SSANGYONG OM600, Service Manual

Page 1: ...B3 80 Crankshaft Ball Bearing 1B3 82 Crankshaft 1B3 83 Flywheel 1B3 93 Machining of Flywheel 1B3 97 Flywheel Ring Gear 1B3 98 Hydraulic Valve Clearance Compensation Element Check 1B3 101 Valve Tappets 1B3 103 Valve Spring Check 1B3 105 Valve Springs Cylinder Head Removed 1B3 106 TABLE OF CONTENTS Valve Springs Cylinder Head Installed 1B3 109 Valve Stem Seals 1B3 112 Check and Replacement of Valve ...

Page 2: ...ft Bolt Nut Axle Propeller Shaft Bolt Nut T C Engine Mounting Nut Application Cooling Fan Belt Pulley Bolt Socket Bolt Tighten The Bolt End Cover Bolt Crankshaft Bearing Cap Bolt Ball Bearing Camshaft Sprocket Bolt Oil Pump Sprocket Bolt Application Connecting Rod Bolt Application 12 Sided Stretch Bolt EngineAssembly CrankshaftAssembly Piston Flywheel Cylinder Head Application Prechamber Threaded ...

Page 3: ...n Bolt M6 Oil Pan Bolt M23 Belt Pulley Bolt Guide Pulley Bolt Guide Pulley Bracket Nut Chain Tensioner Tesioning Lever Bolt Cylinder Head Application Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt Exhaust Pipe Bolt Nut Chain Tensioner Injection Nozzle Intake Manifold Not Injection Nozzle Pipe Not Oil Dipstick Tube Bolt Screw Plug M18 x 15 N m 25 25 90 25 80 40 25 18 10 50 Cam Support Shaft Timin...

Page 4: ...TABLE 603 589 00 09 00 Serration Wrench 657 589 03 63 00 Sliding Hammer 000 589 77 03 00 Box Wrench Insert 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge 602 589 00 40 00 Engine Lock 116 589 20 33 00 Sliding Hammer 603 589 00 40 00 Counter Holder ...

Page 5: ... Type Socket Wrench 601 589 00 25 00 SPECIAL TOOLS TABLE Cont d 115 589 34 63 00 601 589 00 10 00 Cylinder Head Bolt 102 102 589 12 15 00 φ φ φ φ φ 17 Drift 102 589 00 15 00 φ φ φ φ φ 34 Drift 617 589 10 21 00 RI Sensor 601 589 05 14 00 Assembly Cage ...

Page 6: ...08 15 00 Drift 001 589 53 21 00 Dial Gauge 601 589 03 14 00 Sleeve SPECIAL TOOLS TABLE Cont d 103 589 00 33 00 Puller 601 589 07 21 00 Depth Gauge 667 589 01 21 00 Fixing Device 366 589 00 21 05 Extension 601 589 03 43 00 Oil Seal Assembler ...

Page 7: ...Gauge Holder 000 589 33 33 00 Counter Support 000 589 04 14 00 Tensioning Strap SPECIAL TOOLS TABLE Cont d 116 589 07 15 00 Drift 000 589 25 33 00 Internal Extractor 102 589 05 33 00 Puller 601 589 01 59 00 Assembling Board 102 589 03 40 00 Magnetic Bar ...

Page 8: ...Supporting Bridge 667 589 00 31 00 Press Lever 104 589 00 37 00 Pliers SPECIAL TOOLS TABLE Cont d 667 584 02 63 00 Supporting Bar 116 589 06 63 00 Magnetic Finger 603 589 01 40 00 Holding Wheel 000 589 10 68 00 Cylinder Brush 601 589 02 43 00 Drift ...

Page 9: ... 589 03 15 00 Drift for Intake 601 589 06 15 00 Drift for Exhaust SPECIAL TOOLS TABLE Cont d 601 589 05 15 00 Drift for Intake 103 589 02 15 00 Drift for Exhaust 346 589 00 63 00 Super Cooling Box 000 589 21 53 00 Reamer for Intake 000 589 10 53 00 Reamer for Exhaust ...

Page 10: ...ial Gauge 001 589 53 21 00 Dial Gauge 667 589 02 21 00 TDC Pulse Generator SPECIAL TOOLS TABLE Cont d 124 589 15 21 00 Tester 000 589 58 43 00 Chain Assembling Device 201 589 13 21 00 Vacuum Tester 617 589 04 21 00 Tester 501 589 73 21 00 Vacuum Pump ...

