engine SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-25
6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).
Installation Notice
Insert spring (17) with color coding (blue/violet) facing up.
8. Pry off the closing cover (12) and remove the socket bolt
(11) and then remove the tensioning pulley (10).
Installation Notice
Tightening Torque 29 Nm
9. Pry off the closing cover (16) and remove the fit bolt (15).
10. Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice
Apply Loctite on thread of fit bolt.
Tightening Torque 100 Nm
12. Installation should follow the removal procedure in the
reverse order.

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

OM600 ENGINE MECHANICAL 1B3-27
Inspection Procedure
lMark poly V-belt at a clearly visible point with chalk.
lRotate 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 MECHANICAL
7. 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 Procedure
Notice
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 SURFACE
1 Drift
2 Sleeve
3 Milling Cutter4 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. For
this reason, spacer rings should be inserted on remachined
sealing 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 dropping
into 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 MECHANICAL
8. 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, the
necessary thickness of spacer ring should be within
0.3 ~ 0.5mm and the thickness of spacer ring to be
installed 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 prechamber
sealing 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