2003 SSANGYONG MUSSO engine oil

OM600 ENGINE MECHANICAL 1B3-81
Notice The sealing lip of the repair radial seal is offset to the inside by 2mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange.A Standard Radial SealB Repair Radial Seal
Replacement Procedure
1. Pull out the radial seal (1) and be careful not to damage the sealing surface of timing case cover.
2. Thoroughly clean the mounting bore of the radial seal.
3. Coat a little oil on the sealing lip of new radial (1) and contact surface. Notice Don ’t use grease.
4. Install the radial seal (1) by using a sleeve (4).
NoticeAlign the groove of sleeve and woodruff key(arrow).
Sleeve 601 589 03 14

OM600 ENGINE MECHANICAL 1B3-89
14. Measure crankshaft bearing journal diameter (F).Notice When measured in A and B, the runout should not exceed 0.010mm.
8. Thoroughly clean the oil gallery.
9. Select a proper new bearing shells with reference to table.
10. Coat the new bearing shells with oil and insert into the crankcase and into the crankshaft bearing caps. Notice Do not mix up upper and lower crankshaft bearing shells.
11. Install the bearing caps according to marking and tighten the 12-sided stretch bolts.
Tightening Torque 35 - 40 Nm
Notice No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E).
Extension 366 589 00 21 05
13. Measure at 3 points (A, B and C) and if the average value of B and C is less than A ’s value, the average value of B
and C is the mean value and if more than A ’s value, A ’ s
value is the mean value.

1B3-90 OM600 ENGINE MECHANICAL
15. Measure radial clearance of crankshaft bearing (G).
Clearance ‘G’ 0.027 - 0.051mm
Notice If ‘G’ is out of standard, replace the bearing shells and
adjust the radial clearance of crankshaft bearing.Example) Measured value ‘E’ = 57.700mm
Measured value ‘F’ = 57.659mm
Clearance ‘G’ = 0.041mm
16. Remove the crankshaft bearing cap.
17. Measure width of thrust bearing journal (H) and adjust with
proper thrust bearings (see table). Notice The same thickness of thrust washers should be installed on both sides of the thrust bearing.
18. Coat the upper thrust bearing (4) with oil and insert intothe crankcase so that the oil grooves are facing the crank webs (arrow).
19. Coat the lower thrust bearing (7) with oil and insert into the crankshaft bearing cap so that the oil grooves are facingthe crank webs (arrow). Notice The retaining lugs should be positioned in the grooves (arrow).

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.

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °

OM600 ENGINE MECHANICAL 1B3-93
FLYWHEEL
Preceding Work : Removal of the transmissionRemoval of the clutch
1 Oil Pan
2 Straight Pin
3 Flywheel 4 12-Sided Stretch Bolt
............ Check, 45Nm + 90 °
5 Drive Plate (Automatic Transmission)
6 Flywheel (Automatic Transmission)

1B3-102 OM600 ENGINE MECHANICAL
CheckingNotice The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it doesnot need to be repaired. Determine the malfunctions in valveclearance compensation device with noise through following
tests. If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4 minutes.
2. Stop the engine. After 5minutes, check the engine oil level and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cylinders.
5. Using a drift, lightly press the valve tappet and measure clearance between the cam and valve tappet. Notice If the clearance exceeds 0.4mm, replace the valve tappet.
6. If a valve tappet moves down too far in comparison to the others, replace the valve tappet.
7. Rotate the engine and check the remaining valve tappets.
Notice
Unnecessary rotation of the engine will damage the valve tappets.
Do not rotate the engine by using the camshaft sprocket bolt or to the opposite direction of the engine rotation.

OM600 ENGINE MECHANICAL 1B3-103
VALVE TAPPETS Preceding Work : Removal of camshaft1 Valve Tappet
2 Cylinder Head
3 Oil Gallery 4 Seal
....................................................... Replace
5 Screw Plug
Tools Required 102 589 03 40 00 Magnetic Bar