2003 SSANGYONG MUSSO height

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

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

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

1B3-32 OM600 ENGINE MECHANICAL
MILLING OF PRECHAMBER SEALING SURFACE1 Drift
2 Sleeve
3 Milling Cutter 4 Counter Sink (Special Tool - 601 589 00 66)
5 Cylinder Head
Tightening Torque 0.3, 0.6, 1.0 mm
Milling of the Prechamber Sealing Surface
Notice The prechamber sealing surface may only be remachined once with the cylinder head fitted. It is essential to adhere to the specified projection ‘C’ of the prechamber of 7.6 -
8.1mm. This ensures that the required clearance exists between prechamber and piston crown with the piston in TDC. Forthis reason, spacer rings should be inserted on remachinedsealing surfaces. If a spacer ring is already fitted, or a marking is made on the cylinder head, the cylinder head must be removed and size
‘C’ measured if further remachining is necessary on a
prechamber sealing surface.
Tools Required 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge

OM600 ENGINE MECHANICAL 1B3-33
6. Measure the ‘X’ by using a vernier caliper.
7. Mount the turning tool onto the countersink tool and rotate to the right approx. 5 revolutions by applying slight pressure.
1. Remove the injection nozzle.
2. Remove the prechamber.
3. Cover the prechamber bore to avoid any chips droppinginto the combustion chamber.
4. Remove the protective sleeve from the countersink and rotate the countersink into the prechamber bore to be machined as far as the stop.
Counter Sink 601 589 00 66 00
5. Maintain size ‘X’ from the top edge of mandrel to the top
edge of the sleeve with the gauge.
Height Gauge 667 589 00 23 00

1B3-122 OM600 ENGINE MECHANICAL
VALVE SEAT RINGS
Preceding Work : Removal of valveChecking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head
2 Valve Seat Ring
3 Valve Guide
A Height (Cylinder Head Upper / Lower Surface)
B Height (cylinder Head Cover Surface - Seat of Valve Seat Ring) D Valve Seat Ring Outer Diameter
D1 Valve Seat Ring Inner Diameter
D2 Basic Bore Diameter
H Height of Valve Seat Ring
Service Data
Item D2D
D1 H
Overlap U=D-D2
B A Intake
40.000 - 40.016mm40.084 - 40.100mm33.400 - 33.600mm 6.955 - 7.045mm0.068 - 0.100mm
133.4mm142.5mm Exhaust
37.000 - 37.016mm37.084 - 37.100mm30.400 - 30.600mm 6.955 - 7.045mm0.068 - 0.100mm
133.4mm142.5mm

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