check engine SSANGYONG MUSSO 2003 Manual Online

OM600 ENGINE MECHANICAL 1B3-109
VALVE SPRINGS (CYLINDER HEAD INSTALLED) Preceding Work : Removal of camshaft1 Valve Tappet
2 Valve Cotters
3 Spring Retainer 4 Valve Spring
.......... Check, replace if necessary
5 Timing Chain
6 Cylinder Head
Notice Remove the valve springs only when the piston is at TDC.
Tools Required 102 589 03 40 00 Magnetic Bar
116 589 06 63 00 Magnetic Finger603 589 01 40 00 Holding Wheel667 589 00 31 00 Press Lever667 589 02 63 00 Supporting Bar

OM600 ENGINE MECHANICAL 1B3-111
6. Remove the spring retainer(3) and spring (4).
7. Check the valve spring and replace if necessary.
8. Insert valve spring (4) with the color coding (arrow) facingdown and insert valve spring Retainer(3).
9. By press the spring retainer(3) with press lever (90), install the valve cotters with magnetic finger (10).
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00
10. Remove the supporting bar.
11. Remove the holding wheel (7) from the timing chain (5). Holding Wheel 603 589 01 40 00
13. Coat the valve tappet with oil and install it. Magnetic Bar 102 589 03 40 00

1B3-112 OM600 ENGINE MECHANICAL
VALVE STEM SEALS Preceding Work : Removal of camshaft.
1 Valve Tappet
2 Valve Cotters
3 Spring Retainer4 Valve Spring
...........Check, replace if necessary
5 Valve Stem Seal
6 Valve
Notice Remove the valve stem seals when the piston is positioned at TDC.

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

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

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.

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

OM600 ENGINE MECHANICAL 1B3-127
CHECK AND MACHINING OF VALVES
Preceding Works : Removal of cylinder headRemoval of the vale spring Removal of the valve
I Valve Length
W Camshaft Cam Basic Diameter X Distance (Camshaft Basic Bore - Valve Stem) Y Half Camshaft Basic Bore Diameter
Z Distance (Cylinder Head Cover Parting Surface - Valve Stem)

OM600 ENGINE MECHANICAL 1B3-129
Tools Required 001 589 32 21 00 Dial Gauge Checking and Machining
1. Clean the valves and do visual check.Valves with wobbled valve disc, with worn or scored valve stem should be replaced.
2. Measure valve disc height ‘h’.
Service data
Intake
Exhaust 1.7 ± 0.15 mm 1.7 ± 0.15 mm
3. Machine the valve. Notice Pay attention to setting angle ‘ ’ .
Commercial Tool
Valve corn grinding machine
4. Measure radial runout between valve stem and valve seat.
Limit Max. 0.03mm
Dial Gauge 001 589 32 21 00

1B3-138 OM600 ENGINE MECHANICAL
6. Check the timing.New
After approx. 20,000km ATDC 11.33
°
ATDC 12 °
Notice If timing is out standard, the camshaft should be checked for wear and the timing chain for stretch. If a difference of more than 4 ° exists, the timing chain should be replaced.
7. Replace the gasket and install the cylinder head cover.
Tightening Torque 10 Nm
Measurement Procedure
1. Remove the cylinder head cover.
2. Rotate the engine in the direction of engine rotation until the intake valve of NO. 1 cylinder is completely closed. The cam lobe faces up (arrow). Notice Do not rotate the engine at the bolt of the crankshaft sprocket. Do not rotate the engine in the opposite directionof engine rotation. If do, this will cause serious measuringerrors.
3. Install the dial gauge holder and dial gauge (7) with theextension (8) to the cylinder head and position the tracer pin (9) onto the valve tappet (intake valve of cylinder NO.1)with a preload of min. 3mm. Notice The tracer pin should be positioned exactly vertical.
Dial gauge Holder 363 589 02 21 00Dial Gauge 001 589 53 21 00Extension 366 589 00 21 05
4. Set the dial gauge to ‘0’.
5. Rotate the engine further in direction of rotation until the dial gauge has moved back by 2mm (valve lift) to 1mm.
Tools Required 001 589 53 21 00 Dial Gauge363 589 02 21 00 Dial Gauge Holder366 589 00 21 05 Extension