engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1B2-108 M161 ENGINE MECHANICAL
Group Code Letter and Cylinder Bore Size
CYLINDER BORE
Group Code Letter of Cylinder
A
X
B
X + 5
X + 10
A
X
B
X + 5
X + 10Piston Type to be Used
A or X
A, X or B
X or B
X + 5
X + 10
A or X
A, X or B
X or B
X + 5
X + 10Cylinder Bore Size (mm)
f 90.906 - f 90.912
f 90.906 - f 90.912
f 90.912 - f 90.918
f 90.950 - f 90.968
f 91.000 - f 91.018
f 89.900 - f 90.906
f 89.906 - f 89.912
f 89.912 - f 89.918
f 89.950 - f 89.968
f 90.000 - f 90.018
Engine
E23
E20

M161 ENGINE MECHANICAL 1B2-109
Service Data Standard
Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points
A . Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
Wear Limit in Longitudinal and Transverse Direction
Permissible Deviation of Cylinder Out-of-round
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)
Basic Peak-to-valley Height After Final Honing and Brushing
Chamfer Angle
Honing AngleWhen new
Wear limit0.1 mm
0.007 mm
0.05 mm
0.05 mm
0.003 - 0.006 mm
75°
50° ± 10°
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.Type
Standard Size
E20 :
f 89.9
E23 :
f 90.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5)Group Code Letter
1)
A
X
B
A
X
B
A
X
BCylinder Bore Size (mm)f 89.900 - f 90.906
f 89.906 - f 89.912
f 89.912 - f 89.918
f 90.150 - f 90.156
f 89.156 - f 90.162
f 90.162 - f 90.168
f 90.400 - f 90.406
f 90.406 - f 90.412
f 90.412 - f 90.418

1B2-110 M161 ENGINE MECHANICAL
CRANKCASE MATING SURFACE
Service Data Standard
Height of the Crankcase “H” (When New)
Minimum Height After Milling
Flatness
Permissible Deviation of Parallelism of the
Upper to Lower Mating Surface
Peak-to-valley HeightCrankcase Upper Mating Surface
Crankcase Lower Mating Surface
Axial Direction
Transverse Direction
Crankcase Upper Mating Surface
Crankcase Lower Mating Surface289.35 - 289.45mm
289.05mm
0.03mm
0.04mm
0.1mm
0.05mm
0.012 - 0.009mm
0.025 - 0.020mm

M161 ENGINE MECHANICAL 1B2-111
Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder after
finishing the chamfering with a suitable tool (e.g., hand milling
cutter).

1B2-112 M161 ENGINE MECHANICAL
CYLINDER HEAD MATING SURFACE
Preceding Work : Removal of valves
Service Data Standard
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.Overall Height of Cylinder Head
Minimum Height After Machining
Flatness
Distance ‘T’
(Between Camshaft Bearing
and Valve Stem)Axial Direction
Transverse Direction
Standard Size
Repair Size135.9 - 136.0 mm
135.5 mm
0.08 mm
0.0 mm
24.21 - 24.75 mm
22.21 - 22.75 mm
23.96 - 24.51 mm
21.96 - 22.51 mm
Intake
Exhaust
Intake
Exhaust

M161 ENGINE MECHANICAL 1B2-113
Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard
).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to
Service data standard).
7. Mill the cylinder head valve seat (refer to
Service data
standard
).
Universal Tool
Surface Grinding MachineSceledum, Type RTY
Roaro
Schio/Italy