Page 11: ... Tester 001 589 65 09 00 Serration Wrench 116 589 02 34 00 Thread Bolt SPECIAL TOOLS TABLE Cont d 000 589 00 68 00 Cleaning Set 601 589 05 21 00 Looking Screw 617 589 08 21 00 Position Sensor 667 589 04 63 00 Retaining Plate 601 589 00 08 00 Flange ...

Page 12: ...1B3 12 OM600 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON VEHICLE SERVICE ENGINE ASSEMBLY ...

Page 13: ...ightening Torque 28 47 Nm 5 Remove the drain plug 1 and seal 2 from the cylinder block and drain the coolant completely 6 After draining replace the seal and reinstall the drain plug Installation Notice 7 Disconnect the lower coolant hose from the radiator Tightening Torque 30 Nm Removal Installation Procedure 1 Disconnect the negative terminal of battery 2 Remove the hood ...

Page 14: ...t and remove the coolant pipe and cooling fan shroud 10 Remove the hoses air intake to intercooler intercooler to intake duct 8 Disconnect the upper coolant hose from the radiator Tightening Torque 3 7 Nm 11 Remove the pipes connected to intercooler ...

Page 15: ...rom the compressor Notice Evacuate the refrigerant before removal 12 Remove the hose air cleaner to turbocharger with blow by hose 13 Disconnect the air cleaner intake hose and remove the air cleaner cover and element 14 Disconnect the coolant hose from the water inlet ...

Page 16: ...Completely drain the fluid 17 Disconnect the fuel feed line with prefilter from the feed pump on injection pump 18 Vehicle with automatic transmission Remove the hydraulic lines 19 20 from oil cooler 2 19 Disconnect the engine harness 20 Disconnect the preheating time relay cable ...

Page 17: ...res and remove the starter motor 21 Remove the fuel lines from the fuel filter and cover the filter with plug 22 Disconnect the brake booster hose from vacuum pump 23 Disconnect the other vacuum lines 24 Disconnect the ground cable 25 Disconnect the alternator wires ...

Page 18: ...me relay sensor plug 28 Disconnect the coolant temperature sensor plug 29 Disconnect the accelerator cable from the control linkage Installation Notice Tightening Torque 8 18 Nm 30 Loosen the connection of control pressure cable an arrow used in auto transmission ...

Page 19: ...tening Torque Axle 70 80 Nm T C 81 89 Nm Tightening Torque 20 34 Nm 31 Separate the exhaust pipe flange from the turbo charger Installation Notice 32 Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder Installation Notice Tightening Torque 30 Nm Tightening Torque 30 Nm 34 Remove the propeller shaft from the transmission Installation Notice ...

Page 20: ...7 Loosen the engine mounting bracket nut Installation Notice 38 Remove the engine assembly from the vehicle by using a hoist or crane 39 Installation should follow the removal procedure in the reverse order Tightening Torque 50 75 Nm ...

Page 21: ...OM600 ENGINE MECHANICAL 1B3 21 POLY V BELT 1 Nut 23Nm 2 Tensioning Lever 3 Bolt 4 Spring 5 Tensioning Lever 6 Poly V Belt ...

Page 22: ...ll out the bolt to the rear 3 Push back the tensioning lever arrow direction to release the spring tension and remove the belt 4 Install the poly V belt beginning at the tensioning pulley 7 7 Tensioning Pulley 8 Crankshaft 9 Alternator 10 Coolant Pump 11 Guide Pulley 12 Power Steering Pump 13 Aircon Compressor Lengthe of Belt Length L Without Air Conditioner 2 100 mm 2 040 mm ...

Page 23: ...f cooling fan 1 Bolt 21Nm 2 Damper 3 Nut 21Nm 4 Tensioning Lever 5 Guide Rail Pin 6 Bolt 7 Poly V Belt 8 Belt Pulley 9 Bolt 10Nm 10 Tensioning Pulley 11 Socket Bolt 29Nm 12 Closing Cover 13 Washer 14 Tensioning Lever 15 Fit Bolt 100Nm 16 Closing Cover 17 Spring 18 Bolt 20Nm ...

