engine SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE MECHANICAL 1B3-93
FLYWHEEL
Preceding Work : Removal of the transmissionRemoval of the clutch
1 Oil Pan
2 Straight Pin
3 Flywheel 4 12-Sided Stretch Bolt
............ Check, 45Nm + 90 °
5 Drive Plate (Automatic Transmission)
6 Flywheel (Automatic Transmission)

1B3-94 OM600 ENGINE MECHANICAL
Manual transmission flywheel
Automatic transmission flywheel
OM661LA
OM662LA

OM600 ENGINE MECHANICAL 1B3-95
3. Remove the flywheel (3), if equipped with manualtransmission. Installation Notice Correctly align the position of dowel pin (2).
Tools Required 602 589 00 40 00 Engine Lock Removal & Installation Procedure
1. Install the engine lock.
Engine Lock 602 589 02 40 00
2. Remove the 12-sided stretch bolts (4). Installation Notice
Tightening Torque 45 Nm + 90 °
Notice If the length ‘L’ of bolts exceeds 22.5mm, replace the bolts.

1B3-96 OM600 ENGINE MECHANICAL
4. Remove the flywheel (6) and driven plate (5), if equippedwith automatic transmission. Installation Notice Correctly align the position of dowel pin (2).
5. Installation should follow the removal procedure in the reverse order.

OM600 ENGINE MECHANICAL 1B3-97
MACHINING OF FLYWHEEL
1 Flywheel
Machining of Flywheel Notice Flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding orprecision-turning. If the scores or cracks are severe thanpermissible specifications, replace the flywheel.
When machining the clutch surface ‘A’, the mounting
surface (B) for the clutch pressure plate should also be machined in accordance with ‘A’ to keep the distance ‘a’.
Do not machine under ‘b’ value.
When machining, fix the flywheel exactly not to exceed the standard runout.
OM662LA
OM662LA
Max. axial runout
Distance ‘a’
New
Repair up to 19.3 - 19.5 mm16.6 mm
15.6 mm
0.05 mmDistance ‘b’

1B3-98 OM600 ENGINE MECHANICAL
FLYWHEEL RING GEAR Preceding Work : Removal of flywheel
1 Ring Gear
2 Flywheel3 Centering Collar Diameter
Tools Required 001 589 53 21 00 Dial Gauge363 589 02 21 00 Dial Gauge Holder

OM600 ENGINE MECHANICAL 1B3-99
Diameter ‘a’ 275 + 0.5mm
Replacement Procedure
1. Drill a hole into the ring gear (1) (arrow) and snap
with a chisel.
2. Thoroughly clean the collar surfaces of ring gear.
3. Measure diameter (a) of centering collar.
Notice If out of standard, replace the flywheel.
4. Heat up the new ring gear up to 220 °C by using a
heating device. Notice Use temperature measuring chalk.
5. Install the new ring gear (1) onto the flywheel by using a drift.

1B3-100 OM600 ENGINE MECHANICAL
6. Measure axial runout of ring gear (1) on a surface plate.
LimitMax. 0.4mm
Notice For correct measurement, put the flywheel on the flat measuring board.
Dial Gauge 001 589 53 21 00
Dial Gauge Holder 363 589 02 21 00

OM600 ENGINE MECHANICAL 1B3-101
HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK
1 Cylinder Head Cover
2 Bolt............................................................ 10Nm
3 Gasket ................................................... Replace4 Valve Tappet
5 Cylinder Head

1B3-102 OM600 ENGINE MECHANICAL
CheckingNotice The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it doesnot need to be repaired. Determine the malfunctions in valveclearance compensation device with noise through following
tests. If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4 minutes.
2. Stop the engine. After 5minutes, check the engine oil level and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cylinders.
5. Using a drift, lightly press the valve tappet and measure clearance between the cam and valve tappet. Notice If the clearance exceeds 0.4mm, replace the valve tappet.
6. If a valve tappet moves down too far in comparison to the others, replace the valve tappet.
7. Rotate the engine and check the remaining valve tappets.
Notice
Unnecessary rotation of the engine will damage the valve tappets.
Do not rotate the engine by using the camshaft sprocket bolt or to the opposite direction of the engine rotation.