SECTION 1B3
OM600 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B3-2
Fastener Tightening Specifications . . . . . . . . 1B3-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B3-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B3-4
Maintenance and Repair . . . . . . . . . . . . . 1B3-12
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B3-12
Engine Assembly . . . . . . . . . . . . . . . . . . . . 1B3-12
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-21
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B3-23
Poly V-Belt Alignment & Inspection . . . . . . . 1B3-26
Prechamber . . . . . . . . . . . . . . . . . . . . . . . . 1B3-29
Milling of Prechamber Sealing Surface . . . . 1B3-32
TDC (TDC Sensor Bracket) Setting . . . . . . 1B3-35
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B3-37
Timing Case Cover . . . . . . . . . . . . . . . . . . . 1B3-63
Crankshaft End Cover . . . . . . . . . . . . . . . . 1B3-71
Vibration Damper and Hub . . . . . . . . . . . . . 1B3-74
Crankshaft Front Radial Seal . . . . . . . . . . . 1B3-80
Crankshaft Ball Bearing . . . . . . . . . . . . . . . 1B3-82
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-83
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-93
Machining of Flywheel . . . . . . . . . . . . . . . . 1B3-97
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . 1B3-98
Hydraulic Valve Clearance Compensation
Element Check . . . . . . . . . . . . . . . . . . . . 1B3-101
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . 1B3-103
Valve Spring Check . . . . . . . . . . . . . . . . . 1B3-105
Valve Springs (Cylinder Head Removed) . 1B3-106
TABLE OF CONTENTS
Valve Springs (Cylinder Head Installed) . . 1B3-109
Valve Stem Seals . . . . . . . . . . . . . . . . . . . 1B3-112
Check and Replacement of
Valve Guides . . . . . . . . . . . . . . . . . . . . . 1B3-116
Valve Seat Rings . . . . . . . . . . . . . . . . . . . 1B3-122
Check and Machining of Valves . . . . . . . . 1B3-127
Machining of Valve Seat . . . . . . . . . . . . . . 1B3-132
Camshaft Timing Test . . . . . . . . . . . . . . . . 1B3-137
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-139
Chain Tensioner . . . . . . . . . . . . . . . . . . . . 1B3-145
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . 1B3-147
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . 1B3-151
Cylinder Head Guide Rail . . . . . . . . . . . . . 1B3-152
Timing Case Cover Guide Rail . . . . . . . . . 1B3-156
Crankshaft Sprocket . . . . . . . . . . . . . . . . . 1B3-158
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-163
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-169
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-171
Oil Spray Nozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-175
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B3-177
Cylinder Head Pressure Leakage Test . . . 1B3-177
Facing Cylinder Head Mating Surface . . . . 1B3-178
Replacement of Crankcase Core Plug . . . 1B3-180
Facing Crankcase Contacting Surface . . . 1B3-182
Oil Gallery Steel Ball . . . . . . . . . . . . . . . . . 1B3-183
Cylinder Bore Measurement . . . . . . . . . . . 1B3-187

1B3-2 OM600 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N
· ·· ·
·m
28 - 47
30
3 - 7
8 - 18
20 - 34
30
70 - 80
81 - 84
50 - 75
N
· ·· ·
·m
10
23
200 / 90°
10
55 / 90°
45 / 90°
25 / 90°
25
N
· ·· ·
·m
35 / 90°
N
· ·· ·
·m
45 / 90°Application
Skid Plate Bolt
Drain Plug Bolt
Coolong Fan Shroud Bolt
Control Linkage Nut
Clutch Linkage Cylinder Nut
Exhaust Manifold Bolt
Propeller Shaft Bolt & Nut (Axle)
Propeller Shaft Bolt & Nut(T/C)
Engine Mounting Nut
Application
Cooling Fan Belt Pulley Bolt
Socket Bolt
Tighten The Bolt
End Cover Bolt
Crankshaft Bearing Cap Bolt
Ball Bearing
Camshaft Sprocket Bolt
Oil Pump Sprocket Bolt
Application
Connecting Rod Bolt
Application
12-Sided Stretch Bolt
Engine Assembly
Crankshaft Assembly
Piston
Flywheel
Cylinder Head
Application
Prechamber Threaded Ring
Cylinder Head Cover Bolt
Fuel Injsction Pipe Nut
Socket Bolt
Fuel Filter Pipe Bolt
Idle Pulley Bolt
Damper BoltN
· ·· ·
·m
130
10
18
25
25
23
21

OM600 ENGINE MECHANICAL 1B3-3
N
· ·· ·
·m
12
25
25
25 / 90°
N
· ·· ·
·m
10
10
23
32
4
23
80
23Application
Stud Bolt
Exhaust Manifold Not
CamShaft Bearing Cap Bolt
12-Sided Bolt (M11)
Application
Oil Pan Bolt-Socket Bolt
Oil Pan Bolt- M6
Oil Pan Bolt- M23
Belt Pulley Bolt
Guide Pulley Bolt
Guide Pulley Bracket Nut
Chain Tensioner
Tesioning Lever Bolt
Cylinder Head
Application
Camshaft Bearing Cap Bolt
Camshaft Sprocket Bolt
Exhaust Pipe Bolt& Nut
Chain Tensioner
Injection Nozzle
Intake Manifold Not
Injection Nozzle Pipe Not
Oil Dipstick Tube Bolt
Screw Plug M18 x 15N
· ·· ·
·m
25
25 / 90°
25
80
40
25
18
10
50
Cam Support & Shaft
Timing Cover

1B3-4 OM600 ENGINE MECHANICAL
SPECIAL TOOLS
SPECIAL TOOLS TABLE
603 589 00 09 00
Serration Wrench
657 589 03 63 00
Sliding Hammer000 589 77 03 00
Box Wrench Insert
601 589 00 66 00
Counter Sink
667 589 00 23 00
Height Gauge602 589 00 40 00
Engine Lock
116 589 20 33 00
Sliding Hammer603 589 00 40 00
Counter Holder