engine SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE MECHANICAL 1B3-23
TENSIONING DEVICE Preceding Work : Removal of cooling fan
1 Bolt............................................................ 21Nm
2 Damper
3 Nut ............................................................. 21Nm
4 Tensioning Lever
5 Guide Rail Pin
6 Bolt
7 Poly V-Belt
8 Belt Pulley
9 Bolt ............................................................ 10Nm10 Tensioning Pulley
11 Socket Bolt ................................................ 29Nm
12 Closing Cover
13 Washer
14 Tensioning Lever
15 Fit Bolt ..................................................... 100Nm
16 Closing Cover
17 Spring
18 Bolt ............................................................ 20Nm

1B3-24 OM600 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the nut.Installation Notice
Tightening Torque 10 Nm
2. Push the tensioning lever in direction of arrow with a rod ( F12 ´ 180mm ) and push out the bolt to the rear.
3. Push back the tensioning lever to release the spring tension and remove the belt.
4. Remove the bolt (9) and then remove the belt pulley (8).
5. Remove the bolt (1, 18) and take off the damper (2). Notice
Pay attention to installation position of the damper.

OM600 ENGINE MECHANICAL 1B3-25
6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).Installation NoticeInsert spring (17) with color coding (blue/violet) facing up.
8. Pry off the closing cover (12) and remove the socket bolt(11) and then remove the tensioning pulley (10). Installation Notice
Tightening Torque 29 Nm
9. Pry off the closing cover (16) and remove the fit bolt (15).
10. Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice Apply Loctite on thread of fit bolt.
Tightening Torque 100 Nm
12. Installation should follow the removal procedure in the reverse order.

1B3-26 OM600 ENGINE MECHANICAL
POLY V-BELT ALIGNMENT & INSPECTION Without Air Conditioner
With Air Conditioner

OM600 ENGINE MECHANICAL 1B3-27
Inspection Procedure
Mark poly V-belt at a clearly visible point with chalk.
Rotate the engine and check the belt. Notice If one of the following types of damage is found, replace the belt.
1. Rubber lumps in the base of rips.
2. Dirt or grit ingrained.
5. Cord torn out at the side.
6. Outer cords frayed.
3. Pointed rips.
4. Belt cord visible in the base of rips.

1B3-28 OM600 ENGINE MECHANICAL7. Belt detached from the base of rip.
8. Splits across the rips.
9. Sections of rip torn out.
10. Splits across several rips.
11. Splits across the back.

OM600 ENGINE MECHANICAL 1B3-29
1 Threaded Ring........................................ 130 Nm
2 Prechamber
PRECHAMBER
Preceding Work : Removal of glow plug
Removal of fuel injection nozzle
3 Cylinder Head

1B3-30 OM600 ENGINE MECHANICAL
Tools Required
2. Install the sliding hammer into the prechamber.Sliding Hammer 667 589 03 63 00
Removal & Installation Procedure
1. Using the serration wrench (4), remove the threaded ring
(1).
Serration Wrench 603 589 00 09 00
3. Remove the perchamber (2). Notice
After removing the prechamber, cover over the bores with clean rag.
603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer
4. Inspect the prechamber.
Notice If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced, the sealing surfaces in the cylinder head must be remachined.

OM600 ENGINE MECHANICAL 1B3-31
Assembly ProcedureNotice In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used.
1. Clean the sealing surface of the prechamber.
2. Insert the prechamber into the cylinder head at the same time aligning the cam on the collar of the prechambers with the slots in the cylinder head. Notice If the spacer rings are fitted to the prechambers, the spacer rings should be replaced with rings of the same thickness.
Thickness of Spacer Ring 0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the ring by using the serration wrench.
Tightening Torque 130 Nm

1B3-32 OM600 ENGINE MECHANICAL
MILLING OF PRECHAMBER SEALING SURFACE1 Drift
2 Sleeve
3 Milling Cutter 4 Counter Sink (Special Tool - 601 589 00 66)
5 Cylinder Head
Tightening Torque 0.3, 0.6, 1.0 mm
Milling of the Prechamber Sealing Surface
Notice The prechamber sealing surface may only be remachined once with the cylinder head fitted. It is essential to adhere to the specified projection ‘C’ of the prechamber of 7.6 -
8.1mm. This ensures that the required clearance exists between prechamber and piston crown with the piston in TDC. Forthis reason, spacer rings should be inserted on remachinedsealing surfaces. If a spacer ring is already fitted, or a marking is made on the cylinder head, the cylinder head must be removed and size
‘C’ measured if further remachining is necessary on a
prechamber sealing surface.
Tools Required 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge