2003 SSANGYONG MUSSO check engine

OM600 ENGINE MECHANICAL 1B3-27
Inspection Procedure
Mark poly V-belt at a clearly visible point with chalk.
Rotate the engine and check the belt. Notice If one of the following types of damage is found, replace the belt.
1. Rubber lumps in the base of rips.
2. Dirt or grit ingrained.
5. Cord torn out at the side.
6. Outer cords frayed.
3. Pointed rips.
4. Belt cord visible in the base of rips.

OM600 ENGINE MECHANICAL 1B3-37
CYLINDER HEAD1 Fuel Injection Pipe ..................................... 18Nm
2 Cylinder Head
3 Gasket ................................................... Replace
4 Bolt ............................................................ 25Nm
5 Washer
6 Clamp
7 Heater Feed Pipe
8 Bolt
9 Washer
10 Bolt 11 Nozzle Washer ....................................... Replace
12 Fuel Injection Nozzle ............................ 35-40 Nm
13 Hexagon Socket Bolt ................................. 25 Nm
14 Washer
15 Bolt ........................................................... 25 Nm
16 Cylinder Head Bolt ..............................See Table
17 Cylinder Head Cover
18 Bolt ........................................................... 10 Nm
19 Gasket
2 0 Camshaft 21 Camshaft Drive Sprocket
....................... Replace
22 Washer
23 Bolt(12-Sided) .................................. 25Nm + 90 °
24 Sliding Rail
25 Sliding Rail Pin
26 Sliding Rail Pin
27 Chain Tensioner ....................................... 80 Nm
28 Gasket ................................................... Replace
29 Cooling Fan .............................................. Check
30 Hexagon Socket Bolt ................................. 45 Nm
31 Tensioning Lever
32 Bolt ........................................................... 25 Nm
33 Bolt
34 Nut ............................................................ 23 Nm
35 Fuel Filter
36 Turbo Charger
37 Intake Duct
38 Gasket ................................................... Replace
39 Intake Manifold

1B3-48 OM600 ENGINE MECHANICAL
38. Remove the camshaft bearing cap bolts according to thenumerical sequence. Notice Remove the No.1 bolts first and then remove the No. 2 bolts. Do not remove the bolts at a time completely butremove them step by step evenly or camshaft can beseriously damaged.
OM662LA
39. Remove the bearing caps and then pull out the camshaft(20) upward. Notice
Be careful not to miss the locking washer.
40. Remove the locking washer. Notice
Check the locking washer and replace if necessary.
OM661LA

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.

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
°

1B3-70 OM600 ENGINE MECHANICAL
15. Install the guide pulley (22) and fit the closing cover (20).
16. Replace the gasket (3) and install the cylinder head cover(2).
17. Install the cooling fan belt pulley and fan clutch.
18. Install the belt tensioning device and then install the belt.
19. Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.
Tightening Torque 23 Nm
Tightening Torque 10 Nm

OM600 ENGINE MECHANICAL 1B3-91
Notice If the max. length of bolts(L) exceed 63.8mm, replace them.
19. Coat the new crankshaft with engine oil and place it on the crankcase.
20. Install the crankshaft bearing caps according to marking and tighten the bolts.
Tightening Torque 55 Nm + 90 °
Notice Install from No. 1 cap.
22. Rotate the crankshaft with hand and check whether it rotates smoothly.
23. Measure crankshaft bearing axial clearance.
Clearance 0.100 - 0.245mm
Notice If the clearance is out of standard, adjust the axial clearance of crankshaft bearing by replacing the thrust washers.
Dial Gauge 001 589 53 21 00
Dial Gauge Holder 363 589 02 21 00
Notice The same thickness of thrust washers should be installed on both sides of the thrust bearing.

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °