oil SSANGYONG MUSSO 2003 Service Manual

1B3-142 OM600 ENGINE MECHANICAL
4. Install the camshaft bearing caps according to markings(1,2, 3 etc.).
7. Remove the camshaft bearing cap.
8. Pull off the camshaft.
Notice
Be careful not to miss front locking washer.
9. Pull out the locking washer.Notice Check the condition of locking washer and replace if
necessary.
Installation Procedure
1. Insert the locking washer.
2. Check the valve tappet and ensure that tappet moves smoothly.
3. Coat the camshaft with oil and install the camshaft onto the cylinder head so that the TDC marking (arrow) is positioned
upward vertically.

1B3-144 OM600 ENGINE MECHANICAL
10. Check the TDC marking of OT on the crankshaft.8. Install the chain tensioner.
Tightening Torque 80 Nm
Notice Replace the seal.Before installation, by pumping in the oil approx. 10 times, fill the oil.
9. Remove the engine lock.
Notice If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.

1B3-146 OM600 ENGINE MECHANICAL
Notice Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill
Faulty chain tensioners should be replaced completely.
3 Screw Plug
4 Aluminum Gasket
5 Ball
6 Ball Guide
7 Compression Spring
8 Compression Spring
9 Housing
10 Thrust Pin 11 Valve Disc
12 O-Ring
13 Snap Ring
14 Compression Spring
15 Filler
A Feed Bore from Cylinder Head
B To Oil Pan

1B3-156 OM600 ENGINE MECHANICAL
TIMING CASE COVER GUIDE RAIL Preceding Work : Removal of cylinder head cover1 Bearing Pin
2 Bearing Pin
3 Guide Rail
4 Oil Pump Chain 5 Crankshaft
6 Spring
7 Bushing
8 Tensioning Lever

1B3-158 OM600 ENGINE MECHANICAL
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil panRemoval of timing case cover
1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90 °
2 Washer
3 Camshaft Sprocket
4 Timing Chain
5 Bearing Pin
6 Bearing Pin
7 Oil Pump
8 Oil Pump Sprocket
9 Oil Pump Chain
10 Washer 11 Bolt
............................................................ 25Nm
12 Crankshaft Sprocket
13 Crankshaft
15 Key
16 Guide Rail
17 Spring
18 Bushing
19 Tensioning Lever

OM600 ENGINE MECHANICAL 1B3-159
Special Tools
116 589 07 15 00 Drift102 589 05 33 00 Puller Removal Procedure
1. Pull out the tensioning lever (19) together with the spring(17) and guide rail (16) far enough until the tensioning lever has passed the oil pump chain (9) and is resting againstthe crankshaft (13).
2. Pull out tensioning lever (19), spring (17) and bushing (18) from the bearing pin (6).
3. Pull out the guide rail (16).
4. Remove the bolt(11) and then remove the washer (10), oil pump chin (9) and sprocket (8).

OM600 ENGINE MECHANICAL 1B3-161
Installation Procedure
1. Put the same alignment mark on the new crankshaftsprocket as in the old sprocket. Notice Check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for
wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a drift (21). Notice Align the groove of sprocket and woodruff key (arrow)
exactly. Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket (12). Notice Align the alignment marks (arrow) on the chain and sprocket.
4. Install the camshaft sprocket (3).
Tightening Torque 25 Nm + 90 °
Notice Pay attention on the alignment marks and dowel pin (arrow).

1B3-162 OM600 ENGINE MECHANICALNotice If the max. length ‘L’ of the stretch bolt exceeds 53.6mm,
replace it.
5. Fit the oil pump chain (9) on the crankshaft sprocket (12) and insert the oil pump sprocket (8) into the oil pump chain and then install it on the oil pump. Notice The curved side of the oil pump sprocket should face the oil pump.
6. Insert the woodruff key (15).
7. Install the guide rail (16). Attach the spring (17) to guide rail and to tensioning lever together onto the bearing pins (5,6). Notice Ensure that the spring is correctly located in the guide rail (arrow).

OM600 ENGINE MECHANICAL 1B3-163
PISTON
Preceding Work : Removal of the cylinder headRemoval of the oil pump
1 Oil Ring
2 2nd Ring
3 Top Ring
4 Snap Ring.............................................. Replace
5 Piston Pin
6 Piston
7 Connecting Rod Bushing .......................... Check 8 Connecting Rod
9 Connecting Rod Upper Bearing Shell
10 Connecting Rod Lower Bearing Shell 11 Connecting Rod Bearing Cap
12 Connecting Rod Bolt ......................... 35Nm + 90 °
13 Crankcase
14 Cylinder Bore
Notice There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there would be a unbalancing of engine.

1B3-166 OM600 ENGINE MECHANICAL Installation Procedure
1. Fit the piston onto the connecting rod so that the arrow(15) and the locking slot (16) are facing in direction of the vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand. Notice Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if necessary.
5. Install and arrange the piston rings to be evenly 120 ° from
each ends gap.