Page 24: ...nsioning lever in direction of arrow with a rod F12 180mm and push out the bolt to the rear 3 Push back the tensioning lever to release the spring tension and remove the belt 4 Remove the bolt 9 and then remove the belt pulley 8 5 Remove the bolt 1 18 and take off the damper 2 Notice Pay attention to installation position of the damper ...

Page 25: ...emove the socket bolt 11 and then remove the tensioning pulley 10 Installation Notice Tightening Torque 29 Nm 9 Pry off the closing cover 16 and remove the fit bolt 15 10 Remove the tensioning lever 14 and washer 13 11 Clean thread in the timing case cover and fit bolt Installation Notice Apply Loctite on thread of fit bolt Tightening Torque 100 Nm 12 Installation should follow the removal procedu...

Page 26: ...1B3 26 OM600 ENGINE MECHANICAL POLY V BELT ALIGNMENT INSPECTION Without Air Conditioner With Air Conditioner ...

Page 27: ... point with chalk l 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 ...

Page 28: ...1B3 28 OM600 ENGINE MECHANICAL 7 Belt detached from the base of rip 8 Splits across the rips 9 Sections of rip torn out 10 Splits across several rips 11 Splits across the back ...

Page 29: ...OM600 ENGINE MECHANICAL 1B3 29 1 Threaded Ring 130 Nm 2 Prechamber PRECHAMBER Preceding Work Removal of glow plug Removal of fuel injection nozzle 3 Cylinder Head ...

Page 30: ...readed ring 1 Serration Wrench 603 589 00 09 00 3 Remove the perchamber 2 Notice After removing the prechamber cover over the bores with clean rag 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer 4 Inspect the prechamber Notice If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced the sealing surfaces in the cylinder head must be remachined ...

Page 31: ...mber 2 Insert the prechamber into the cylinder head at the same time aligning the cam on the collar of the prechambers with the slots in the cylinder head Notice If the spacer rings are fitted to the prechambers the spacer rings should be replaced with rings of the same thickness Thickness of Spacer Ring 0 3 0 6 1 0 mm 3 Coat the threaded ring with oil and assemble the ring by using the serration ...

Page 32: ...essential to adhere to the specified projection C of the prechamber of 7 6 8 1mm This ensures that the required clearance exists between prechamber and piston crown with the piston in TDC For this reason spacer rings should be inserted on remachined sealing surfaces If a spacer ring is already fitted or a marking is made on the cylinder head the cylinder head must be removed and size C measured if...

Page 33: ...njection nozzle 2 Remove the prechamber 3 Cover the prechamber bore to avoid any chips dropping into the combustion chamber 4 Remove the protective sleeve from the countersink and rotate the countersink into the prechamber bore to be machined as far as the stop Counter Sink 601 589 00 66 00 5 Maintain size X from the top edge of mandrel to the top edge of the sleeve with the gauge Height Gauge 667...

Page 34: ...nstalled is 0 3mm 9 Remove the countersink tool and clean the chips Notice If the sealing surface is not completely flat remachine the sealing surface 10 emove rag from the prechamber bore and crank the engine with starter motor to threw out any chips which may have got into the combustion chamber 11 Insert the proper spacer ring into the prechamber sealing surface 12 Punch a mark on the cylinder ...

Page 35: ... 00 Fixing Device Notice l The TDC sensor bracket must be adjusted in case of followings l When replacing the TDC sensor bracket l When replacing the crankshaft the hub or the vibration damper l When replacing or installing the timing case cover l After engine overhauling If the cylinder head is removed the measuring pin of the dial gauge can be positioned on the piston crown This is done by placi...

Page 36: ...f TDC is when the large pointer on the dial gauge is stopped before moving back 5 remove the reinstall the measuring device and position the dial gauge scale at 0 6 Slowly rotate the crankshaft in the direction of engine rotation until the dial gauge has moved back counterclockwise by 3 65mm 7 Insert fixing device into the sensor bracket Notice The pin on the vibration damper must engage into the ...

Page 37: ...Washer 15 Bolt 25 Nm 16 Cylinder Head Bolt See Table 17 Cylinder Head Cover 18 Bolt 10 Nm 19 Gasket 20 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...

Page 38: ...0 T Type Socket Wrench 116 589 20 33 00 Sliding Hammer 601 589 00 10 00 Cylinder Head Bolt Wrench 602 589 00 40 00 Engine Lock 603 589 00 40 00 Counter Holder Tools Required Cylinder Bolts 12 sided socket head Engine cold M8 Cylinder Head Bolts Tightening Torque stage1 stage2 stage3 10 Nm 35 Nm 180 25 Nm Tightening Sequence for Cylinder Head Bolts OM 662LA Engine OM 661LA Engine ...

