engine SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE MECHANICAL 1B3-123
Cylinder Head Clamping Device
Valve Seat Turning Tool
Ring Seat Turning Tool Pneumatic Removal / Installation Device (Drift : 8mm, 9mm, 14mm)
Tensioning Head
Cutting Tool for Recessing Grooves
Test Set for Valves Internal Dial Gauge (Range : 25 - 60mm) External Micrometer (Range : 25 - 60mm)
Electrically Heated Water Tank
Commercial ToolsHunger D-8000 M
ünchen 70
Type Ventilknecht K2000 Order No. 221 00 100 HungerD-8000 M ünchen 70
Type VDS 1AOrder No. 236 03 308 Hunger D-8000 M ünchen 70
Type RDS 1Order No. 219 00 100Hunger D-8000 M ünchen 70
Type PVM 1 HungerD-8000 M ünchen 70
Order No. 250 15 250 Hunger D-8000 M ünchen 70
Order No. 217 93 601HungerD-8000 M ünchen 70
Order No. 216 69 210MahrD-7300 EsslingenOrder No. 844Mahr D-7300 Esslingen Order No. 40 SOtto D ürr
D-7123 Sachsenherm - Ochsenbach

1B3-124 OM600 ENGINE MECHANICAL
1. Measure dimension ‘A’ .
Removal Procedure
Limit
142.5mm
2. Clamp the cylinder head with clamping device.
3. Cut groove into the valve seat ring so that dimension ‘C’ is
approx. 2mm and dimension ‘E’ is approx. 6mm.
4. Remove the cylinder head from the clamping device and place it onto wooden blocks.
5. Remove the valve guide (3).
Drift (Intake) 8mm
Drift (Exhaust) 9mm
6. Insert the tensioning head (4) and extracted wedges(arrow) by turning the bolt (5). Notice Carefully tighten the bolt (5) otherwise the valve seat ring in the cylinder head will be excessively tensioned.
7. Lock the bolt (5) with nut (6).

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 V alue ‘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).
NoticeMaintain minimum value of ‘B’.
- Machine the basic bore.
Limit Intake
Exhaust
Max. D2
Min. B40.516mm 37.516mm133.4mm
- 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 overlapvalue.

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 assemblingtool. 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 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 1B3-129
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
Exhaust 1.7 ± 0.15 mm 1.7 ± 0.15 mm
3. Machine the valve. Notice Pay attention to setting angle ‘ ’ .
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 prechamberRemoval 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 Guide a Valve Seat Angle
b Valve Seat Free Angle