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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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.

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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)