SSANGYONG MUSSO 2003 Service Manual

1B3-46 OM600 ENGINE MECHANICAL
30. Rotate the crankshaft and set the no.1 cylinder at TDC.Notice Do not rotate the crankshaft to the opposite direction of engine revolution.
31. Place alignment marks on the camshaft gear and timing chain.
32. Ensure that the camshaft and the bearing cap marking are aligned.
33. Remove the starter motor and install the engine lock onto the flywheel ring gear.
Engine Lock 602 589 00 40 00

OM600 ENGINE MECHANICAL 1B3-47
34. Remove the turbocharger.
35. Remove the exhaust manifold and gasket.
36. Remove the chain tensioner and seal.
37. Remove the bolt and separate the drive sprocket(21).Notice During removal, be careful not to drop the sprocket and chain into the timing case. Carefully pull off the chain and then pull out the sprocket.

1B3-48 OM600 ENGINE MECHANICAL
38. Remove the camshaft bearing cap bolts according to thenumerical sequence. Notice Remove the No.1 bolts first and then remove the No. 2 bolts. Do not remove the bolts at a time completely butremove them step by step evenly or camshaft can beseriously damaged.
OM662LA
39. Remove the bearing caps and then pull out the camshaft(20) upward. Notice
Be careful not to miss the locking washer.
40. Remove the locking washer. Notice
Check the locking washer and replace if necessary.
OM661LA

OM600 ENGINE MECHANICAL 1B3-49
41. Remove the bolt(32).
42. Separate the spring and pull out the tensioning lever(31).
43. Pry off the closing cover. Remove the bolt and then removethe idle pulley.
44. Using the sliding hammer(36) and the threaded pin(37), pull out the sliding rail pins(25, 26) and remove the sliding rail(24).
Sliding Hammer 116 589 20 33 00Threaded Pin 116 589 02 34 00

1B3-50 OM600 ENGINE MECHANICALOM 662LA
46. Disconnect the vacuum pipe from thermo valve.
47. Remove the socket bolts(13) of the chain box.
T Type Socket Wrench 116 589 03 07 00Magnetic Bar 102 589 03 40 00
48. Remove the cylinder head bolts in numerical se-quence. Cylinder Head Bolt Wrench 601 589 00 10 00
45. Remove the vacuum line from the vacuum pump.

OM600 ENGINE MECHANICAL 1B3-51
49. Remove the cylinder head(2) and gasket(3).
OM 661LA

1B3-52 OM600 ENGINE MECHANICALLength(L)
Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.
Notice Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts. Notice If the max. length is exceeded, replace the bolts.
Thread Dia. Max. Limit(L)
M10 M10 M1080mm
102mm 115mm 82mm
104mm 117mm
when new
4. Coat the head contact surface of bolts and thread with oil
and insert them as shown. - Cylinder head bolts arrangement
Bore 1 ........................................... M10 ×
80
2 ........................................... M10 × 102
3 ........................................... M10 × 11 5
4 ........................................... M 8 × 50
5 ........................................... M 8 × 80 OM662LA

OM600 ENGINE MECHANICAL 1B3-53
5. Tighten the cylinder head bolts to specified torque andtorque angle.
OM 662LA
OM 661LA
6. Install the socket bolts in the chain box.
Tightening Torque 25 Nm
Stage 1 Stage 2
Torque angle
Wait for
Torque angle 15 Nm35 Nm
90 °
10 minutes
90°
7. Connect the vacuum pipe to the thermo valve.

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 1B3-55
12. Install the idle pulley and fit the closing cover.
Tightening Torque 25 Nm
13. Insert the tensioning lever(31) and install the spring.
14. Install the damper.
Tightening Torque 23 Nm
Notice Insert the tensioning lever bolts onto the mounting hole.
15. Insert the locking washer.
16. Inspect the valve tappet and check that the tappet moves smoothly.