Page 39: ...ngle It is not necessary to retighten the cylinder head bolts at the 1000 1500km inspection or after 1000 1500km of repairs Notice The cylinder head may only be removed when the engine has cooled down The cylinder head is removed together with the exhaust manifold As the cylinder head bolts undergo a permanent tightening They require to be replaced if they exceed the maximum lengthes indicated in ...

Page 40: ...olt 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 the rod 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 dipstic...

Page 41: ...ove 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 ...

Page 42: ... Remove the fuel injection line 1 from the fuel injection nozzle 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 ...

Page 43: ...NICAL 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 ...

Page 44: ...e the cable channel 23 Disconnect the cables from the glow plug sensor and coolant 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 ...

Page 45: ...5 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 nozzle washer 11 Socket Wrench Insert 001 589 65 09 00 ...

Page 46: ...te 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 ...

Page 47: ...e 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 ...

Page 48: ...move the No 2 bolts Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously 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 ...

Page 49: ...l out the tensioning lever 31 43 Pry off the closing cover Remove the bolt and then remove the idle pulley 44 Using the sliding hammer 36 and the threaded pin 37 pull out the sliding rail pins 25 26 and remove the sliding rail 24 SlidingHammer116589203300 Threaded Pin 116 589 02 34 00 ...

Page 50: ... thermo valve 47 Remove the socket bolts 13 of the chain box T Type Socket Wrench 116 589 03 07 00 Magnetic Bar 102 589 03 40 00 48 Remove the cylinder head bolts in numerical se quence Cylinder Head Bolt Wrench 601 589 00 10 00 45 Remove the vacuum line from the vacuum pump ...

Page 51: ...OM600 ENGINE MECHANICAL 1B3 51 49 Remove the cylinder head 2 and gasket 3 OM661LA ...

Page 52: ... with the guide pins 3 Measure the length L of cylinder head bolts Notice If the max length is exceeded replace the bolts Thread Dia Max Limit L M10 M10 M10 80mm 102mm 115mm 82mm 104mm 117mm when new 4 Coat the head contact surface of bolts and thread with oil and insert them as shown Cylinder head bolts arrangement Bore 1 M10 80 2 M10 102 3 M10 115 4 M 8 50 5 M 8 80 OM662LA ...

Page 53: ...ad bolts to specified torque and torque angle OM 662LA OM 661LA 6 Install the socket bolts in the chain box Tightening Torque 25 Nm Stage 1 Stage 2 Torque angle Wait for Torque angle 15 Nm 35 Nm 90 10 minutes 90 7 Connect the vacuum pipe to the thermo valve ...

Page 54: ...tening Torque 25 Nm Notice Be careful not to be confused the connections and hoses 10 Connect the fuel pipe to the injection pump 11 Install the sliding rail 24 and insert the sliding rail pins 25 26 Notice Apply sealing compound on the each collar of the sliding rail pins SlidingHammer 116589203300 Threaded Pin 116 589 02 34 00 ...

Page 55: ...ightening 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 ...

Page 56: ...ay 0 06 0 21mm Notice If out of standard adjust it with the proper thickness of locking washer 19 Install the bearing caps on the camshaft according to the number on the caps 20 Tighten the bearing cap bolts according to the numerical sequence Tightening Torque 25 Nm Notice Tighten the No 1 bolts light arrow first and then tighten the No 2 bolts dark arrow stage by stage OM662LA OM661LA ...

Page 57: ... Position the camshaft on marking and install the camshaft sprocket 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 ...

Page 58: ...ANICAL 24 Install the exhaust manifold and gasket 25 Install the turbocharger 26 Install the exhaust pipe onto the turbocharger Tightening Torque 25 Nm Notice Measure the max length L and replace the bolt if it exceeds 53 6mm ...

Page 59: ...ensioner Tightening Torque 80 Nm 28 Remove the engine lock 29 Insert the nozzle washer into the hole to face round part downward 30 Install the fuel injection nozzle Tightening Torque 40 Nm 31 Connect the fuel hose 32 Install the cable channel and connect the cables to glow plugs ...

