2003 SSANGYONG MUSSO Service Manual

OM600 ENGINE CONTROLS 1F3-31
Tools Required 601 589 00 08 00Flange
601 589 05 21 00 Locking Screw
116 589 20 33 00 Sliding Hammer
116 589 02 34 00 Threaded Bolt
667 589 04 63 00 Retaining Plate Removal & Installation Procedure
1. Remove the bolts (2) and then remove the cylinder head cover (1) and gasket (3). Installation Notice
Tightening Torque 10 Nm
Notice Replace the gasket.Rotate the engine 1 revolution by hand and check TDC marking of the crankshaft and camshaft.
2. Loosen the camshaft sprocket bolt (14). Notice Do not remove the bolt. Installation Notice Notice If max. length of bolt exceeds 53.6mm, replace it.
Tightening Torque 25Nm + 90 °
3. Loosen the bolt (11) (left-hand thread).
Notice Do not remove the bolt.

1F3-32 OM600 ENGINE CONTROLS
5. Remove the plug (6) and seal (5) from the fuel injection pump and collect oil in a suitable vessel. Installation Notice
Notice Replace the seal.
Tightening Torque 30 Nm
6. Install the locking screw (18) into the injection pump. Notice Before tightening the bolts for the injection timing device and the camshaft sprocket, always remove the locking screw from the injection pump and reinstall the plug.
Locking Screw 601 589 05 21 00
7. Place alignment marks (arrow) on the timing chain (12) and camshaft sprocket (15).
4. Position the no.1 cylinder at A
TDC 15°.
Notice Do not rotate the engine with camshaft sprocket bolt or opposite direction of the engine rotation.

OM600 ENGINE CONTROLS 1F3-33
9. Pull out the 12-sided stretch bolt (14) and washer andremove the camshaft sprocket (12).
Tightening Torque 46 Nm
11. Using special tool (24, 25), remove the locking pin (8). Sliding Hammer 116 589 20 33 00Threaded Bolt 116 589 02 34 00
8. Remove the chain tensioner (17).
Installation Notice
Tightening Torque 80 Nm
Notice Replace the seal (16).
10. Pull out the bolt (11) and washer (10). Notice Be careful that the bolt is left-hand thread. Installation Notice

1F3-34 OM600 ENGINE CONTROLS
12. Push back the timing chain with retaining plate (26) and remove the injection timing device (9).
Retaining Plate 667 589 04 63 00
13. Installation should follow the removal procedure in the reverse order.
14. After assembling the engine, check start of delivery and adjust if necessary.

OM600 ENGINE CONTROLS 1F3-35
INJECTION TIMING DEVICE Preceding Work : Removal of injection timing device
1 Cam Sprocket........................................... Check
2 Bushing .................................................... Check
3 Governor Weights 4 Segment Flange and Drive Hub
5 Compression Springs

1F3-36 OM600 ENGINE CONTROLS
Disassembly & Assembly
1. Remove the governor weights (3).
2. Pull out the compression springs (5) and cam sprocket (1)from the segment flange (4).
3. Knock out the bushing with a proper drift.
4. Installation should follow the removal procedure in the reverse order.

OM600 ENGINE CONTROLS 1F3-37
START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD)1 Position Sensor
2 Battery
3 Fuel Injection Pump 4 Seal
....................................................... Replace
5 Screw Plug ................................................. 30Nm
Service Data
Start of Delivery (RIV) ATDC 14° - 16 °

1F3-38 OM600 ENGINE CONTROLS
Tools Required 617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel.
2. Install the position sensor (1) into the governor housing of
the injection pump to be the guide pin of the position sensor facing up.
3. Connect the battery terminal of position sensor (1) to positive terminal (+) of battery.
Position Sensor 617 589 08 21 00
4. Rotate the crankshaft by hand (in direction of engine rotation) until the lamp ‘B’ lights up. Rotate the crankshaft carefully
further until both lamps ‘A and B ’ come on. In this position,
check the Rl value on the crankshaft vibration damper. Notice If only lamp ‘A’ lights up, repeat the test and if out of
specification, adjust start of delivery.
Specification A TDC 14° - 16 °