SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-39
Length(L) When New
80mm
102mm
115mm Thread Dia.
M10
M10
M10Max. Length(L)
82mm
104mm
117mm
The twelve-sided socket head bolts are tightened with each
stages of torque and torque angle.
It is not necessary to retighten the cylinder head bolts at
the 1000~1500km inspection or after 1000~1500km of
repairs.
Notice
The cylinder head may only be removed when the engine
has cooled down. The cylinder head is removed together
with the exhaust manifold. As the cylinder head bolts
undergo a permanent tightening. They require to be
replaced if they exceed the maximum lengthes indicated
in the table.

1B3-40 OM600 ENGINE MECHANICAL
Disassembly Procedure
1. Completely drain the coolant from the radiator and cylinder
block.
2. Remove the cooling fan shroud.
3. Hold the fan with counter holder and remove the bolt and
then remove the cooling fan.
Notice
Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
5. Remove the nut.
6. Remove the nut on the tensioning lever and insert the
rod(F12 ´ 180mm). By pushing the rod to the arrow direction,
pull back the bolt.
7. Push the tensioning lever to the opposite direction to release
the spring tension and remove the poly V-belt. 4. Remove the bracket oil dipstick tube.

OM600 ENGINE MECHANICAL 1B3-41
8. Remove the air cleaner cover and element and then
remove the air cleaner housing.
9. Remove the oil return hose and plug.
Notice
Cover them to prevent chips from coming into.
10. Unscrew the EGR pipe mounting bolts onto the exhaust
manifold.
11. Remove the duct bracket from the cylinder head.
12. Unscrew the intake duct mounting bolts onto the intake
manifold.
13. Separate the connecting rod from the control lever.

1B3-42 OM600 ENGINE MECHANICAL
14. Pull out the accelerator control linkage.
15. Remove the fuel injection line(1) from the fuel injection
nozzle(12).
Box Wrench Inset 000 589 77 03 00
16. Remove the fuel injection line from the fuel injection pump.
Box Wrench Insert 000 589 77 03 00
17. Remove the bracket mounting bolts and then remove the
fuel injection line(1).

OM600 ENGINE MECHANICAL 1B3-43
18. Disconnect the booster hose connected to intake manifold.
19. Remove the intake manifold and gasket.
20. Remove the cylinder head cover and gasket with the blow-
by gas hose.
21. Disconnect the glow plug cables.

1B3-44 OM600 ENGINE MECHANICAL
22. Remove the cable channel.
23. Disconnect the cables from the glow plug sensor and
coolant temperature sensor.
24. Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe forward
and then pull out the pipe.

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