SSANGYONG MUSSO 2003 Service Manual

M161 ENGINE MECHANICAL 1B2-109
Service Data Standard Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size inaxial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points
A . Axial Direction B. Transverse Directiona. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c . Location of the Oil Ring at BDC
Chamfer Angle
Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out-of-round Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) Basic Peak-to-valley Height After Final Honing and Brushing Chamfer AngleHoning Angle When new
Wear limit
0.1 mm
0.007 mm 0.05 mm0.05 mm
0.003 - 0.006 mm
75°
50 ° ± 10 °
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase. Type
Standard Size E20 :
89.9
E23 :
90.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5) Group Code Letter
1)
A XB A XBAX B Cylinder Bore Size (mm)
89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
90.150 - 90.156
89.156 -
90.162
90.162 - 90.168
90.400 - 90.406
90.406 - 90.412
90.412 - 90.418

1B2-110 M161 ENGINE MECHANICAL
CRANKCASE MATING SURFACE
Service Data StandardHeight of the Crankcase “H” (When New)
Minimum Height After Milling Flatness Permissible Deviation of Parallelism of the Upper to Lower Mating SurfacePeak-to-valley Height Crankcase Upper Mating SurfaceCrankcase Lower Mating SurfaceAxial Direction
Transverse Direction Crankcase Upper Mating SurfaceCrankcase Lower Mating Surface289.35 - 289.45mm
289.05mm0.03mm0.04mm0.1mm
0.05mm
0.012 - 0.009mm0.025 - 0.020mm

M161 ENGINE MECHANICAL 1B2-111
Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

1B2-112 M161 ENGINE MECHANICAL
CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves
Service Data Standard Notice Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.Overall Height of Cylinder HeadMinimum Height After MachiningFlatness Distance
‘T’
(Between Camshaft Bearing
and Valve Stem) Axial Direction
Transverse DirectionStandard Size Repair Size 135.9 - 136.0 mm
135.5 mm0.08 mm 0.0 mm
24.21 - 24.75 mm 22.21 - 22.75 mm 23.96 - 24.51 mm21.96 - 22.51 mm
Intake ExhaustIntakeExhaust

M161 ENGINE MECHANICAL 1B2-113
Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard ).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard ).
Universal Tool Surface Grinding Machine
Sceledum, Type RTYRoaro
Schio/Italy

SECTION 1B3
OM600 ENGINE MECHANICAL
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 otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B3-2Fastener Tightening Specifications . . . . . . . . 1B3-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B3-4 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B3-4
Maintenance and Repair . . . . . . . . . . . . . 1B3-12
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B3-12
Engine Assembly . . . . . . . . . . . . . . . . . . . . 1B3-12
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-21
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B3-23
Poly V-Belt Alignment & Inspection . . . . . . . 1B3-26
Prechamber . . . . . . . . . . . . . . . . . . . . . . . . 1B3-29
Milling of Prechamber Sealing Surface . . . . 1B3-32
TDC (TDC Sensor Bracket) Setting . . . . . . 1B3-35
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B3-37
Timing Case Cover . . . . . . . . . . . . . . . . . . . 1B3-63
Crankshaft End Cover . . . . . . . . . . . . . . . . 1B3-71
Vibration Damper and Hub . . . . . . . . . . . . . 1B3-74
Crankshaft Front Radial Seal . . . . . . . . . . . 1B3-80
Crankshaft Ball Bearing . . . . . . . . . . . . . . . 1B3-82
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-83
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-93
Machining of Flywheel . . . . . . . . . . . . . . . . 1B3-97
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . 1B3-98
Hydraulic Valve Clearance Compensation
Element Check . . . . . . . . . . . . . . . . . . . . 1B3-101
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . 1B3-103
Valve Spring Check . . . . . . . . . . . . . . . . . 1B3-105
Valve Springs (Cylinder Head Removed) . 1B3-106
TABLE OF CONTENTS
Valve Springs (Cylinder Head Installed) . . 1B3-109
Valve Stem Seals . . . . . . . . . . . . . . . . . . . 1B3-112
Check and Replacement of Valve Guides . . . . . . . . . . . . . . . . . . . . . 1B3-116
Valve Seat Rings . . . . . . . . . . . . . . . . . . . 1B3-122
Check and Machining of Valves . . . . . . . . 1B3-127
Machining of Valve Seat . . . . . . . . . . . . . . 1B3-132
Camshaft Timing Test . . . . . . . . . . . . . . . . 1B3-137
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-139
Chain Tensioner . . . . . . . . . . . . . . . . . . . . 1B3-145
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . 1B3-147
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . 1B3-151
Cylinder Head Guide Rail . . . . . . . . . . . . . 1B3-152
Timing Case Cover Guide Rail . . . . . . . . . 1B3-156
Crankshaft Sprocket . . . . . . . . . . . . . . . . . 1B3-158
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-163
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-169
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-171
Oil Spray Nozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-175
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B3-177
Cylinder Head Pressure Leakage Test . . . 1B3-177
Facing Cylinder Head Mating Surface . . . . 1B3-178
Replacement of Crankcase Core Plug . . . 1B3-180
Facing Crankcase Contacting Surface . . . 1B3-182
Oil Gallery Steel Ball . . . . . . . . . . . . . . . . . 1B3-183
Cylinder Bore Measurement . . . . . . . . . . . 1B3-187

