engine SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-45
26. Disconnect the fuel lines from the fuel filter.
27. Disconnect the fuel lines from the injection pump.
28. Remove the fuel filter(35).
29. Remove the fuel injection nozzle(12) and nozzle
washer(11).
Socket Wrench Insert 001 589 65 09 00

1B3-46 OM600 ENGINE MECHANICAL
30. Rotate the crankshaft and set the no.1 cylinder at TDC.
Notice
Do not rotate the crankshaft to the opposite direction of
engine revolution.
31. Place alignment marks on the camshaft gear and timing
chain.
32. Ensure that the camshaft and the bearing cap marking
are aligned.
33. Remove the starter motor and install the engine lock onto
the flywheel ring gear.
Engine Lock 602 589 00 40 00

OM600 ENGINE MECHANICAL 1B3-47
34. Remove the turbocharger.
35. Remove the exhaust manifold and gasket.
36. Remove the chain tensioner and seal.
37. Remove the bolt and separate the drive sprocket(21).
Notice
During removal, be careful not to drop the sprocket and
chain into the timing case.
Carefully pull off the chain and then pull out the sprocket.

1B3-48 OM600 ENGINE MECHANICAL
38. Remove the camshaft bearing cap bolts according to the
numerical sequence.
Notice
Remove the No.1 bolts first and then remove the No. 2
bolts. Do not remove the bolts at a time completely but
remove them step by step evenly or camshaft can be
seriously damaged.
OM662LA
39. Remove the bearing caps and then pull out the
camshaft(20) upward.
Notice
Be careful not to miss the locking washer.
40. Remove the locking washer.
Notice
Check the locking washer and replace if necessary.
OM661LA

OM600 ENGINE MECHANICAL 1B3-49
41. Remove the bolt(32).
42. Separate the spring and pull out the tensioning lever(31).
43. Pry off the closing cover. Remove the bolt and then remove
the idle pulley.
44. Using the sliding hammer(36) and the threaded pin(37),
pull out the sliding rail pins(25, 26) and remove the sliding
rail(24).
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00

1B3-50 OM600 ENGINE MECHANICAL
OM 662LA
46. Disconnect the vacuum pipe from thermo valve.
47. Remove the socket bolts(13) of the chain box.
T Type Socket Wrench 116 589 03 07 00
Magnetic Bar 102 589 03 40 00
48. Remove the cylinder head bolts in numerical se-quence.
Cylinder Head Bolt Wrench 601 589 00 10 00
45. Remove the vacuum line from the vacuum pump.

OM600 ENGINE MECHANICAL 1B3-51
49. Remove the cylinder head(2) and gasket(3).
OM 661LA

1B3-52 OM600 ENGINE MECHANICAL
Length(L)
Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.
Notice
Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts.
Notice
If the max. length is exceeded, replace the bolts.
Thread Dia. Max. Limit(L)
M10
M10
M1080mm
102mm
115mm82mm
104mm
117mm when new
4. Coat the head contact surface of bolts and thread with oil
and insert them as shown.
- Cylinder head bolts arrangement
Bore
1 ...........................................M10
× 80
2 ...........................................M10
× 102
3 ...........................................M10
× 11 5
4 ........................................... M 8
× 50
5 ........................................... M 8
× 80
OM662LA

OM600 ENGINE MECHANICAL 1B3-53
5. Tighten the cylinder head bolts to specified torque and
torque angle.
OM 662LA
OM 661LA
6. Install the socket bolts in the chain box.
Tightening Torque 25 Nm
Stage 1
Stage 2
Torque angle
Wait for
Torque angle15 Nm
35 Nm
90°
10 minutes
90°
7. Connect the vacuum pipe to the thermo valve.

1B3-54 OM600 ENGINE MECHANICAL
8. Connect the vacuum lines to the vacuum pump.
9. Install the fuel filter and connect the pipe.
Tightening Torque 25 Nm
Notice
Be careful not to be confused the connections and hoses.
10. Connect the fuel pipe to the injection pump.
11. Install the sliding rail(24) and insert the sliding rail pins(25,
26).
Notice
Apply sealing compound on the each collar of the sliding
rail pins.
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00