engine SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE MECHANICAL 1B3-113
Tools Required 667 589 00 31 00 Press Lever104 589 00 37 00 Pliers102 589 03 40 00 Magnetic Lifter603 589 01 40 00 Holding Wheel601 589 02 43 00 Drift
116 589 06 63 00 Magnetic Finger667 589 02 63 00 Supporting BarA : Intake valve stem seal
B : Exhaust valve stem seal
Chamfer Inner diameter ‘d’
ColorWire ring Intake valve stem seal
Offset
7.3mm Brown Black Exhaust valve stem seal
All round8.2mmGreen Yellow

1B3-114 OM600 ENGINE MECHANICAL Replacement Procedure
1. Remove the valve tappet (1) with magnetic lifter.Notice Place the valve tappets upside down (open end upward).
Magnetic Lifter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain (11). Holding Wheel 603 589 01 40 00
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8). Supporting Bar 667 589 02 63 00
5. Using press lever (9), press the spring retainer(3) downward and remove the valve collets with magnetic finger (10).
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00

OM600 ENGINE MECHANICAL 1B3-115
6. Remove the spring retainer(3) and valve spring (4).
7. Remove the valve stem seal (5).Pliers 104 589 00 37 00
8. Insert the cap (12) onto the valve (6) and install the new valve stem seal (5) and then remover the cap.
Drift 601 589 02 43 00
9. By pressing the spring seat with press lever (9), install the valve cotters(2) with magnetic finger (10). Notice Be careful not to damage guide bore of the valve tappet.
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00

1B3-116 OM600 ENGINE MECHANICAL8.000
- 8.030 9.000
- 9.050 39.5
Intake Exhaust 0.029
- 0.051 0.029
- 0.051
Red
White Red
White
Diameter ‘a’
Service DataItemBasic Bore
Repair size 1 Repair size 2 Repair size 1Repair size 2Outer Diameter ‘D’
14.251
14.440 - 14.451 14.240 - 14.25114.440 - 14.451 Color Code
14.200 - 14.211
14.400 - 14.411
14.200 - 14.211
14.400 - 14.411Overlap‘D’ - ‘a’Valve Guide
Inner Diameter ‘A’
37.7
Length ‘L’
CHECK AND REPLACEMENT OF VALVE GUIDES
Preceding Work : Removal of cylinder head
Removal of valve spring
Removal of valve
1 Cylinder Head
2 Valve Guide 3 Valve Seat Ring
a Basic Bore Diameter

OM600 ENGINE MECHANICAL 1B3-117
Tools Required
000 589 10 53 00 Reamer (for Exhaust)
000 589 10 68 00 Cylinder Brush
000 589 21 53 00 Reamer (for Intake)
102 589 00 23 00 GO / NO GO Gauge (for Intake)
103 589 02 15 00 Drift (for Exhaust)
103 589 03 15 00 Drift (for Intake)
117 589 03 25 00 GO / NO GO Gauge (for Exhaust)
346 589 00 63 00 Super Cooling Box
601 589 02 23 00 GO/NO GO Gauge
601 589 05 15 00 Drift (for Intake)
Notice Measure center (arrow) of the valve guide and if the inner diameter ‘A’ exceeds standard value, replace the guide.
601 589 06 15 00 Drift (for Exhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves Valve SeatIntake
Exhaust Intake
Exhaust Broaching Tool No.
115 589 00 53 00 (14.2mm)
115 589 01 53 00 (14.4mm) Guide Sleeve Tool No.
102 589 00 63 00 102 589 08 63 00 Guide Sleeve Side
BBAB
601 589 15 63 00

1B3-118 OM600 ENGINE MECHANICAL
2. Thoroughly clean the basic bore by using a cylinder brush.Cylinder Brush 000 589 10 68 00
3. Check the basic bore in cylinder head for scoring marks and ream to next repair size if necessary.
2. Insert the GO/NO GO gauge into the valve guide bore. Ifthe NO GO side is inserted fully, replace the valve guide (Intake 8mm, Exhaust 9mm).
GO/NO GO Gauge 601 589 02 23 00
Replacement Procedure
1. Drive out the valve guide (2) by using a drift (5). Notice The valve guide must be driven out upward of the cylinder head.
Drift (for Intake) 103 589 03 15 00
Drift (for Exhaust) 103 589 02 15 00
Checking
1. Thoroughly clean the valve guide bore using a cylinder
brush.
Cylinder Brush 000 589 10 68 00

OM600 ENGINE MECHANICAL 1B3-119
4. Reaming basic bore in cylinder head (repair size).- Thoroughly remove carbon deposits in cylinder head.
Notice Particularly remove the insides of the valve seat rings.
- Remove the elevation (arrow) of intake valve seat rings.
- Select correct broaching tool and guide sleeve (refer to the table). Notice Before broaching work, the broaching tool must be cleared of swarf with a stiff plastic brush.
- Lubricate the basic bore, guide sleeve and broaching tool with petroleum.
- Push broaching tool (6) in broaching direction (arrow) into the guide sleeve (7) far enough so that the first cut of thebroaching tool is positioned in the basic bore when guide sleeve is fitted onto the valve seat ring (3).
6. Broaching tool7. Guide sleeve
See the ‘standard data ’
- Center the guide sleeve (7) in the valve seat ring (3) by
turning.
- Knock through the broaching tool (6) with a plastic hammer (approx. 25g). and aluminum drift.

1B3-120 OM600 ENGINE MECHANICAL
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
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
5. Heat the cylinder head (1) in a wear tank to approx. 80 °C.

OM600 ENGINE MECHANICAL 1B3-121
9. If necessary, ream the valve guide bore evenly.Notice Never turn the reamer against the direction of rotation.
Reamer (for Exhaust) 000 589 10 53 00Reamer (for Intake) 000 589 21 53 00

1B3-122 OM600 ENGINE MECHANICAL
VALVE SEAT RINGS
Preceding Work : Removal of valveChecking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head
2 Valve Seat Ring
3 Valve Guide
A Height (Cylinder Head Upper / Lower Surface)
B Height (cylinder Head Cover Surface - Seat of Valve Seat Ring) D Valve Seat Ring Outer Diameter
D1 Valve Seat Ring Inner Diameter
D2 Basic Bore Diameter
H Height of Valve Seat Ring
Service Data
Item D2D
D1 H
Overlap U=D-D2
B A Intake
40.000 - 40.016mm40.084 - 40.100mm33.400 - 33.600mm 6.955 - 7.045mm0.068 - 0.100mm
133.4mm142.5mm Exhaust
37.000 - 37.016mm37.084 - 37.100mm30.400 - 30.600mm 6.955 - 7.045mm0.068 - 0.100mm
133.4mm142.5mm