SSANGYONG MUSSO 2003 Service Manual

1B3-26 OM600 ENGINE MECHANICAL
POLY V-BELT ALIGNMENT & INSPECTION Without Air Conditioner
With Air Conditioner

OM600 ENGINE MECHANICAL 1B3-27
Inspection Procedure
Mark poly V-belt at a clearly visible point with chalk.
Rotate the engine and check the belt. Notice If one of the following types of damage is found, replace the belt.
1. Rubber lumps in the base of rips.
2. Dirt or grit ingrained.
5. Cord torn out at the side.
6. Outer cords frayed.
3. Pointed rips.
4. Belt cord visible in the base of rips.

1B3-28 OM600 ENGINE MECHANICAL7. Belt detached from the base of rip.
8. Splits across the rips.
9. Sections of rip torn out.
10. Splits across several rips.
11. Splits across the back.

OM600 ENGINE MECHANICAL 1B3-29
1 Threaded Ring........................................ 130 Nm
2 Prechamber
PRECHAMBER
Preceding Work : Removal of glow plug
Removal of fuel injection nozzle
3 Cylinder Head

1B3-30 OM600 ENGINE MECHANICAL
Tools Required
2. Install the sliding hammer into the prechamber.Sliding Hammer 667 589 03 63 00
Removal & Installation Procedure
1. Using the serration wrench (4), remove the threaded ring
(1).
Serration Wrench 603 589 00 09 00
3. Remove the perchamber (2). Notice
After removing the prechamber, cover over the bores with clean rag.
603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer
4. Inspect the prechamber.
Notice If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced, the sealing surfaces in the cylinder head must be remachined.

OM600 ENGINE MECHANICAL 1B3-31
Assembly ProcedureNotice In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used.
1. Clean the sealing surface of the prechamber.
2. Insert the prechamber into the cylinder head at the same time aligning the cam on the collar of the prechambers with the slots in the cylinder head. Notice If the spacer rings are fitted to the prechambers, the spacer rings should be replaced with rings of the same thickness.
Thickness of Spacer Ring 0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the ring by using the serration wrench.
Tightening Torque 130 Nm

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

1B3-34 OM600 ENGINE MECHANICAL8. Remeasure size ‘X ’ and compare it with the first
measurement and determine the thickness of spacer ring.
Size before machining 25.7 mm
Size after machining 25.5 mm
Ex
The spacer ring should be selected so that it is at least 0.1mm and not more than 0.3mm thicker than the measured on the sealing surface. In this example, thenecessary thickness of spacer ring should be within0.3 ~ 0.5mm and the thickness of spacer ring to beinstalled is 0.3mm.
9. Remove the countersink tool and clean the chips.
Notice If the sealing surface is not completely flat, remachine the sealing surface.
10. emove rag from the prechamber bore and crank the engine with starter motor to threw out any chips which may have
got into the combustion chamber.
11. Insert the proper spacer ring into the prechamber sealing surface.
12. Punch a mark on the cylinder head above the prechambersealing surface which has been machined.
13. Install the prechambers.
Notice If the cylinder head is removed, the projection ‘C’ is
measured in place of size ‘X’ and the appropriate size of
spacer ring selected.
Normal Projection (c) 7.6 - 8.1mm

OM600 ENGINE MECHANICAL 1B3-35
TDC (TDC SENSOR BRACKET) SETTING Preceding Work : Removal of No.1 cylinder prechamber
1 Measuring Device
2 Dial Gauge
3 Cylinder Head
4 Piston................................................ Set at TDC
Tools Service 001 589 32 21 00 Dial Gauge601 589 07 21 00 Deqth Gauge667 589 01 21 00 Fixing Device Notice
The TDC sensor bra cket must be adjusted in case of
followings.
When replacing the TDC sensor bracket.
When replacing the crankshaft, the hub or the vibration
damper.
When replacing or installing the timing case cover.
After engine overhauling.
If the cylinder head is removed, the measuring pin of the dial gauge can be positioned on the piston crown. This is done by placing the magnetic dial holder on the mating surface of the crankcase.