2003 SSANGYONG MUSSO Service Manual

1B3-120 OM600 ENGINE MECHANICAL
8. Check the valve guide bore with GO / NO GO gauge (9).The GO side (marked ‘0’) should just still drop. If the GO
side cannot be inserted, the bore of valve guide should be reamed. Notice Perform the check only on cooled down cylinder head.
GO / NO GO Gauge (for Intake) 102 589 00 23 00
GO / NO GO Gauge (for Exhaust) 117 589 03 23 00
6. Cool down the new valve guide (2) with liquid nitrogen.
Notice Do not touch the cooled valve guide by hand.
Super Cooling box 346 589 00 63 00
7. Drive in new valve guide with drift (8) until the wire ring makes contact. Notice The valve guide must be driven in from the cylinder head
cover.
Drift (for Intake) 601 589 05 15 00
Drift (for Exhaust) 601 589 06 15 00
5. Heat the cylinder head (1) in a wear tank to approx. 80 °C.

OM600 ENGINE MECHANICAL 1B3-121
9. If necessary, ream the valve guide bore evenly.Notice Never turn the reamer against the direction of rotation.
Reamer (for Exhaust) 000 589 10 53 00Reamer (for Intake) 000 589 21 53 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

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)