2003 SSANGYONG MUSSO Service Manual

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).

OM600 ENGINE MECHANICAL 1B3-43
18. Disconnect the booster hose connected to intake manifold.
19. Remove the intake manifold and gasket.
20. Remove the cylinder head cover and gasket with the blow-by gas hose.
21. Disconnect the glow plug cables.

1B3-44 OM600 ENGINE MECHANICAL
22. Remove the cable channel.
23. Disconnect the cables from the glow plug sensor andcoolant temperature sensor.
24. Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe.

OM600 ENGINE MECHANICAL 1B3-45
26. Disconnect the fuel lines from the fuel filter.
27. Disconnect the fuel lines from the injection pump.
28. Remove the fuel filter(35).
29. Remove the fuel injection nozzle(12) and nozzlewasher(11).
Socket Wrench Insert 001 589 65 09 00

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.