). Remove the bolts(21) and
then remove the guide pulley (22).
8. Remove the guide pulley bracket (24).
--- Page 29 ---
1B3-78 OM600 ENGINE MECHANICAL
Installation Procedure
1. Install the hub.
Notice
Exactly align the woodruff key and the groove of hub (arrow).
2. Install the washer (7) and tighten the bolt (6).
Washer (new) : 1 EA 200 Nm + 90°
3. Install the vibration damper.
Notice
Exactly align and insert onto the straight pin.
4. Install the belt pulley.
Tightening Torque 25 Nm
Notice
Align the alignment marks.
--- Page 30 ---
1B3-92 OM600 ENGINE MECHANICAL
24. Insert the new connecting rod bearing shells into the
connecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
Tightening Torque 40 Nm + 90°
25. Measure inner diameter of connecting rod bearing.
26. Measure connecting rod bearing journal diameter (K).
Notice
Refer to measurement of the crankshaft bearing journal
diameter.
27. Measure the radial clearance (L) of the connecting rod
bearing.
Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial clearance ‘L’ 0.026 - 0.068mm
Notice
If the clearance is out of standard, adjust the radial
clearance of connecting rod bearing by replacing the
connecting rod bearing shells.
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotates
smoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve.
- clean the oil pump and oil filter housing carefully and
replace the hose if necessary.
Notice
After assembling the engine, check the camshaft timing,
adjust the start of fuel injection and check the TDC sensor
bracket setting.
32. Fill oil and run the engine and then check the oil pressure
and oil level.
Notice
Install the original oil filter element and then change the
engine oil and oil filter element after 1,000 - 1,500km.
--- Page 31 ---
1B3-106 OM600 ENGINE MECHANICAL
VALVE SPRINGS (CYLINDER HEAD REMOVED)
1 Valve Tappet 6 Stud Bolt .................................................... 12Nm
2 Valve Cotters 7 Washer
3 Spring Retainer 8 Nut .............................................. Replace, 25Nm
4 Valve Spring ........... Check, replace if necessary 9 Exhaust Manifold
5 Cylinder Head
--- Page 32 ---
1B3-120 OM600 ENGINE MECHANICAL
5. Heat the cylinder head (1) in a wear tank to approx. 80°C.
6. Cool down the new valve guide (2) with liquid nitrogen.
Notice
Do not touch the cooled valve guide by hand.
Super Cooling box 346 589 00 63 00
7. Drive in new valve guide with drift (8) until the wire ring makes
contact.
Notice
The valve guide must be driven in from the cylinder head
cover.
Drift (for Intake) 601 589 05 15 00
Drift (for Exhaust) 601 589 06 15 00
8. Check the valve guide bore with GO / NO GO gauge (9).
The GO side (marked ‘0’) should just still drop. If the GO
side cannot be inserted, the bore of valve guide should be
reamed.
Notice
Perform the check only on cooled down cylinder head.
GO / NO GO Gauge (for Intake) 102 589 00 23 00
GO / NO GO Gauge (for Exhaust) 117 589 03 23 00
--- Page 33 ---
1B3-134 OM600 ENGINE MECHANICAL
Machining Procedure
Valve machining is required :
- When the valve is leaking.
- When replacing the valve.
- When replacing the valve guide.
- When replacing the valve seat or valve seat ring.
1. Machine the valve seat (a=45°).
2. Measure valve seat width ‘b’.
Valve seat Intake 1.2 - 1.7 mm
width ‘b’ Exhaust 1.5 - 2.0 mm
3. If the specification is exceeded, the valve seat width has to
be corrected at the lower free angle of ‘b’=65°.
4. Measure radial runout.
Runout Max. 0.03mm
--- Page 34 ---
1B3-148 OM600 ENGINE MECHANICAL
Tools Required
000 589 58 43 00 Chain Assembling Device
Replacement Procedure
1. Cover over the chain box with cleaning rag and grind off
both chain pins (arrow) at a chain link (1) of the timing chain.
2. Remove the outer plate (4) and chain link (1).
Notice
Ensure that the ends of the timing chain do not drop into
the chain box.
3. Loosen the chain tension with approx. 4 turns.
4. Connect the new timing chain (arrow) with chain link (1) to
the old timing chain (2).
5. By rotating the crankshaft in the of engine rotation, pull out
the old timing chain with installing the new timing chain.
6. Remove the old timing chain and hold the ends of the new
timing chain to camshaft sprocket (3) with wire (arrow).
--- Page 35 ---
1B3-162 OM600 ENGINE MECHANICAL
Notice
If the max. length ‘L’ of the stretch bolt exceeds 53.6mm,
replace it.
5. Fit the oil pump chain (9) on the crankshaft sprocket (12)
and insert the oil pump sprocket (8) into the oil pump chain
and then install it on the oil pump.
Notice
The curved side of the oil pump sprocket should face the
oil pump.
6. Insert the woodruff key (15).
7. Install the guide rail (16). Attach the spring (17) to guide rail
and to tensioning lever together onto the bearing pins (5,6).
Notice
Ensure that the spring is correctly located in the guide rail
(arrow).
--- Page 36 ---
1B3-176 OM600 ENGINE MECHANICAL
3. Unscrew the oil strainer bracket bolt.
Tightening Torque 10 Nm
4. Remove the oil pump.
5. Unscrew the screw plug and remove the relief valve.
6. Installation should follow the removal procedure in the
reverse order.
--- Page 37 ---
M162 ENGINE COOLING 1D1-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
124 589 15 21 00 603 589 00 40
Tester Counter Holder
--- Page 38 ---
SECTION 1D2
M161 ENGINE COOLING
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 . . . . . . . . . . . . . . . . . . . . . . . 1D2-1 Coolant Drain and Fill Up . . . . . . . . . . . . . . . 1D2-5
General Specifications . . . . . . . . . . . . . . . . . 1D2-1 Cooling Fan and Viscous Clutch . . . . . . . . . . 1D2-7
Fastener Tightening Specifications . . . . . . . . 1D2-2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D2-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D2-3 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D2-11
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D2-3 Thermostat Housing Assembly . . . . . . . . . . 1D2-12
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D2-4 Removal and Installation of Cooling
Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . 1D2-14
System Leakage Test . . . . . . . . . . . . . . . . . . 1D2-4
Removal and Installation of Radiator . . . . . 1D2-15
Maintenance and Repair . . . . . . . . . . . . . . 1D2-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1D2-5