engine SSANGYONG MUSSO 2003 Service Manual

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.

1B3-56 OM600 ENGINE MECHANICAL
17. Coat the camshaft with oil and install the camshaft on thecylinder head to be TDC mark(arrow) upward.
18. Measure the axial end play of the camshaft.
End Play 0.06 - 0.21mm
Notice If out of standard, adjust it with the proper thickness of
locking washer.
19. Install the bearing caps on the camshaft according to the number on the caps.
20. Tighten the bearing cap bolts according to the numerical sequence.
Tightening Torque 25 Nm
Notice
Tighten the No. 1 bolts(light arrow) first and then tighten the No. 2 bolts(dark arrow) stage by stage.
OM662LA OM661LA

OM600 ENGINE MECHANICAL 1B3-57
21. Position the camshaft on marking and install the camshaftsprocket. Notice Align the alignment marks on the chain and sprocket.
23. Install the camshaft sprocket bolt.
22. Check the TDC position of the crankshaft.
Tightening Torque 25 Nm + 90
°

1B3-58 OM600 ENGINE MECHANICAL
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.
Tightening Torque 25 Nm
Notice Measure the max. length ‘L’ and replace the bolt if it exceeds
53.6mm.

OM600 ENGINE MECHANICAL 1B3-59
27. Replace the seal and then install the chain tensioner.
Tightening Torque 80 Nm
28. Remove the engine lock.
29. Insert the nozzle washer into the hole to face round part downward.
30. Install the fuel injection nozzle.
Tightening Torque 40 Nm
31. Connect the fuel hose.
32. Install the cable channel and connect the cables to glow plugs.

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.

OM600 ENGINE MECHANICAL 1B3-61
38. Replace the O-ring of heater feed pipe and install it to thecylinder head. NoticeFor installation, clean the hole.
39. Install the bracket of heater feed pipe to the oil filter.
40. Install the fuel pipe and the accelerator control linkage.
41. Connect the fuel lines to the injection nozzles and to the injection pump. Box Wrench Insert 000 589 77 03 00
Tightening Torque 18 Nm

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