engine SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-85
3 Crankshaft Main Bearing Shells (Upper)
4 Thrust Bearings (Upper)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)A Radial Bearings
B Radial and Axial Bearings (Thrust Bearing)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.
OM661LA Engine

1B3-86 OM600 ENGINE MECHANICAL
24.500 - 24.533
24.600 - 24.633
24.700 - 24.733
24.900 - 24.933
25.000 - 25.033New
Limit
New
Limit Radial clearances
Axial clearancesCrankshaft bearing
journal diameter Crankshaft Standard and Repair Sizes
Standard size 50.950 - 57.965
journal width
24.500 - 24.533
24.600 - 24.633
24.700 - 24.733
24.900 - 24.933
25.000 - 25.033
-Thrust bearing
journal diameter
47.950 - 47.965 Thrust bearing
47.700 - 47.715
47.450 - 47.650
47.200 - 47.215
46.950 - 46.965 57.500 - 57.715
57.450 - 57.465
57.200 - 57.215
56.950 - 56.965 Repair size 1
Repair size 2
Repair size 3
Repair size 4
Bearing Clearances
Thrust bearingCrankshaft bearing
0.026 - 0.068
Max. 0.080
-
- 0.027 - 0.051
Max. 0.070
0.100 - 0.254
Max. 0.300
Matching Fit Bearing Journal Width to Thrust Bearings
Fit bearing journal width Thrust bearings thickness
2.15
2.20
2.25
2.35
2.40
Notice
lMeasure crankshaft axial clearance and adjust with proper thrust Bearing.
lThe same thickness of washer must be installed on both sides of the fit bearing.mm
mm
mm

OM600 ENGINE MECHANICAL 1B3-87
bearing shell Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft
Marking of basic bearing bore in lowerColor code of relevant crankshaft
parting surface
1 punch mark or blue
2 punch marks or yellow
3 punch marks or redbearing shell
Blue or white-blue
Yellow or white-yellow
Red or white-red
Marking of bearing journals on crank websColor code of relevant crankshaft
Blue or white-blue
Yellow or white-blue
Red or white-blueBlue or white-blue
Yellow or white-yellow
Red or white-red

1B3-88 OM600 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the bearing cab bolt.
2. Remove the bearing caps (8).
Notice
The crankshaft bearing caps are marked with stamped
numbers. Remove the bearing cap from the vibration
damper side.
3. Remove the crankshaft bearing caps (9) and lower thrust
bearings (7).
4. Remove the lower thrust bearings (6) from the bearing cap
(9).
5. Remove the crankshaft (5).
6. Remove the upper thrust bearings(4).
7. Remove the upper bearing shells (3) from crankcase.

OM600 ENGINE MECHANICAL 1B3-89
14. Measure crankshaft bearing journal diameter (F).
Notice
When measured in A and B, the runout should not exceed
0.010mm.
8. Thoroughly clean the oil gallery.
9. Select a proper new bearing shells with reference to table.
10. Coat the new bearing shells with oil and insert into the
crankcase and into the crankshaft bearing caps.
Notice
Do not mix up upper and lower crankshaft bearing shells.
11. Install the bearing caps according to marking and tighten
the 12-sided stretch bolts.
Tightening Torque 35 - 40 Nm
Notice
No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E).
Extension 366 589 00 21 05
13. Measure at 3 points (A, B and C) and if the average value
of B and C is less than A’s value, the average value of B
and C is the mean value and if more than A’s value, A’s
value is the mean value.

1B3-90 OM600 ENGINE MECHANICAL
15. Measure radial clearance of crankshaft bearing (G).
Clearance ‘G’0.027 - 0.051mm
Notice
If ‘G’ is out of standard, replace the bearing shells and
adjust the radial clearance of crankshaft bearing.
Example)Measured value ‘E’ = 57.700mm
Measured value ‘F’ = 57.659mm
Clearance ‘G’ = 0.041mm
16. Remove the crankshaft bearing cap.
17. Measure width of thrust bearing journal (H) and adjust with
proper thrust bearings (see table).
Notice
The same thickness of thrust washers should be installed
on both sides of the thrust bearing.
18. Coat the upper thrust bearing (4) with oil and insert into
the crankcase so that the oil grooves are facing the crank
webs (arrow).
19. Coat the lower thrust bearing (7) with oil and insert into the
crankshaft bearing cap so that the oil grooves are facing
the crank webs (arrow).
Notice
The retaining lugs should be positioned in the grooves
(arrow).

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.

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotates
smoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve.
- clean the oil pump and oil filter housing carefully and
replace the hose if necessary.
Notice
After assembling the engine, check the camshaft timing,
adjust the start of fuel injection and check the TDC sensor
bracket setting.
32. Fill oil and run the engine and then check the oil pressure
and oil level.
Notice
Install the original oil filter element and then change the
engine oil and oil filter element after 1,000 - 1,500km. 27. Measure the radial clearance (L) of the connecting rod
bearing.
Example)Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’ 0.026 - 0.068mm
Notice
If the clearance is out of standard, adjust the radial
clearance of connecting rod bearing by replacing the
connecting rod bearing shells. 26. Measure connecting rod bearing journal diameter (K).
Notice
Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into the
connecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90°

OM600 ENGINE MECHANICAL 1B3-93
FLYWHEEL
Preceding Work : Removal of the transmission
Removal of the clutch
1 Oil Pan
2 Straight Pin
3 Flywheel4 12-Sided Stretch Bolt............Check, 45Nm + 90°
5 Drive Plate (Automatic Transmission)
6 Flywheel (Automatic Transmission)

1B3-94 OM600 ENGINE MECHANICAL
lManual transmission flywheel
lAutomatic transmission flywheel
OM661LA OM662LA