engine SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-55
12. Install the idle pulley and fit the closing cover.
Tightening Torque 25 Nm
13. Insert the tensioning lever(31) and install the spring.
14. Install the damper.
Tightening Torque 23 Nm
Notice
Insert the tensioning lever bolts onto the mounting hole.
15. Insert the locking washer.
16. Inspect the valve tappet and check that the tappet moves
smoothly.

1B3-56 OM600 ENGINE MECHANICAL
17. Coat the camshaft with oil and install the camshaft on the
cylinder head to be TDC mark(arrow) upward.
18. Measure the axial end play of the camshaft.
End Play 0.06 - 0.21mm
Notice
If out of standard, adjust it with the proper thickness of
locking washer.
19. Install the bearing caps on the camshaft according to the
number on the caps.
20. Tighten the bearing cap bolts according to the numerical
sequence.
Tightening Torque 25 Nm
Notice
Tighten the No. 1 bolts(light arrow) first and then tighten
the No. 2 bolts(dark arrow) stage by stage.
OM662LA
OM661LA

OM600 ENGINE MECHANICAL 1B3-57
21. Position the camshaft on marking and install the camshaft
sprocket.
Notice
Align the alignment marks on the chain and sprocket.
23. Install the camshaft sprocket bolt. 22. Check the TDC position of the crankshaft.
Tightening Torque 25 Nm + 90°

1B3-58 OM600 ENGINE MECHANICAL
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.
Tightening Torque 25 Nm
Notice
Measure the max. length ‘L’ and replace the bolt if it exceeds
53.6mm.

OM600 ENGINE MECHANICAL 1B3-59
27. Replace the seal and then install the chain tensioner.
Tightening Torque 80 Nm
28. Remove the engine lock.
29. Insert the nozzle washer into the hole to face round part
downward.
30. Install the fuel injection nozzle.
Tightening Torque 40 Nm
31. Connect the fuel hose.
32. Install the cable channel and connect the cables to glow
plugs.

1B3-60 OM600 ENGINE MECHANICAL
35. Connect the wires to the coolant temperature sensor and
the glow plug sensor.
36. Replace the intake manifold gasket.
37. Install the intake manifold.
Tightening Torque 25 Nm
33. Replace the gasket and install the cylinder head cover.
Tightening Torque 10 Nm
34. Install the blow-by hose.

OM600 ENGINE MECHANICAL 1B3-61
38. Replace the O-ring of heater feed pipe and install it to the
cylinder head.
Notice
For installation, clean the hole.
39. Install the bracket of heater feed pipe to the oil filter.
40. Install the fuel pipe and the accelerator control linkage.
41. Connect the fuel lines to the injection nozzles and to the
injection pump.
Box Wrench Insert 000 589 77 03 00
Tightening Torque 18 Nm

1B3-62 OM600 ENGINE MECHANICAL
43. By inserting a rod into the tensioning lever upper hole and
pulling the rod, install the bolt and then tighten the nut.
44. Install the oil dipstick tube bracket.
Tightening Torque 10 Nm
45. Hold the cooling fan with the counter holder and tighten
the bolt.
42. Install the poly V-belt.
Notice
Be careful not to contaminate the belt.
Tightening Torque 23 Nm

OM600 ENGINE MECHANICAL 1B3-63
TIMING CASE COVER
Preceding Work : Removal of the cooling fan
Rmoval of the V-belt tensioning device
Removal of the vibration damper and hub
Removal of the alternator
1 Bolt............................................................10Nm
2 Cylinder Head Cover
3 Gasket ................................................... Replace
4 Socket Bolt................................................25Nm
5 Fuel Filter
6 Square Nut
7 Oil Pan
8 Socket Bolt................................................10Nm
9 Bolt.................................................... M6 : 10Nm
M8 : 23Nm
10 Power Steering Pump
11 Bolt
12 Belt Pulley1 3 Bolt............................................................32Nm
14 Timing Case Cover
1 5 Bolt............................................................23Nm
16 Alternator Bracket
1 7 Bolt............................................................45Nm
1 8 Bolt............................................................25Nm
1 9 Bolt............................................................10Nm
20 Closing Cover
21 Socket Bolt................................................23Nm
22 Guide Pulley
2 3 Bolt.............................................................. 9Nm
24 Guide Pulley Bracket
25 Nut .............................................................23Nm

1B3-64 OM600 ENGINE MECHANICAL
8. Remove the guide pulley bracket (24).
Tools Required
116 589 03 07 00 Socket Wrench
Removal Procedure
1. Remove the fan clutch and cooling fan belt pulley.
2. Drain the engine oil completely.
3. Remove the oil dipstick tube bracket bolts.
4. Remove the crankshaft pulley.
5. Loosen the bolt (1) and then remove the cylinder head cover
(2) and gasket.
6. Remove the vacuum pump.
7. Detach the closing cover (20). Remove the bolts(21) and
then remove the guide pulley (22).