fuel filter SSANGYONG MUSSO 2003 User Guide

1B3-16 OM600 ENGINE MECHANICAL
16. Remove the power steering pump lines.Notice Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump.
18. Vehicle with automatic transmission. Remove the hydraulic lines (19, 20) from oil cooler (2).
19. Disconnect the engine harness.
20. Disconnect the preheating time relay cable.

OM600 ENGINE MECHANICAL 1B3-17
26. Disconnect the starter motor wires and remove the startermotor.
21. Remove the fuel lines from the fuel filter and cover thefilter with plug.
22. Disconnect the brake booster hose from vacuum pump.
23. Disconnect the other vacuum lines.
24. Disconnect the ground cable.
25. Disconnect the alternator wires.

OM600 ENGINE MECHANICAL 1B3-37
CYLINDER HEAD1 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
10 Bolt 11 Nozzle Washer ....................................... Replace
12 Fuel Injection Nozzle ............................ 35-40 Nm
13 Hexagon Socket Bolt ................................. 25 Nm
14 Washer
15 Bolt ........................................................... 25 Nm
16 Cylinder Head Bolt ..............................See Table
17 Cylinder Head Cover
18 Bolt ........................................................... 10 Nm
19 Gasket
2 0 Camshaft 21 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
32 Bolt ........................................................... 25 Nm
33 Bolt
34 Nut ............................................................ 23 Nm
35 Fuel Filter
36 Turbo Charger
37 Intake Duct
38 Gasket ................................................... Replace
39 Intake Manifold

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 nozzlewasher(11).
Socket Wrench Insert 001 589 65 09 00

1B3-54 OM600 ENGINE MECHANICAL8. 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 00Threaded Pin 116 589 02 34 00

OM600 ENGINE MECHANICAL 1B3-61
38. Replace the O-ring of heater feed pipe and install it to thecylinder head. NoticeFor 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

OM600 ENGINE MECHANICAL 1B3-63
TIMING CASE COVER
Preceding Work : Removal of the cooling fanRmoval 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 Pulley 13 Bolt
............................................................ 32Nm
14 Timing Case Cover
15 Bolt ............................................................ 23Nm
16 Alternator Bracket
17 Bolt ............................................................ 45Nm
18 Bolt ............................................................ 25Nm
19 Bolt ............................................................ 10Nm
20 Closing Cover
21 Socket Bolt ................................................ 23Nm
22 Guide Pulley
23 Bolt .............................................................. 9Nm
24 Guide Pulley Bracket
25 Nut ............................................................. 23Nm

OM600 ENGINE MECHANICAL 1B3-65
11. Remove the alternator bracket (16).
9. Disconnect the pipes of power steering pump and removethe belt pulley. Notice
Be careful not to lose the key.
10. Remove the nut and pull out the bolt and then remove the power steering pump.
12. Remove the fuel filter.

OM600 ENGINE MECHANICAL 1B3-69
10. Install the fuel filter.
11. Install the vacuum pump.
12. Install the power steering pump.
13. Install the power steering pump pulley.
Tightening Torque 25 Nm
Tightening Torque 10 Nm
Tightening Torque 23 Nm
Tightening Torque 32 Nm
14. Install the guide pulley bracket.
Tightening Torque 9 Nm

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °