length SSANGYONG MUSSO 1998 Workshop User Guide

OM600 ENGINE MECHANICAL 1B3-39
Length(L) When New
80mm
102mm
115mm Thread Dia.
M10
M10
M10Max. Length(L)
82mm
104mm
117mm
The twelve-sided socket head bolts are tightened with each
stages of torque and torque angle.
It is not necessary to retighten the cylinder head bolts at
the 1000~1500km inspection or after 1000~1500km of
repairs.
Notice
The cylinder head may only be removed when the engine
has cooled down. The cylinder head is removed together
with the exhaust manifold. As the cylinder head bolts
undergo a permanent tightening. They require to be
replaced if they exceed the maximum lengthes indicated
in the table.

1B3-52 OM600 ENGINE MECHANICAL
Length(L)
Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.
Notice
Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts.
Notice
If the max. length is exceeded, replace the bolts.
Thread Dia. Max. Limit(L)
M10
M10
M1080mm
102mm
115mm82mm
104mm
117mm when new
4. Coat the head contact surface of bolts and thread with oil
and insert them as shown.
- Cylinder head bolts arrangement
Bore
1 ...........................................M10
× 80
2 ...........................................M10
× 102
3 ...........................................M10
× 11 5
4 ........................................... M 8
× 50
5 ........................................... M 8
× 80
OM662LA

1B3-58 OM600 ENGINE MECHANICAL
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.
Tightening Torque 25 Nm
Notice
Measure the max. length ‘L’ and replace the bolt if it exceeds
53.6mm.

OM600 ENGINE MECHANICAL 1B3-91
Notice
If the max. length of bolts(L) exceed 63.8mm, replace them.
19. Coat the new crankshaft with engine oil and place it on the
crankcase.
20. Install the crankshaft bearing caps according to marking
and tighten the bolts.
Tightening Torque 55 Nm + 90°
Notice
Install from No. 1 cap.
22. Rotate the crankshaft with hand and check whether it
rotates smoothly.
23. Measure crankshaft bearing axial clearance.
Clearance 0.100 - 0.245mm
Notice
If the clearance is out of standard, adjust the axial clearance
of crankshaft bearing by replacing the thrust washers.
Dial Gauge 001 589 53 21 00
Dial Gauge Holder 363 589 02 21 00
Notice
The same thickness of thrust washers should be installed
on both sides of the thrust bearing.

OM600 ENGINE MECHANICAL 1B3-95
3. Remove the flywheel (3), if equipped with manual
transmission.
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.

OM600 ENGINE MECHANICAL 1B3-105
VALVE SPRINGS CHECK
Preceding Work : Removal of valve spring
1 Valve Spring
Service Data
Outer diameter
33.1mmWire diameter
4.20mmFree length
50.0mmAt preloaded
Length Tension (new)
680 - 740N 27mmLimit
612N
2 Spring Scale

1B3-116 OM600 ENGINE MECHANICAL
8.000
- 8.030
9.000
- 9.05039.5 Intake
Exhaust0.029
- 0.051
0.029
- 0.051 Red
White
Red
White
Diameter ‘a’
Service Data
ItemBasic Bore
Repair size 1
Repair size 2
Repair size 1
Repair size 2Outer Diameter ‘D’
14.251
14.440 - 14.451
14.240 - 14.251
14.440 - 14.451Color 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 Guide3 Valve Seat Ring
a Basic Bore Diameter

OM600 ENGINE MECHANICAL 1B3-127
CHECK AND MACHINING OF VALVES
Preceding Works : Removal of cylinder head
Removal 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)

1B3-128 OM600 ENGINE MECHANICAL
Intake Valve Exhaust Valve
Item
Valve Disc Diameter ‘d’
Valve Disc Height ‘h’
Setting Angle “a” or Machining the Valve
Valve Stem Diameter ‘d1’
Valve Length ‘I’Intake Valve
37.90 - 38.10 mm
1.7 mm
45°
7.955 - 7.970 mm
106.20 - 106.60 mm
105.30 - 105.70
0.03 mmExhaust Valve
34.90 - 35.10 mm
1.7 mm
45°
9.945 - 8.960 mm
106.20 - 106.60 mm
105.30 - 105.70 mm
0.03 mm
Standard
Repair
Max. Permis Sible Runout at Valve Stem and Valve Seat
W = 38.0 ± 0.2mm
Matching Valves
Camshaft Cam Basic Dia.
Size (x)
Size (x)
Size (x)19.5 - 20.3mm
20.4 - 21.4mm
21.4 - 21.97mmW = 36.6 ± 0.2mm Camshaft Cam Basic Dia.
19.5 - 20.1mm
20.2 - 21.2mm
21.2 - 21.97mmValve to be Used
Use machined valve,
if needed
new repair valve
I = 105.5 ± 0.2mm
Reuse valve
Use standard size
valve
I = 106.4 ± 0.2mm

OM600 ENGINE MECHANICAL 1B3-133
Service Data
Item
Valve Arrears ‘a’
Valve Seat Width ‘b’
Valve Seat Angle ‘
a’
Valve Seat Free Angle ‘
b’
Permissible Radial Runout
Valve Length ‘I’Intake
0.1 - 0.7 mm
1.2 - 1.7 mm
45°
65°
0.03 mm
106.20 - 106.60 mm
105.30 - 105.70 mmExhaust
0.1 - 0.7 mm
1.5 - 2.0 mm
45°
65°
0.03 mm
106.20 - 106.60 mm
105.30 - 105.70 mm
Standard
Repair
w = 38.0 ± 0.2 mm
Matching Valves
Camshaft cam basic dia.
Size (x)
Size (x)
Size (x)19.5 - 20.3mm
20.4 - 21.4mm
21.4 - 21.97mmw = 37.6 ± 0.2 mm Camshaft cam basic dia.
19.5 - 20.1mm
20.2 - 21.2mm
21.2 - 21.97mmValve to be used
Use machined valve,
if needed
use pair valve
1 = 105.5 ± 0.2mm
Reuse valve
Use standard size
valve
I = 106.4 ± 0.2mm
Commercial Tools
Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Hunger
D-8000 München 70
Order No. 217 93 601 Cylinder Head Clamping Devie
Valve Seat Turning Tool
Test Sat for Valves