SSANGYONG MUSSO 2003 Service Manual

1B3-156 OM600 ENGINE MECHANICAL
TIMING CASE COVER GUIDE RAIL Preceding Work : Removal of cylinder head cover1 Bearing Pin
2 Bearing Pin
3 Guide Rail
4 Oil Pump Chain 5 Crankshaft
6 Spring
7 Bushing
8 Tensioning Lever

1B3-158 OM600 ENGINE MECHANICAL
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil panRemoval of timing case cover
1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90 °
2 Washer
3 Camshaft Sprocket
4 Timing Chain
5 Bearing Pin
6 Bearing Pin
7 Oil Pump
8 Oil Pump Sprocket
9 Oil Pump Chain
10 Washer 11 Bolt
............................................................ 25Nm
12 Crankshaft Sprocket
13 Crankshaft
15 Key
16 Guide Rail
17 Spring
18 Bushing
19 Tensioning Lever

OM600 ENGINE MECHANICAL 1B3-159
Special Tools
116 589 07 15 00 Drift102 589 05 33 00 Puller Removal Procedure
1. Pull out the tensioning lever (19) together with the spring(17) and guide rail (16) far enough until the tensioning lever has passed the oil pump chain (9) and is resting againstthe crankshaft (13).
2. Pull out tensioning lever (19), spring (17) and bushing (18) from the bearing pin (6).
3. Pull out the guide rail (16).
4. Remove the bolt(11) and then remove the washer (10), oil pump chin (9) and sprocket (8).

1B3-160 OM600 ENGINE MECHANICAL
10. Remove the crankshaft sprocket (12) by using a puller(20).
Puller 102 589 05 33 00
5. Place alignment marks (arrow) on the timing chain (4) and
crankshaft sprocket (12).
6. Remove the woodruff key(15).
7. Place alignment marks (arrow) on the timing chain (4) and camshaft sprocket (3).
8. Remove the chain tensioner.
9. Remove the bolt (1) and then remove the washer (2) and camshaft sprocket (3).

OM600 ENGINE MECHANICAL 1B3-161
Installation Procedure
1. Put the same alignment mark on the new crankshaftsprocket as in the old sprocket. Notice Check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for
wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a drift (21). Notice Align the groove of sprocket and woodruff key (arrow)
exactly. Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket (12). Notice Align the alignment marks (arrow) on the chain and sprocket.
4. Install the camshaft sprocket (3).
Tightening Torque 25 Nm + 90 °
Notice Pay attention on the alignment marks and dowel pin (arrow).

1B3-162 OM600 ENGINE MECHANICALNotice If the max. length ‘L’ of the stretch bolt exceeds 53.6mm,
replace it.
5. Fit the oil pump chain (9) on the crankshaft sprocket (12) and insert the oil pump sprocket (8) into the oil pump chain and then install it on the oil pump. Notice The curved side of the oil pump sprocket should face the oil pump.
6. Insert the woodruff key (15).
7. Install the guide rail (16). Attach the spring (17) to guide rail and to tensioning lever together onto the bearing pins (5,6). Notice Ensure that the spring is correctly located in the guide rail (arrow).

OM600 ENGINE MECHANICAL 1B3-163
PISTON
Preceding Work : Removal of the cylinder headRemoval of the oil pump
1 Oil Ring
2 2nd Ring
3 Top Ring
4 Snap Ring.............................................. Replace
5 Piston Pin
6 Piston
7 Connecting Rod Bushing .......................... Check 8 Connecting Rod
9 Connecting Rod Upper Bearing Shell
10 Connecting Rod Lower Bearing Shell 11 Connecting Rod Bearing Cap
12 Connecting Rod Bolt ......................... 35Nm + 90 °
13 Crankcase
14 Cylinder Bore
Notice There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there would be a unbalancing of engine.

1B3-164 OM600 ENGINE MECHANICAL Service Data
Piston clearance Piston crown protrusion in TDC position Connecting rod bushing diameterMax. 0.12 mm
0.735 - 0.965 mm
26.012 - 26.018 mm
Connecting Rod Bolt Dimensions
Thread Stretch shaft(C) diameter (new)Minimum stretch shaft diameter (C)Length(L)(new)
Tools Required
000 589 04 14 00 Tensioning Strap 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder M9 x 1
7.4 -0.1
mm
7.1 mm
52 -0.3
mm

OM600 ENGINE MECHANICAL 1B3-165
Removal Procedure
1. Remove combustion residues from the cylinder bores.
2. Remove the connecting rod bolts (12) and then removethe connecting rod bearing caps(11).
3. Remove the connecting rod bearing shells (9, 10). Notice
Be careful not mix the bearing caps and shells each other.
4. Remove the piston (6) and connecting rod (8).
5. Remove the snap ring (4) and pull out the piston pin (5).
6. Separate the piston and connecting rod.

1B3-166 OM600 ENGINE MECHANICAL Installation Procedure
1. Fit the piston onto the connecting rod so that the arrow(15) and the locking slot (16) are facing in direction of the vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand. Notice Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if necessary.
5. Install and arrange the piston rings to be evenly 120 ° from
each ends gap.