SSANGYONG MUSSO 2003 Service Manual

1B3-146 OM600 ENGINE MECHANICAL
Notice Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill
Faulty chain tensioners should be replaced completely.
3 Screw Plug
4 Aluminum Gasket
5 Ball
6 Ball Guide
7 Compression Spring
8 Compression Spring
9 Housing
10 Thrust Pin 11 Valve Disc
12 O-Ring
13 Snap Ring
14 Compression Spring
15 Filler
A Feed Bore from Cylinder Head
B To Oil Pan

OM600 ENGINE MECHANICAL 1B3-147
TIMING CHAIN Preceding Work : Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover
1 Chain Link
2 Timing Chain
3 Camshaft Sprocket
4 Outer Plate

1B3-148 OM600 ENGINE MECHANICAL
5. By rotating the crankshaft in the of engine rotation, pull outthe old timing chain with installing the new timing chain.
6. Remove the old timing chain and hold the ends of the new timing chain to camshaft sprocket (3) with wire (arrow).
Tools Required 000 589 58 43 00 Chain Assembling Device
Replacement Procedure
1. Cover over the chain box with cleaning rag and grind offboth chain pins (arrow) at a chain link (1) of the timing chain.
2. Remove the outer plate (4) and chain link (1). Notice Ensure that the ends of the timing chain do not drop into the chain box.
3. Loosen the chain tension with approx. 4 turns.
4. Connect the new timing chain (arrow) with chain link (1) to the old timing chain (2).

OM600 ENGINE MECHANICAL 1B3-149
7. Insert the new chain link (1) to connect the chain.
8. Insert the new outer plate (4) into the fitting tool (8) andthen the outer plate will be held by a magnet.
Chain Assembling Device 000 589 58 43 00
9. Place the fitting tool (8) onto the chain link and press theouter plate on as far as the stop.
10. Switch over the die (9) of the fitting tool (8).

1B3-150 OM600 ENGINE MECHANICALIn this position, the marking on camshaft / camshaft bearing cap (arrow) must also be aligned. If the markings are notaligned, the timing chain must be re-set and the injectionpump timing has to be set.
14. Position the no.1 cylinder at TDC.
11. Place the fitting tool (8) onto the chain link and rivet thechain pins one by one.
12. Check the riveting of chain pins and re-rivet if necessary.
13. Remove the wire.
Tightening Torque 35 - 40 Nm

OM600 ENGINE MECHANICAL 1B3-151
TENSIONING RAIL
Preceding Work : Removal of cylinder headRemoval of timing case cover
1 Tensioning Rail 2 Bearing Pin
Notice The plastic coating of the tensioning rail can not be replaced.

1B3-152 OM600 ENGINE MECHANICAL
CYLINDER HEAD GUIDE RAIL
Preceding Work : Removal of the cooling fanRemoval of poly V-belt
Removal of chain tensioner
1 Cylinder Head Cover
2 Bolt............................................................ 10Nm
3 Gasket ................................................... Replace
4 Camshaft Sprocket
5 Washer
6 12-Sided Bolt (M11) ............ Inspect, 25Nm + 90 °
7 Tensioning Lever
8 Bolt ............................................................ 23Nm9 Bearing Pin
........................... Sealing Compound
10 Guide Rail
11 Bearing Pin
12 Guide Pulley
13 Socket Bolt ................................................ 23Nm
14 Closing Cover
15 Spring
16 Timing Chain

OM600 ENGINE MECHANICAL 1B3-153
Tools Required
115 589 02 34 00 Sliding Hammer
116 589 20 33 00 Threaded Pin Removal Procedure
1. Removal the cylinder head cover.
2. Pull off the tensioning lever (7) and remove from the spring(15).
3. Pry off the closing cover (14) and remove the bolt (13) and then remove the guide pulley (12).
4. Place alignment marks (arrow) on the timing chain (16) and camshaft sprocket (4).
5. Remove the camshaft sprocket.

1B3-154 OM600 ENGINE MECHANICAL
4. Position the no. 1 cylinder at the TDC of OT.
6. Pull out the bearing pins (9, 11) with sliding hammer andremove the guide rail 10.
Sliding Hammer 116 589 20 33 00Threaded Pin 116 589 02 34 00
Installation Procedure
1. Apply collar of both bearing pins with sealing compound.
2. Position the guide rail and insert the bearing pins.
3. Install the camshaft sprocket.
Tightening Torque 10 Nm
Notice If the max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.

OM600 ENGINE MECHANICAL 1B3-155
In this position, the marking on the camshaft / camshaft bearing cap (arrow) must also be aligned.
5. Install the guide pulley (12).
Tightening Torque 23 Nm
6. Attach the tensioning lever (7) to the spring (15) and install.
7. Replace the gasket and install the cylinder head cover.
Tightening Torque 10 Nm