1998 SSANGYONG MUSSO Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-163
PISTON
Preceding Work : Removal of the cylinder head
Removal of the oil pump
1 Oil Ring
2 2nd Ring
3 Top Ring
4 Snap Ring.............................................. Replace
5 Piston Pin
6 Piston
7 Connecting Rod Bushing.......................... Check8 Connecting Rod
9 Connecting Rod Upper Bearing Shell
10 Connecting Rod Lower Bearing Shell
11 Connecting Rod Bearing Cap
12 Connecting Rod Bolt.........................35Nm + 90°
13 Crankcase
14 Cylinder Bore
Notice
There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing
the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there
would be a unbalancing of engine.

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

OM600 ENGINE MECHANICAL 1B3-165
Removal Procedure
1. Remove combustion residues from the cylinder bores.
2. Remove the connecting rod bolts (12) and then remove
the connecting rod bearing caps(11).
3. Remove the connecting rod bearing shells (9, 10).
Notice
Be careful not mix the bearing caps and shells each other.
4. Remove the piston (6) and connecting rod (8).
5. Remove the snap ring (4) and pull out the piston pin (5).
6. Separate the piston and connecting rod.

1B3-166 OM600 ENGINE MECHANICAL
Installation Procedure
1. Fit the piston onto the connecting rod so that the arrow
(15) and the locking slot (16) are facing in direction of the
vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand.
Notice
Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if
necessary.
5. Install and arrange the piston rings to be evenly 120° from
each ends gap.

OM600 ENGINE MECHANICAL 1B3-167
6. Coat the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap (7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a wooden
stick (18).
Notice
The arrow on the piston crown must point toward the front
of vehicle.
9. Insert the connecting rod bearing shells (9, 10).
Notice
Be careful of the difference in upper and lower bearing
shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice
Position so that the retaining lugs are on the same side of
the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connecting rod
bolts.
Limit ‘C’ 7.1mm

1B3-168 OM600 ENGINE MECHANICAL
12. Coat the bolts (12) with oil and then tighten the bolts.
Tightening Torque 40Nm + 90°
13. Rotate the crankshaft and check axial clearance between
the connecting rod and crankshaft.
14. Measure clearance between the piston crown and cylinder
StandardMax. 0.12mm
15. Position the piston at TDC and measure the distance
between the piston crown and the crankcase surface.
Notice
Measure at points marked.
Dial Gauge 001 589 00 53 21
Dial Gauge Holder 363 589 02 21 00
Standard Max. 0.965 mm

OM600 ENGINE MECHANICAL 1B3-169
OIL FILTER
1 Nut ............................................................ 25 Nm
2 Oil Filter..................................................... Cover
3 O-Ring ................................................... Replace
4 Oil Filter...............Element Replace If necessary
5 Oil Filter Housing6 Bolt (M8)....................................................10Nm
7 Oil Pressure Switch
8 Gasket
9 Bolt........................................................... 25 Nm

1B3-170 OM600 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the oil filter cover and then drain the oil.
2. Remove the oil pressure switch line.
3. Remove the oil filter housing.
4. Clean the sealing surface.
5. Installation should follow the removal procedure in the
reverse order.