SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-109
VALVE SPRINGS (CYLINDER HEAD INSTALLED)
Preceding Work : Removal of camshaft
1 Valve Tappet
2 Valve Cotters
3 Spring Retainer4 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 Finger
603 589 01 40 00 Holding Wheel
667 589 00 31 00 Press Lever
667 589 02 63 00 Supporting Bar

1B3-110 OM600 ENGINE MECHANICAL
5. Using the press lever (9), press the spring retainer(3)
downward and remove the valve cotters (2) with magnetic
finger (10).
Notice
Be careful not to damage guide bore of the valve tappet.
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00
Removal & Installation Procedure
1. Remove the valve tappet (1) with magentic lifter.
Notice
Place the valve tappets upside down (open end upward)
Magentic Liter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain of camshaft
sprocket piston.
Holding Wheel 603 589 01 40 00
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
Supporting Bar 667 589 02 63 00

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) facing
down 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.

OM600 ENGINE MECHANICAL 1B3-113
Tools Required
667 589 00 31 00 Press Lever
104 589 00 37 00 Pliers
102 589 03 40 00 Magnetic Lifter
603 589 01 40 00 Holding Wheel
601 589 02 43 00 Drift
116 589 06 63 00 Magnetic Finger
667 589 02 63 00 Supporting Bar
A : Intake valve stem seal
B : Exhaust valve stem seal
Chamfer
Inner diameter ‘d’
Color
Wire ringIntake valve stem seal
Offset
7.3mm
Brown
BlackExhaust valve stem seal
All round
8.2mm
Green
Yellow

1B3-114 OM600 ENGINE MECHANICAL
Replacement Procedure
1. Remove the valve tappet (1) with magnetic lifter.
Notice
Place the valve tappets upside down (open end upward).
Magnetic Lifter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain (11).
Holding Wheel 603 589 01 40 00
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
Supporting Bar 667 589 02 63 00
5. Using press lever (9), press the spring retainer(3) downward
and remove the valve collets with magnetic finger (10).
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00

OM600 ENGINE MECHANICAL 1B3-115
6. Remove the spring retainer(3) and valve spring (4).
7. Remove the valve stem seal (5).
Pliers 104 589 00 37 00
8. Insert the cap (12) onto the valve (6) and install the new
valve stem seal (5) and then remover the cap.
Drift 601 589 02 43 00
9. By pressing the spring seat with press lever (9), install the
valve cotters(2) with magnetic finger (10).
Notice
Be careful not to damage guide bore of the valve tappet.
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00

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 1B3-117
Tools Required
000 589 10 53 00 Reamer (for Exhaust)
000 589 10 68 00 Cylinder Brush
000 589 21 53 00 Reamer (for Intake)
102 589 00 23 00 GO / NO GO Gauge (for Intake)
103 589 02 15 00 Drift (for Exhaust)
103 589 03 15 00 Drift (for Intake)
117 589 03 25 00 GO / NO GO Gauge (for Exhaust)
346 589 00 63 00 Super Cooling Box
601 589 02 23 00 GO/NO GO Gauge
601 589 05 15 00 Drift (for Intake)
Notice
Measure center (arrow) of the valve guide and if the inner
diameter ‘A’ exceeds standard value, replace the guide.
601 589 06 15 00 Drift (for Exhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves
Valve Seat
Intake
Exhaust
Intake
ExhaustBroaching Tool No.
115 589 00 53 00
(14.2mm)
115 589 01 53 00
(14.4mm)Guide Sleeve Tool No.
102 589 00 63 00
102 589 08 63 00Guide Sleeve Side
B
B
A
B
601 589 15 63 00

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. If
the 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