length SSANGYONG MUSSO 2003 User Guide

OM600 ENGINE MECHANICAL 1B3-39
Length(L) When New80mm
102mm 115mm
Thread Dia.
M10 M10M10Max. Length(L) 82mm
104mm 117mm
The twelve-sided socket head bolts are tightened with each stages of torque and torque angle. It is not necessary to retighten the cylinder head bolts at the 1000~1500km inspection or after 1000~1500km of repairs.
Notice The cylinder head may only be removed when the engine has cooled down. The cylinder head is removed together with the exhaust manifold. As the cylinder head bolts undergo a permanent tightening. They require to bereplaced if they exceed the maximum lengthes indicatedin the table.

1B3-52 OM600 ENGINE MECHANICALLength(L)
Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.
Notice Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts. Notice If the max. length is exceeded, replace the bolts.
Thread Dia. Max. Limit(L)
M10 M10 M1080mm
102mm 115mm 82mm
104mm 117mm
when new
4. Coat the head contact surface of bolts and thread with oil
and insert them as shown. - Cylinder head bolts arrangement
Bore 1 ........................................... M10 ×
80
2 ........................................... M10 × 102
3 ........................................... M10 × 11 5
4 ........................................... M 8 × 50
5 ........................................... M 8 × 80 OM662LA

1B3-58 OM600 ENGINE MECHANICAL
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.
Tightening Torque 25 Nm
Notice Measure the max. length ‘L’ and replace the bolt if it exceeds
53.6mm.

OM600 ENGINE MECHANICAL 1B3-91
Notice If the max. length of bolts(L) exceed 63.8mm, replace them.
19. Coat the new crankshaft with engine oil and place it on the crankcase.
20. Install the crankshaft bearing caps according to marking and tighten the bolts.
Tightening Torque 55 Nm + 90 °
Notice Install from No. 1 cap.
22. Rotate the crankshaft with hand and check whether it rotates smoothly.
23. Measure crankshaft bearing axial clearance.
Clearance 0.100 - 0.245mm
Notice If the clearance is out of standard, adjust the axial clearance of crankshaft bearing by replacing the thrust washers.
Dial Gauge 001 589 53 21 00
Dial Gauge Holder 363 589 02 21 00
Notice The same thickness of thrust washers should be installed on both sides of the thrust bearing.

OM600 ENGINE MECHANICAL 1B3-95
3. Remove the flywheel (3), if equipped with manualtransmission. Installation Notice Correctly align the position of dowel pin (2).
Tools Required 602 589 00 40 00 Engine Lock Removal & Installation Procedure
1. Install the engine lock.
Engine Lock 602 589 02 40 00
2. Remove the 12-sided stretch bolts (4). Installation Notice
Tightening Torque 45 Nm + 90 °
Notice If the length ‘L’ of bolts exceeds 22.5mm, replace the bolts.

OM600 ENGINE MECHANICAL 1B3-105
VALVE SPRINGS CHECK Preceding Work : Removal of valve spring
1 Valve Spring
Service Data
Outer diameter33.1mm Wire diameter
4.20mm Free length
50.0mm At preloaded
Length Tension (new)
680 - 740N
27mm Limit
612N
2 Spring Scale

1B3-116 OM600 ENGINE MECHANICAL8.000
- 8.030 9.000
- 9.050 39.5
Intake Exhaust 0.029
- 0.051 0.029
- 0.051
Red
White Red
White
Diameter ‘a’
Service DataItemBasic Bore
Repair size 1 Repair size 2 Repair size 1Repair size 2Outer Diameter ‘D’
14.251
14.440 - 14.451 14.240 - 14.25114.440 - 14.451 Color 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 Guide 3 Valve Seat Ring
a Basic Bore Diameter

OM600 ENGINE MECHANICAL 1B3-127
CHECK AND MACHINING OF VALVES
Preceding Works : Removal of cylinder headRemoval 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 ValveExhaust Valve
Item
Valve Disc Diameter ‘d’
Valve Disc Height ‘h’
Setting Angle “ ” or Machining the Valve
Valve Stem Diameter ‘d1 ’
Valve Length ‘I’ Intake Valve
37.90 - 38.10 mm 1.7 mm45 °
7.955 - 7.970 mm
106.20 - 106.60 mm 105.30 - 105.70 0.03 mm Exhaust V
alve
34.90 - 35.10 mm 1.7 mm45 °
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 ValvesCamshaft Cam Basic Dia.
Size (x)
Size (x) Size (x) 19.5 - 20.3mm
20.4 - 21.4mm
21.4 - 21.97mm W = 36.6 ± 0.2mm
Camshaft Cam Basic Dia.
19.5 - 20.1mm
20.2 - 21.2mm
21.2 - 21.97mm Valve 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 1B3-133
Service DataItem
Valve Arrears ‘a’
Valve Seat W idth ‘ b ’
Valve Seat Angle ‘ ’
Valve Seat Free Angle ‘ ’
Permissible Radial Runout
Valve Length ‘I’ Intake
0.1 - 0.7 mm1.2 - 1.7 mm 45°
65 °
0.03 mm
106.20 - 106.60 mm105.30 - 105.70 mm Exhaust
0.1 - 0.7 mm1.5 - 2.0 mm 45°
65 °
0.03 mm
106.20 - 106.60 mm105.30 - 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 - 21.97mm w = 37.6 ± 0.2 mm
Camshaft cam basic dia.
19.5 - 20.1mm
20.2 - 21.2mm
21.2 - 21.97mm Valve 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 M ünchen 70
Type Ventilknecht K2000 Order No. 221 00 100HungerD-8000 M ünchen 70
Type VDS 1AOrder No. 236 03 308HungerD-8000 M ünchen 70
Order No. 217 93 601
Cylinder Head Clamping Devie
Valve Seat Turning Tool
Test Sat for Valves