SSANGYONG MUSSO 1998 Workshop Repair Manual

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

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 Gauge
601 589 07 21 00 Deqth Gauge
667 589 01 21 00 Fixing Device
Notice
lThe TDC sensor bracket must be adjusted in case of
followings.
lWhen replacing the TDC sensor bracket.
lWhen replacing the crankshaft, the hub or the vibration
damper.
lWhen replacing or installing the timing case cover.
lAfter 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.

1B3-36 OM600 ENGINE MECHANICAL
Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber bore and
position the dial gauge with a preload of 5mm.
Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of engine rotation
until the large pointer on the dial gauge stops (TDC position).
Notice
The position of TDC is when the large pointer on the dial
gauge is stopped before moving back.
5. remove the reinstall the measuring device and position the
dial gauge scale at ‘0’.
6. Slowly rotate the crankshaft in the direction of engine rotation
until the dial gauge has moved back (counterclockwise) by
3.65mm.
7. Insert fixing device into the sensor bracket.
Notice
The pin on the vibration damper must engage into the slot
of the fixing device.
Fixing Device 667 589 01 21 00
8. If the pin does not engage, adjust the setting of the sensor
bracket by removing and tightening of the sensor bracket
bolts.
Tightening Torque 10 Nm
Notice
The timing mark on the damper must be positioned at ATDC
20.

OM600 ENGINE MECHANICAL 1B3-37
CYLINDER HEAD
1 Fuel Injection Pipe.....................................18Nm
2 Cylinder Head
3 Gasket ................................................... Replace
4 Bolt............................................................25Nm
5 Washer
6 Clamp
7 Heater Feed Pipe
8 Bolt
9 Washer
1 0 Bolt
11 Nozzle Washer....................................... Replace
12 Fuel Injection Nozzle............................35-40 Nm
13 Hexagon Socket Bolt................................. 25 Nm
14 Washer
1 5 Bolt........................................................... 25 Nm
16 Cylinder Head Bolt..............................See Table
17 Cylinder Head Cover
1 8 Bolt........................................................... 10 Nm
19 Gasket
2 0 Camshaft21 Camshaft Drive Sprocket....................... Replace
22 Washer
23 Bolt(12-Sided) ..................................25Nm + 90°
24 Sliding Rail
25 Sliding Rail Pin
26 Sliding Rail Pin
27 Chain Tensioner....................................... 80 Nm
28 Gasket ................................................... Replace
29 Cooling Fan.............................................. Check
30 Hexagon Socket Bolt................................. 45 Nm
31 Tensioning Lever
3 2 Bolt........................................................... 25 Nm
3 3 Bolt
34 Nut ............................................................ 23 Nm
35 Fuel Filter
36 Turbo Charger
37 Intake Duct
38 Gasket ................................................... Replace
39 Intake Manifold

1B3-38 OM600 ENGINE MECHANICAL
000 589 77 03 00 Box Wrench Insert
001 589 65 09 00 Socket Wrench Insert
102 589 03 40 00 Magnetic Bar
116 589 02 34 00 Threaded Pin
116 589 03 07 00 T Type Socket Wrench
116 589 20 33 00 Sliding Hammer
601 589 00 10 00 Cylinder Head Bolt Wrench
602 589 00 40 00 Engine Lock
603 589 00 40 00 Counter Holder
Tools Required
Cylinder Bolts (12-sided socket head)
(Engine cold)
M8 Cylinder Head Bolts
Tightening Torque
stage1
stage2
stage310 Nm
35 Nm
180°
25 Nm
Tightening Sequence for Cylinder Head Bolts
OM 662LA Engine
OM 661LA Engine