2003 SSANGYONG MUSSO engine oil

1B2-104 M161 ENGINE MECHANICAL
OIL NON-RETURN VALVE Preceding Work : Removal of timing gear case cover
1 Oil Non-Return Valve
Functions The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As aresult, the chain tensioner can be activated with oil in itself.
Replacement Procedure
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

M161 ENGINE MECHANICAL 1B2-105
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge
2 Oil Dipstick Guide Tube
3 O-ring
Removal & Installation Procedure
1. Pull out the oil dipstick level gauge (1).
2. Unscrew the bolt (4) and remove the oil dipstick guide tube (2).Installation Notice 4 Bolt (M6 X 16, 1 piece)
........................... 9-11 Nm
5 Clamp
Tightening Torque 9 - 11 Nm
It is very hard to remove the oil dipstick guide tube without
special tool. If it is not necessary, do not remove the guide tube.
3. Installation should follow the removal procedure in the reverse order.
4. Check for leaks by starting the engine.

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

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

1B3-6 OM600 ENGINE MECHANICAL601 589 08 15 00Drift
001 589 53 21 00Dial Gauge 601 589 03 14 00
Sleeve
SPECIAL TOOLS TABLE (Co n t
’d)
103 589 00 33 00
Puller
601 589 07 21 00Depth Gauge
667 589 01 21 00Fixing Device 366 589 00 21 05
Extension
601 589 03 43 00
Oil Seal Assembler

1B3-16 OM600 ENGINE MECHANICAL
16. Remove the power steering pump lines.Notice Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump.
18. Vehicle with automatic transmission. Remove the hydraulic lines (19, 20) from oil cooler (2).
19. Disconnect the engine harness.
20. Disconnect the preheating time relay cable.