engine SSANGYONG MUSSO 2003 Service Manual

1B3-164 OM600 ENGINE MECHANICAL Service Data
Piston clearance Piston crown protrusion in TDC position Connecting rod bushing diameterMax. 0.12 mm
0.735 - 0.965 mm
26.012 - 26.018 mm
Connecting Rod Bolt Dimensions
Thread Stretch shaft(C) diameter (new)Minimum stretch shaft diameter (C)Length(L)(new)
Tools Required
000 589 04 14 00 Tensioning Strap 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder M9 x 1
7.4 -0.1
mm
7.1 mm
52 -0.3
mm

OM600 ENGINE MECHANICAL 1B3-165
Removal Procedure
1. Remove combustion residues from the cylinder bores.
2. Remove the connecting rod bolts (12) and then removethe connecting rod bearing caps(11).
3. Remove the connecting rod bearing shells (9, 10). Notice
Be careful not mix the bearing caps and shells each other.
4. Remove the piston (6) and connecting rod (8).
5. Remove the snap ring (4) and pull out the piston pin (5).
6. Separate the piston and connecting rod.

1B3-166 OM600 ENGINE MECHANICAL Installation Procedure
1. Fit the piston onto the connecting rod so that the arrow(15) and the locking slot (16) are facing in direction of the vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand. Notice Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if necessary.
5. Install and arrange the piston rings to be evenly 120 ° from
each ends gap.

OM600 ENGINE MECHANICAL 1B3-167
6. Coat the cylinder bore, connecting rod bearing journal,connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap (7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a wooden stick (18). Notice The arrow on the piston crown must point toward the front of vehicle.
9. Insert the connecting rod bearing shells (9, 10). Notice Be careful of the difference in upper and lower bearing shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice Position so that the retaining lugs are on the same side of the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connecting rod bolts.
Limit ‘ C ’ 7.1mm

1B3-168 OM600 ENGINE MECHANICAL
12. Coat the bolts (12) with oil and then tighten the bolts.
Tightening Torque40Nm + 90°
13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft.
14. Measure clearance between the piston crown and cylinder
Standard Max. 0.12mm
15. Position the piston at TDC and measure the distance between the piston crown and the crankcase surface.
Notice Measure at points marked. Dial Gauge 001 589 00 53 21
Dial Gauge Holder 363 589 02 21 00
Standard Max. 0.965 mm

OM600 ENGINE MECHANICAL 1B3-169
OIL FILTER1 Nut ............................................................ 25 Nm
2 Oil Filter ..................................................... Cover
3 O-Ring ................................................... Replace
4 Oil Filter ...............Element Replace If necessary
5 Oil Filter Housing 6 Bolt (M8)
.................................................... 10Nm
7 Oil Pressure Switch
8 Gasket
9 Bolt ........................................................... 25 Nm

1B3-170 OM600 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the oil filter cover and then drain the oil.
2. Remove the oil pressure switch line.
3. Remove the oil filter housing.
4. Clean the sealing surface.
5. Installation should follow the removal procedure in thereverse order.

OM600 ENGINE MECHANICAL 1B3-171
OIL PAN1 Gasket ................................................... Replace
2 Upper Oil Pan
3 Combination Bolt ...................................... 10 Nm
4 Combination Bolt ...................................... 10 Nm
5 Gasket ................................................... Replace 6 Lower Oil Pan
7 Combination Bolt
...................................... 25 Nm
8 Drain Plug ................................................. 25 Nm
9 Washer Seal .......................................... Replace
10 Oil Pan
*Remove and install as numerical sequence. Notice Replace the washer seal with new one.
OM662LA OM661LA

1B3-172 OM600 ENGINE MECHANICAL Oil Circulation

OM600 ENGINE MECHANICAL 1B3-173
Oil Filter
a From Oil Pump
b To Main Oil Galleryc To Oil Pan