engine SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-125
8. Turn over the cylinder head.
9. Remove the tensioning head (4) and valve seat ring (2)
with drift (14mm) and removal tool.
10. Clean the basic bore of valve seat ring.
11. Measure the basic bore diameter (D2) and outer diameter
(D) of the new valve seat ring (standard size).
12. Calculate the overlap value ‘U’ (D - D2).
Overlap Value ‘U’ 0.068 - 0.100mm
Example)Measured value D = 37.100mm
Measured value D2 = 37.010mm
Overlap value ‘U’ = 0.090mm
If overlap value ‘U’ is out of standard, machine
the basic bore for the valve seat ring.
13. Clamp the cylinder head with clamping device.
14. Machining basic bore for valve seat ring (repair size).
Notice
Maintain minimum value of ‘B’.
- Machine the basic bore.
Limit
Intake
Exhaust
Max. D2
Min. B40.516mm
37.516mm
133.4mm
- Measure machined basic bore and outer diameter ‘D’
of valve seat ring (repair size).
- Measure the overlap ‘U’
Overlap ‘U’ (D - D2) 0.068 - 0.100 mm
Example) Measured value D = 37.600 mm
Measured value D2 = 37.480 mm
Overlap U = 0.120 mm
The basic diameter D2 must be machined by
0.020mm in order to get the required overlap
value.

1B3-126 OM600 ENGINE MECHANICAL
17. Drive in new valve seat ring (2) with a proper wooden drift.
18. Install the valve guide (3) with a proper drift and assembling
tool.
Notice
The valve guide must be driven in from the cylinder head
cover.
Drift (Intake) 8mm
Drift (Exhaust) 9mm
19. Machine the valve seats.
15. Hang the cylinder head (1) to the lifting device and heat in
a water tank to approx. 80°C.
16. Cool down new valve seat ring (2) into the cooling box with
liquid nitrogen.
Notice
Do not touch the cooled valve seat rings with hand.
Super Cooling Box 345 589 00 63 00

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 1B3-129
Tools Required
001 589 32 21 00 Dial Gauge
Checking and Machining
1. Clean the valves and do visual check.
Valves with wobbled valve disc, with worn or scored valve
stem should be replaced.
2. Measure valve disc height ‘h’.
Service data
Intake
Exhaust1.7 ± 0.15 mm
1.7 ± 0.15 mm
3. Machine the valve.
Notice
Pay attention to setting angle ‘a’.
Commercial Tool
Valve corn grinding machine
4. Measure radial runout between valve stem and valve seat.
Limit Max. 0.03mm
Dial Gauge 001 589 32 21 00

1B3-130 OM600 ENGINE MECHANICAL
10. Measure distance ‘z’ (cylinder head cover parting surface
- valve stem). 5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve guide.
7. Insert the valves (1) into the valve guides according to
marking.
8. Measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7 mm
Notice
If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
Diameter ‘w’38 ± 0.2 mm
or 37.6 ± 0.2 mm

OM600 ENGINE MECHANICAL 1B3-131
11. The distance ‘x’ (camshaft basic bore - valve stem).
‘x’ = ‘z’ - ‘y’.
Determine the valve to use according to this measurement
(See ‘matching valves’)
Example)Measured value ‘w’ = 38.2 mm
Measured value ‘z’ = 36.5 mm
Value ‘y’ = 15.5 mm
‘x’ = 36.5 - 15.5 = 21.0mm
In this case according to ‘Matching valves’ table, the
installed valve may be used.

1B3-132 OM600 ENGINE MECHANICAL
MACHINING OF VALVE SEAT
Preceding Work : Removal of prechamber
Removal and inspection of valve, replace if necessary
Inspection of valve guide, replace if necessary
1 Valve
2 Valve Seat Ring
3 Cylinder Head
4 Valve Guidea Valve Seat Angle
b Valve Seat Free Angle

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

1B3-134 OM600 ENGINE MECHANICAL
Machining Procedure
Valve machining is required :
- When the valve is leaking.
- When replacing the valve.
- When replacing the valve guide.
- When replacing the valve seat or valve seat ring.
1. Machine the valve seat (a=45°).
2. Measure valve seat width ‘b’.
Valve seat
width ‘b’1.2 - 1.7 mm
1.5 - 2.0 mm Intake
Exhaust
3. If the specification is exceeded, the valve seat width has to
be corrected at the lower free angle of ‘
b’=65°.
4. Measure radial runout.
Runout Max. 0.03mm