cooling SSANGYONG MUSSO 2003 Owner's Manual

1B3-2 OM600 ENGINE MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N

 m
28 - 47 30
3 - 7
8 - 18
20 - 34 30
70 - 80 81 - 8450 - 75
N 

 m
10 23
200 / 90 °
10
55 / 90 °
45 / 90 °
25 / 90 °
25
N 

 m
35 / 90 °
N 

 m
45 / 90 °
Application
Skid Plate Bolt Drain Plug Bolt Coolong Fan Shroud BoltControl Linkage NutClutch Linkage Cylinder NutExhaust Manifold Bolt
Propeller Shaft Bolt & Nut (Axle) Propeller Shaft Bolt & Nut (T/C)
Engine Mounting Nut
Application
Cooling Fan Belt Pulley Bolt Socket Bolt
Tighten The BoltEnd Cover BoltCrankshaft Bearing Cap Bolt Ball Bearing Camshaft Sprocket BoltOil Pump Sprocket Bolt
Application
Connecting Rod Bolt
Application
12-Sided Stretch Bolt
Engine Assembly
Crankshaft Assembly Piston
Flywheel
Cylinder Head
Application
Prechamber Threaded Ring Cylinder Head Cover Bolt Fuel Injsction Pipe NutSocket BoltFuel Filter Pipe BoltIdle Pulley Bolt Damper Bolt N


 m
130 10 18252523 21

OM600 ENGINE MECHANICAL 1B3-9
601 589 02 23 00
Go/No Go Gauge
105 589 03 15 00 Drift (for Intake) 601 589 06 15 00
Drift (for Exhaust)
SPECIAL TOOLS TABLE (Co n t
’d)
601 589 05 15 00
Drift (for Intake)
103 589 02 15 00
Drift (for Exhaust)
346 589 00 63 00
Super Cooling Box 000 589 21 53 00
Reamer (for Intake) 000 589 10 53 00
Reamer (for Exhaust)

1B3-14 OM600 ENGINE MECHANICAL9. Loosen the bolt and remove the coolant pipe and cooling fan shroud.
10. Remove the hoses (air intake to intercooler, intercooler to intake duct).
8. Disconnect the upper coolant hose from the radiator.
Tightening Torque 3 -7 Nm
11. Remove the pipes connected to intercooler.

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

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

1B3-40 OM600 ENGINE MECHANICAL Disassembly Procedure
1. Completely drain the coolant from the radiator and cylinderblock.
2. Remove the cooling fan shroud.
3. Hold the fan with counter holder and remove the bolt and then remove the cooling fan. Notice Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
5. Remove the nut.
6. Remove the nut on the tensioning lever and insert therod(F12 ´ 180mm). By pushing the rod to the arrow direction,
pull back the bolt.
7. Push the tensioning lever to the opposite direction to release the spring tension and remove the poly V-belt.
4. Remove the bracket oil dipstick tube.

1B3-62 OM600 ENGINE MECHANICAL
43. By inserting a rod into the tensioning lever upper hole andpulling 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 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

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).

1B3-70 OM600 ENGINE MECHANICAL
15. Install the guide pulley (22) and fit the closing cover (20).
16. Replace the gasket (3) and install the cylinder head cover(2).
17. Install the cooling fan belt pulley and fan clutch.
18. Install the belt tensioning device and then install the belt.
19. Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.
Tightening Torque 23 Nm
Tightening Torque 10 Nm