1B3-2 OM600 ENGINE MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N

 m
28 - 47 30
3 - 7
8 - 18
20 - 34 30
70 - 80 81 - 8450 - 75
N 

 m
10 23
200 / 90 °
10
55 / 90 °
45 / 90 °
25 / 90 °
25
N 

 m
35 / 90 °
N 

 m
45 / 90 °
Application
Skid Plate Bolt Drain Plug Bolt Coolong Fan Shroud BoltControl Linkage NutClutch Linkage Cylinder NutExhaust Manifold Bolt
Propeller Shaft Bolt & Nut (Axle) Propeller Shaft Bolt & Nut (T/C)
Engine Mounting Nut
Application
Cooling Fan Belt Pulley Bolt Socket Bolt
Tighten The BoltEnd Cover BoltCrankshaft Bearing Cap Bolt Ball Bearing Camshaft Sprocket BoltOil Pump Sprocket Bolt
Application
Connecting Rod Bolt
Application
12-Sided Stretch Bolt
Engine Assembly
Crankshaft Assembly Piston
Flywheel
Cylinder Head
Application
Prechamber Threaded Ring Cylinder Head Cover Bolt Fuel Injsction Pipe NutSocket BoltFuel Filter Pipe BoltIdle Pulley Bolt Damper Bolt N


 m
130 10 18252523 21

OM600 ENGINE MECHANICAL 1B3-3
N

 m
12 2525
25 / 90 °
N 

 m
1010 23 32 4
2380 23Application
Stud Bolt Exhaust Manifold Not CamShaft Bearing Cap Bolt
12-Sided Bolt (M11)
Application
Oil Pan Bolt-Socket Bolt
Oil Pan Bolt- M6
Oil Pan Bolt- M23Belt Pulley Bolt Guide Pulley Bolt Guide Pulley Bracket Nut
Chain Tensioner
Tesioning Lever Bolt
Cylinder Head
Application
Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt Exhaust Pipe Bolt& Nut
Chain TensionerInjection NozzleIntake Manifold Not Injection Nozzle Pipe Not
Oil Dipstick Tube BoltScrew Plug M18 x 15 N


 m
25
25 / 90 °
25804025 18 1050
Cam Support & Shaft
Timing Cover

1B3-4 OM600 ENGINE MECHANICALSPECIAL TOOLS
SPECIAL TOOLS TABLE
603 589 00 09 00
Serration Wrench
657 589 03 63 00
Sliding Hammer 000 589 77 03 00
Box Wrench Insert
601 589 00 66 00 Counter Sink
667 589 00 23 00 Height Gauge 602 589 00 40 00
Engine Lock
116 589 20 33 00
Sliding Hammer 603 589 00 40 00
Counter Holder

OM600 ENGINE MECHANICAL 1B3-5
116 589 03 07 00
T Type Socket Wrench
601 589 00 25 00
SPECIAL TOOLS TABLE (Co n t
’d)115 589 34 63 00
601 589 00 10 00
Cylinder Head Bolt 102
102 589 12 15 00(


17) Drift 102 589 00 15 00
(


34) Drift
617 589 10 21 00
RI Sensor 601 589 05 14 00
Assembly Cage