SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-179
Measurement Procedure
1. Measure height ‘A’.
Limit 142.5 mm
Notice
If the height is less than 142.5mm, replace the cylinder head.
2. Insert the valve (1) and measure valve arrears ‘a’.
Valve Arrears ‘a’ 0.1 - 0.7 mm
Notice
If out of standard, machine the valve seat.
3. Install the prechamber and measure protrusion ‘C’.
Protrusion ‘C’ 7.6 - 8.1mm
4. Assemble the engine and check the valve timing.

1B3-180 OM600 ENGINE MECHANICAL
REPLACEMENT OF CRANKCASE CORE PLUG
Left Right
Core plug.......................................................
f 34mm
OM661LA - 2EA
OM662LA - 3EACore plug.......................................................f 34mm
OM661LA - 2EA
OM662LA - 3EA
Core plug.......................................................
f 17mm
OM661LA - 1EA
OM662LA - 1EACore plug.......................................................f 34mm
OM661LA - 1EA
OM662LA - 1EA Left
Right

OM600 ENGINE MECHANICAL 1B3-181
Tools Required
102 589 00 15 00 Drift
102 589 12 15 00 Drift
Replacement Procedure
1. Completely drain the coolant.
2. Remove any parts which impede access.
(Example : transmission, injection pump)
3. Place the screwdriver to the deepdrawn edge of the core
plug and pull forward and then rotate 90°.
4. Pull out the core plug with pliers.
5. Thoroughly clean the sealing surface and apply Loctite 241.
6. Install the new core plug by using a drift.
Drift 102 589 00 15 00 (F34)
Drift 102 589 12 15 00 (F17)
7. Install the removed parts and fill the coolant.
Notice
The adhesive must be allowed to harden for about 45
minutes before filling of coolant.
8. Warm up the engine and check the coolant for leaks.

1B3-182 OM600 ENGINE MECHANICAL
Service Data
Height ‘Y’
Permissible unevenness of contacting surface
Permissible roughness upper contacting surface
Permissible variation of parallelism of crankcase upper
surface to lower surface in longitudinal direction
Piston protrusion at TDC to crankcase upper surface
In longitudinal direction (B)
In transverse direction (C)Min. 299.62 mm
0.06 mm
0.06 mm
0.0006 - 0.0016 mm
0.05 mm
0.965 mm
0.735 mm
Max.
Min.
FACING CRANKCASE CONTACTING SURFACE
1 Crankcase
2 Crankcase Contacting Surface
Y Height (crankcase upper surface - crankcase
lower surface)B Longitudinal Direction
C Transverse Direction
H Chamfer Height
b Chamfer Angle

OM600 ENGINE MECHANICAL 1B3-183
OIL GALLERY STEEL BALL
Preceding Work : Removal of cooling fan
Removal of the coolant pump housing
Removal of the flywheel and driven plate
1 Steel Ball.................................................f15mm 2Screw Plug...............................Loctite 241,50Nm
Notice
The screw plug (2) has to be installed as a repair solution if the steel ball (1) is leaking.

1B3-184 OM600 ENGINE MECHANICAL
3 Steel Ball.................................................f17mm
4 Seal5 Screw Plug.................................................50Nm
Notice
The seal (4) and screw plug (5) have to be installed as a repair solution if the steel ball (3) is leaking.
Tools Required
601 589 08 15 00 Drift

OM600 ENGINE MECHANICAL 1B3-185
Removal & Installation Procedure
1. Remove the timing case cover.
2. By inserting a round bar (6) approx. 0.7m from the back to
the front side through the oil gallery, knock out the steel
balls (1,3).
Notice
Be careful not to damage the bores of the steel balls.
6 Shop-made tool
3. Thoroughly clean the bores of steel balls.
4. Place the steel ball (3) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 15 00
5. Place the steel ball (1) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 1500
6. Warm up the engine and check the oil for leaks.

1B3-186 OM600 ENGINE MECHANICAL
Installation of Screw Plug
Notice
If steel ball leaks again, install the screw plug.
1. Remove the steel ball.
2. Tap thread into the bores of the oil gallery.
Notice
Front bore : M18 ´ 1.5, depth 10mm
Rear bore : M16 ´ 1.5, depth 14mm
3. Thoroughly clean the oil gallery.
4. Tighten the front plug (5) with seal (4).
5. Apply Loctite 241 and then tighten the rear plug (2).
Tightening Torque 50 Nm
Tightening Torque 50 Nm

OM600 ENGINE MECHANICAL 1B3-187
Standard size
Wear limit in direction of travel and in transverse direction
Permissible deviation of cylinder shape
Honing angle
CYLINDER BORE MEASUREMENT
a Longitudinal Direction
b Transverse Direction
c, d, e. Measuring Point
1 Crankcase Contacting Surface
2 TDC of 1st Piston Ring
4 BDC of Ring
Service Data
Code letter ‘A’
Code letter ‘X’
Code letter ‘B’
When new
Wear limit89.000 - 89.006mm
89.006 - 89.012mm
89.012 - 89.018mm
Max. 0.20mm
0.01mm
0.05mm
50° ± 10°

SECTION 1D1
M162 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D1-1
General Specifications . . . . . . . . . . . . . . . . . 1D1-1
Fastener Tightening Specifications . . . . . . . . 1D1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D1-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D1-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-4
System Leakage Test . . . . . . . . . . . . . . . . . . 1D1-4
Maintenance and Repair . . . . . . . . . . . . . . 1D1-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1D1-5Coolant Drain and Fill Up . . . . . . . . . . . . . . . 1D1-5
Coolant Connection Fitting . . . . . . . . . . . . . . 1D1-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-10
Oil Cooler Pipe Line . . . . . . . . . . . . . . . . . . 1D1-11
Cooling Fan and Viscous Clutch . . . . . . . . . 1D1-12
Cooling Fan Shroud . . . . . . . . . . . . . . . . . . 1D1-14
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS
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.
TABLE OF CONTENTS
Description
Water Cooling Forced Circulation
Double Cross Flow
70,000 kcal/h
580 x 482 x 45 mm

f 460, Six Blades
ALUTEC - P78
50 : 50
11.3 L
3.4 L
1.4 bar Application
Cooling Type
Radiator
Dimension(Width´Height´Thickeness)
Cooling Fan
Anti-Freeze Agent
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water)
Coolant Capacity
Reservoir Capacity
Cap Operating Pressure (Reservoir Tank Pressure Cap)
Circulation Type
Radiation Capability