service SSANGYONG MUSSO 1998 Workshop Workshop Manual

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

1B3-122 OM600 ENGINE MECHANICAL
VALVE SEAT RINGS
Preceding Work : Removal of valve
Checking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head
2 Valve Seat Ring
3 Valve Guide
A Height (Cylinder Head Upper / Lower Surface)
B Height (cylinder Head Cover Surface - Seat of
Valve Seat Ring)D Valve Seat Ring Outer Diameter
D1 Valve Seat Ring Inner Diameter
D2 Basic Bore Diameter
H Height of Valve Seat Ring
Service Data
Item
D2
D
D1
H
Overlap U=D-D2
B
AIntake
40.000 - 40.016mm
40.084 - 40.100mm
33.400 - 33.600mm
6.955 - 7.045mm
0.068 - 0.100mm
133.4mm
142.5mmExhaust
37.000 - 37.016mm
37.084 - 37.100mm
30.400 - 30.600mm
6.955 - 7.045mm
0.068 - 0.100mm
133.4mm
142.5mm

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

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

1B3-164 OM600 ENGINE MECHANICAL
Service Data
Piston clearance
Piston crown protrusion in TDC position
Connecting rod bushing diameterMax. 0.12 mm
0.735 - 0.965 mm
26.012 - 26.018 mm
Connecting Rod Bolt Dimensions
Thread
Stretch shaft(C) diameter (new)
Minimum stretch shaft diameter (C)
Length(L)(new)
Tools Required
000 589 04 14 00 Tensioning Strap
001 589 53 21 00 Dial Gauge
363 589 02 21 00 Dial Gauge HolderM9 x 1
7.4
-0.1 mm
7.1 mm
52
-0.3 mm

1B3-178 OM600 ENGINE MECHANICAL
Height ‘A’
(cylinder head surface - cylinder head cover surface)
Minimum height after machining
Permissible unevenness of parting surface
Permissible variation of parallelism (longitud. Direction)
Peak-to-valley height
Valve arrears ‘a’
Prechamber protrusion
Service Data
In longitudinal direction
In transverse direction
Intake valve
Exhaust valve142.9 - 143.1mm
142.5mm
0.08mm
0.0mm
Max. 0.1mm
0.0017mm
0.1 - 0.7mm
0.1 - 0.7mm
7.6 - 8.1mm
FACING CYLINDER HEAD MATING SURFACE
Preceding Work : Removal of prechamber
Cylinder head pressure leakage test
1 Valve
2 Cylinder Head
3 Prechamber
A Height of Cylinder HeadB Longitudinal Direction
C Transverse Direction
a Valve Arrears
b Prechamber Protrusion

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 1B3-187
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

M162 ENGINE COOLING 1D1-5
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP
Draning & Filling up Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, the cap must not be opened unless
the coolant temperature is below 90
oC.
2. Loosen the radiator lower drain cock and drain the coolant.
Notice
Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose
(dia. 14mm) onto the drain bolt on the side of crankcase
(exhaust manifold) and by loosening the plug.
Notice
lJust loosen the drain plug to drain the coolant and do
not remove the plug completely.
lCollect coolant by using proper container.
4. After complete draining of the coolant, remove the hose
connector to drain plug and reinstall the drain plug.
Installation Notice
5. Tighten the radiator lower drain cock.
Tightening Torque 30 Nm