engine SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE MECHANICAL 1B3-33
6. Measure the ‘X’ by using a vernier caliper.
7. Mount the turning tool onto the countersink tool and rotate to the right approx. 5 revolutions by applying slight pressure.
1. Remove the injection nozzle.
2. Remove the prechamber.
3. Cover the prechamber bore to avoid any chips droppinginto the combustion chamber.
4. Remove the protective sleeve from the countersink and rotate the countersink into the prechamber bore to be machined as far as the stop.
Counter Sink 601 589 00 66 00
5. Maintain size ‘X’ from the top edge of mandrel to the top
edge of the sleeve with the gauge.
Height Gauge 667 589 00 23 00

1B3-34 OM600 ENGINE MECHANICAL8. Remeasure size ‘X ’ and compare it with the first
measurement and determine the thickness of spacer ring.
Size before machining 25.7 mm
Size after machining 25.5 mm
Ex
The spacer ring should be selected so that it is at least 0.1mm and not more than 0.3mm thicker than the measured on the sealing surface. In this example, thenecessary thickness of spacer ring should be within0.3 ~ 0.5mm and the thickness of spacer ring to beinstalled is 0.3mm.
9. Remove the countersink tool and clean the chips.
Notice If the sealing surface is not completely flat, remachine the sealing surface.
10. emove rag from the prechamber bore and crank the engine with starter motor to threw out any chips which may have
got into the combustion chamber.
11. Insert the proper spacer ring into the prechamber sealing surface.
12. Punch a mark on the cylinder head above the prechambersealing surface which has been machined.
13. Install the prechambers.
Notice If the cylinder head is removed, the projection ‘C’ is
measured in place of size ‘X’ and the appropriate size of
spacer ring selected.
Normal Projection (c) 7.6 - 8.1mm

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.

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

1B3-38 OM600 ENGINE MECHANICAL
000 589 77 03 00 Box Wrench Insert
001 589 65 09 00 Socket Wrench Insert
102 589 03 40 00 Magnetic Bar
116 589 02 34 00 Threaded Pin
116 589 03 07 00 T Type Socket Wrench
116 589 20 33 00 Sliding Hammer
601 589 00 10 00 Cylinder Head Bolt Wrench
602 589 00 40 00 Engine Lock
603 589 00 40 00 Counter Holder
Tools Required
Cylinder Bolts (12-sided socket head) (Engine cold) M8 Cylinder Head Bolts
Tightening Torque
stage1 stage2stage3
10 Nm35 Nm
180 °
25 Nm
Tightening Sequence for Cylinder Head Bolts OM 662LA Engine
OM 661LA Engine

OM600 ENGINE MECHANICAL 1B3-39
Length(L) When New80mm
102mm 115mm
Thread Dia.
M10 M10M10Max. Length(L) 82mm
104mm 117mm
The twelve-sided socket head bolts are tightened with each stages of torque and torque angle. It is not necessary to retighten the cylinder head bolts at the 1000~1500km inspection or after 1000~1500km of repairs.
Notice The cylinder head may only be removed when the engine has cooled down. The cylinder head is removed together with the exhaust manifold. As the cylinder head bolts undergo a permanent tightening. They require to bereplaced if they exceed the maximum lengthes indicatedin the table.

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.

OM600 ENGINE MECHANICAL 1B3-41
8. Remove the air cleaner cover and element and thenremove the air cleaner housing.
9. Remove the oil return hose and plug.
Notice Cover them to prevent chips from coming into.
10. Unscrew the EGR pipe mounting bolts onto the exhaust manifold.
11. Remove the duct bracket from the cylinder head.
12. Unscrew the intake duct mounting bolts onto the intake manifold.
13. Separate the connecting rod from the control lever.

1B3-42 OM600 ENGINE MECHANICAL
14. Pull out the accelerator control linkage.
15. Remove the fuel injection line(1) from the fuel injectionnozzle(12).
Box Wrench Inset 000 589 77 03 00
16. Remove the fuel injection line from the fuel injection pump. Box Wrench Insert 000 589 77 03 00
17. Remove the bracket mounting bolts and then remove the fuel injection line(1).