sensor SSANGYONG MUSSO 2003 User Guide

SECTION 1B3
OM600 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B3-2Fastener Tightening Specifications . . . . . . . . 1B3-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B3-4 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B3-4
Maintenance and Repair . . . . . . . . . . . . . 1B3-12
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B3-12
Engine Assembly . . . . . . . . . . . . . . . . . . . . 1B3-12
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-21
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B3-23
Poly V-Belt Alignment & Inspection . . . . . . . 1B3-26
Prechamber . . . . . . . . . . . . . . . . . . . . . . . . 1B3-29
Milling of Prechamber Sealing Surface . . . . 1B3-32
TDC (TDC Sensor Bracket) Setting . . . . . . 1B3-35
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B3-37
Timing Case Cover . . . . . . . . . . . . . . . . . . . 1B3-63
Crankshaft End Cover . . . . . . . . . . . . . . . . 1B3-71
Vibration Damper and Hub . . . . . . . . . . . . . 1B3-74
Crankshaft Front Radial Seal . . . . . . . . . . . 1B3-80
Crankshaft Ball Bearing . . . . . . . . . . . . . . . 1B3-82
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-83
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-93
Machining of Flywheel . . . . . . . . . . . . . . . . 1B3-97
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . 1B3-98
Hydraulic Valve Clearance Compensation
Element Check . . . . . . . . . . . . . . . . . . . . 1B3-101
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . 1B3-103
Valve Spring Check . . . . . . . . . . . . . . . . . 1B3-105
Valve Springs (Cylinder Head Removed) . 1B3-106
TABLE OF CONTENTS
Valve Springs (Cylinder Head Installed) . . 1B3-109
Valve Stem Seals . . . . . . . . . . . . . . . . . . . 1B3-112
Check and Replacement of Valve Guides . . . . . . . . . . . . . . . . . . . . . 1B3-116
Valve Seat Rings . . . . . . . . . . . . . . . . . . . 1B3-122
Check and Machining of Valves . . . . . . . . 1B3-127
Machining of Valve Seat . . . . . . . . . . . . . . 1B3-132
Camshaft Timing Test . . . . . . . . . . . . . . . . 1B3-137
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-139
Chain Tensioner . . . . . . . . . . . . . . . . . . . . 1B3-145
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . 1B3-147
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . 1B3-151
Cylinder Head Guide Rail . . . . . . . . . . . . . 1B3-152
Timing Case Cover Guide Rail . . . . . . . . . 1B3-156
Crankshaft Sprocket . . . . . . . . . . . . . . . . . 1B3-158
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-163
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-169
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-171
Oil Spray Nozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-175
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B3-177
Cylinder Head Pressure Leakage Test . . . 1B3-177
Facing Cylinder Head Mating Surface . . . . 1B3-178
Replacement of Crankcase Core Plug . . . 1B3-180
Facing Crankcase Contacting Surface . . . 1B3-182
Oil Gallery Steel Ball . . . . . . . . . . . . . . . . . 1B3-183
Cylinder Bore Measurement . . . . . . . . . . . 1B3-187

OM600 ENGINE MECHANICAL 1B3-5
116 589 03 07 00
T Type Socket Wrench
601 589 00 25 00
SPECIAL TOOLS TABLE (Co n t
’d)115 589 34 63 00
601 589 00 10 00
Cylinder Head Bolt 102
102 589 12 15 00(


17) Drift 102 589 00 15 00
(


34) Drift
617 589 10 21 00
RI Sensor 601 589 05 14 00
Assembly Cage

OM600 ENGINE MECHANICAL 1B3-11
000 589 14 21 00Tester
001 589 65 09 00
Serration Wrench 116 589 02 34 00
Thread Bolt
SPECIAL TOOLS TABLE (Co n t
’d)
000 589 00 68 00
Cleaning Set
601 589 05 21 00Looking Screw 617 589 08 21 00 Position Sensor
667 589 04 63 00
Retaining Plate
601 589 00 08 00 Flange

1B3-18 OM600 ENGINE MECHANICAL
27. Disconnect the preheating time relay sensor plug.
28. Disconnect the coolant temperature sensor plug.
29. Disconnect the accelerator cable from the control linkage.Installation Notice
Tightening Torque 8 - 18 Nm
30. Loosen the connection of control pressure cable (an arrow) used in auto transmission.

OM600 ENGINE MECHANICAL 1B3-35
TDC (TDC SENSOR BRACKET) SETTING Preceding Work : Removal of No.1 cylinder prechamber
1 Measuring Device
2 Dial Gauge
3 Cylinder Head
4 Piston................................................ Set at TDC
Tools Service 001 589 32 21 00 Dial Gauge601 589 07 21 00 Deqth Gauge667 589 01 21 00 Fixing Device Notice
The TDC sensor bra cket must be adjusted in case of
followings.
When replacing the TDC sensor bracket.
When replacing the crankshaft, the hub or the vibration
damper.
When replacing or installing the timing case cover.
After engine overhauling.
If the cylinder head is removed, the measuring pin of the dial gauge can be positioned on the piston crown. This is done by placing the magnetic dial holder on the mating surface of the crankcase.

1B3-36 OM600 ENGINE MECHANICAL Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber bore andposition the dial gauge with a preload of 5mm. Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of engine rotation until the large pointer on the dial gauge stops (TDC position). Notice The position of TDC is when the large pointer on the dial gauge is stopped before moving back.
5. remove the reinstall the measuring device and position the dial gauge scale at ‘0’.
6. Slowly rotate the crankshaft in the direction of engine rotation until the dial gauge has moved back (counterclockwise) by3.65mm.
7. Insert fixing device into the sensor bracket. Notice The pin on the vibration damper must engage into the slot of the fixing device. Fixing Device 667 589 01 21 00
8. If the pin does not engage, adjust the setting of the sensor bracket by removing and tightening of the sensor bracketbolts.
Tightening Torque 10 Nm
Notice
The timing mark on the damper must be positioned at ATDC 20.

1B3-44 OM600 ENGINE MECHANICAL
22. Remove the cable channel.
23. Disconnect the cables from the glow plug sensor andcoolant 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.

1B3-60 OM600 ENGINE MECHANICAL
35. Connect the wires to the coolant temperature sensor andthe 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.

1B3-76 OM600 ENGINE MECHANICAL
Removal Procedure
1. Remove the starter motor and install the engine lock intothe wheel ring gear.
Engine Lock 602 589 00 40 00
2. Remove the poly V-belt.
3. Remove the cooling fan. NoticeKeep the fan in vertical position.
4. Remove the cooling fan belt pulley (2).
5. Place alignment marks (arrow) on the vibration damper (5) and crankshaft belt pulley (4).
6. Remove the timing sensor bracket. Notice
Remove if necessary.

OM600 ENGINE MECHANICAL 1B3-79
5. Install the timing sensor bracket.Notice See the ‘TDC setting ’.
6. Install the cooling fan pulley.
Tightening Torque 10 Nm
7. Install the cooling fan.
8. Install the fan belt.
9. Remove the engine lock.