torque SSANGYONG MUSSO 1998 Workshop Repair Manual

1B3-68 OM600 ENGINE MECHANICAL
Tightening Torque25 Nm 5. Install the flange, vibration damper and crankshaft belt
pulley.
Notice
Replace front radial seal if necessary.
6. Install the alternator bracket.
25 Nm Front
Side
7. Install the alternator
Tightening TorqueUpper - 25 Nm
Low - 25 Nm
8. Install the cylinder head cover.
Tightening Torque 10 Nm
9. Tighten the injection pump mounting bolts.
Tightening Torque 23 Nm

OM600 ENGINE MECHANICAL 1B3-69
10. Install the fuel filter.
11. Install the vacuum pump.
12. Install the power steering pump.
13. Install the power steering pump pulley.
Tightening Torque 25 Nm
Tightening Torque 10 Nm
Tightening Torque 23 Nm
Tightening Torque 32 Nm
14. Install the guide pulley bracket.
Tightening Torque 9 Nm

1B3-70 OM600 ENGINE MECHANICAL
15. Install the guide pulley (22) and fit the closing cover (20).
16. Replace the gasket (3) and install the cylinder head cover
(2).
17. Install the cooling fan belt pulley and fan clutch.
18. Install the belt tensioning device and then install the belt.
19. Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.
Tightening Torque 23 Nm
Tightening Torque 10 Nm

1B3-72 OM600 ENGINE MECHANICAL
Tools Required
601 589 03 43 00 Oil Seal Assmbler
Removal Procedure
1. Remove the bolts (3, 6) from end cover, By pulling out the
lugs (arrow), remove the cover.
Notice
Be careful not to damage the oil pan gasket.
2. Remove the radial seal (4) with care not to damage the
sealing surface.
Installation Procedure
1. Thoroughly clean the sealing surface of end cover and apply
Loctite 573.
2. Clean the groove of radial seal.
3. Apply Loctite 573 on the bolts and install the end cover.
Tightening Torque 10 Nm
Notice
Be careful not to damage the oil pan gasket.
4. Install the inner oil seal assembler to the crankshaft flange.
Oil Seal Assembler 601 589 03 43 00

1B3-78 OM600 ENGINE MECHANICAL
Installation Procedure
1. Install the hub.
Notice
Exactly align the woodruff key and the groove of hub (arrow).
2. Install the washer (7) and tighten the bolt (6).
Washer (new) : 1 EA 200 Nm + 90°
3. Install the vibration damper.
Notice
Exactly align and insert onto the straight pin.
4. Install the belt pulley.
Tightening Torque 25 Nm
Notice
Align the alignment marks.

OM600 ENGINE MECHANICAL 1B3-79
5. Install the timing sensor bracket.
Notice
See the ‘TDC setting’.
6. Install the cooling fan pulley.
Tightening Torque 10 Nm
7. Install the cooling fan.
8. Install the fan belt.
9. Remove the engine lock.

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.

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 rotates
smoothly.
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 sensor
bracket 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 the
connecting 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 the
connecting 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 1B3-95
3. Remove the flywheel (3), if equipped with manual
transmission.
Installation Notice
Correctly align the position of dowel pin (2).
Tools Required
602 589 00 40 00 Engine Lock
Removal & Installation Procedure
1. Install the engine lock.
Engine Lock 602 589 02 40 00
2. Remove the 12-sided stretch bolts (4).
Installation Notice
Tightening Torque 45 Nm + 90°
Notice
If the length ‘L’ of bolts exceeds 22.5mm, replace the bolts.