lock SSANGYONG MUSSO 1998 Workshop Owner's Guide

1B2-58 M161 ENGINE MECHANICAL
Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated
on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft
bearing.
Notice
lMeasure at 2 points (1, 2).
lMeasure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft
bearing journal.
Notice
lRecord the mean value when measured at 3 points
(A, B, C).
lMeasure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data,
replace the bearing shell.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and remove
the roll pin, and remove the armature.
Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7).
Installation Notice
Tightening Torque 60 - 70 Nm
Notice
Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical
spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft.
Installation Notice
Tightening Torque1st step 20 Nm
2nd step + 95°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.
12. Installation should follow the removal procedure in the
reverse order.
13. Check and adjust the camshaft timing.

M161 ENGINE MECHANICAL 1B2-73
Tools Required
111 589 01 59 00 Supporting Bar
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece
116 589 06 63 00 Magnetic Finger
Removal & Installation Procedure
1. Place the supporting bar (12) and the slide (9) at the
camshaft bearing cap (Nos 1 & 7/8&14) and tighten them
with the bearing cap bolt.
Installation Notice
2. Turn the crankshaft to position the each cylinder piston at
TDC.
5. Install the engine lock to the ring gear to prevent the
crankshaft from rotating.
6. Blow up with compressed air.Notice
lRemove the valve spring only at TDC.
lAlways rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for
smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug
hole.
Supporting Bar 111 589 01 59 00
Tightening Torque 22.5 - 27.5 Nm
Mark on The Vibration Damper
OT
UTCylinder
1, 4
2, 3

M161 ENGINE MECHANICAL 1B2-83
15. Replace the thrust piece (b) as shown in the figure. 13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool. 12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
16. Install the assembly tool to the link pin and tighten the
spindle (c).
Tightening Torque 30 Nm

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

1B3-4 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

OM600 ENGINE MECHANICAL 1B3-13
4. Remove the radiator drain cock and drain the coolant.
Notice
Open the coolant reservoir tank cap.
3. Remove the skid plate.
Installation Notice
Tightening Torque 28 - 47 Nm
5. Remove the drain plug (1) and seal (2) from the cylinder
block and drain the coolant completely.
6. After draining, replace the seal and reinstall the drain plug.
Installation Notice
7. Disconnect the lower coolant hose from the radiator.
Tightening Torque 30 Nm
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.

1B3-36 OM600 ENGINE MECHANICAL
Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber bore and
position the dial gauge with a preload of 5mm.
Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of engine rotation
until the large pointer on the dial gauge stops (TDC position).
Notice
The position of TDC is when the large pointer on the dial
gauge is stopped before moving back.
5. remove the reinstall the measuring device and position the
dial gauge scale at ‘0’.
6. Slowly rotate the crankshaft in the direction of engine rotation
until the dial gauge has moved back (counterclockwise) by
3.65mm.
7. Insert fixing device into the sensor bracket.
Notice
The pin on the vibration damper must engage into the slot
of the fixing device.
Fixing Device 667 589 01 21 00
8. If the pin does not engage, adjust the setting of the sensor
bracket by removing and tightening of the sensor bracket
bolts.
Tightening Torque 10 Nm
Notice
The timing mark on the damper must be positioned at ATDC
20.

1B3-38 OM600 ENGINE MECHANICAL
000 589 77 03 00 Box Wrench Insert
001 589 65 09 00 Socket Wrench Insert
102 589 03 40 00 Magnetic Bar
116 589 02 34 00 Threaded Pin
116 589 03 07 00 T Type Socket Wrench
116 589 20 33 00 Sliding Hammer
601 589 00 10 00 Cylinder Head Bolt Wrench
602 589 00 40 00 Engine Lock
603 589 00 40 00 Counter Holder
Tools Required
Cylinder Bolts (12-sided socket head)
(Engine cold)
M8 Cylinder Head Bolts
Tightening Torque
stage1
stage2
stage310 Nm
35 Nm
180°
25 Nm
Tightening Sequence for Cylinder Head Bolts
OM 662LA Engine
OM 661LA Engine

1B3-40 OM600 ENGINE MECHANICAL
Disassembly Procedure
1. Completely drain the coolant from the radiator and cylinder
block.
2. Remove the cooling fan shroud.
3. Hold the fan with counter holder and remove the bolt and
then remove the cooling fan.
Notice
Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
5. Remove the nut.
6. Remove the nut on the tensioning lever and insert the
rod(F12 ´ 180mm). By pushing the rod to the arrow direction,
pull back the bolt.
7. Push the tensioning lever to the opposite direction to release
the spring tension and remove the poly V-belt. 4. Remove the bracket oil dipstick tube.