Page 60: ...he coolant temperature sensor and the glow plug sensor 36 Replace the intake manifold gasket 37 Install the intake manifold Tightening Torque 25 Nm 33 Replace the gasket and install the cylinder head cover Tightening Torque 10 Nm 34 Install the blow by hose ...

Page 61: ...r head Notice For installation clean the hole 39 Install the bracket of heater feed pipe to the oil filter 40 Install the fuel pipe and the accelerator control linkage 41 Connect the fuel lines to the injection nozzles and to the injection pump Box Wrench Insert 000 589 77 03 00 Tightening Torque 18 Nm ...

Page 62: ...and pulling the rod install the bolt and then tighten the nut 44 Install the oil dipstick tube bracket Tightening Torque 10 Nm 45 Hold the cooling fan with the counter holder and tighten the bolt 42 Install the poly V belt Notice Be careful not to contaminate the belt Tightening Torque 23 Nm ...

Page 63: ...olt 10Nm 2 Cylinder Head Cover 3 Gasket Replace 4 Socket Bolt 25Nm 5 Fuel Filter 6 Square Nut 7 Oil Pan 8 Socket Bolt 10Nm 9 Bolt M6 10Nm M8 23Nm 10 Power Steering Pump 11 Bolt 12 Belt Pulley 13 Bolt 32Nm 14 Timing Case Cover 15 Bolt 23Nm 16 Alternator Bracket 17 Bolt 45Nm 18 Bolt 25Nm 19 Bolt 10Nm 20 Closing Cover 21 Socket Bolt 23Nm 22 Guide Pulley 23 Bolt 9Nm 24 Guide Pulley Bracket 25 Nut 23Nm...

Page 64: ...ve the fan clutch and cooling fan belt pulley 2 Drain the engine oil completely 3 Remove the oil dipstick tube bracket bolts 4 Remove the crankshaft pulley 5 Loosen the bolt 1 and then remove the cylinder head cover 2 and gasket 6 Remove the vacuum pump 7 Detach the closing cover 20 Remove the bolts 21 and then remove the guide pulley 22 ...

Page 65: ...the alternator bracket 16 9 Disconnect the pipes of power steering pump and remove the belt pulley Notice Be careful not to lose the key 10 Remove the nut and pull out the bolt and then remove the power steering pump 12 Remove the fuel filter ...

Page 66: ...mage the cylinder head gasket or oil pan gasket 13 Remove the camshaft 14 Remove the socket bolts 4 in the chain box Socket Wrench 115 589 03 07 00 15 Remove the injection pump Notice See the Removal of fuel injection pump 16 Remove the oil pan bolts 8 9 in the area of the timing case cover 14 17 Slightly loosen the remaining oil pan bolts ...

Page 67: ...ce and apply sealant 2 Install the timing case cover Notice Bolts arrangement 1 M6 x 60 2 M6 x 70 3 M6 x 40 3 Tighten the socket bolts in the chain box Tightening Torque 10 Nm Tightening Torque 23 Nm 4 Tighten the oil pan bolts Tightening Torque 10 Nm 10 Nm 23 Nm Socket bolt M6 bolt M8 bolt ...

Page 68: ...shaft belt pulley Notice Replace front radial seal if necessary 6 Install the alternator bracket 25 Nm Front Side 7 Install the alternator Tightening Torque Upper 25 Nm Low 25 Nm 8 Install the cylinder head cover Tightening Torque 10 Nm 9 Tighten the injection pump mounting bolts Tightening Torque 23 Nm ...

Page 69: ... 11 Install the vacuum pump 12 Install the power steering pump 13 Install the power steering pump pulley Tightening Torque 25 Nm Tightening Torque 10 Nm Tightening Torque 23 Nm Tightening Torque 32 Nm 14 Install the guide pulley bracket Tightening Torque 9 Nm ...

Page 70: ...e 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 ...

Page 71: ...NICAL 1B3 71 CRANKSHAFT END COVER Preceding Work Removal of flywheel and driven plate 1 Crankshaft Flange 2 End Cover Clean Loctite 573 3 Bolt 10Nm Loctite 573 4 Radial Seal Replace 5 Dowel Sleeve 6 Bolt 10Nm Loctite 573 ...

Page 72: ... 2 Remove the radial seal 4 with care not to damage the sealing surface Installation Procedure 1 Thoroughly clean the sealing surface of end cover and apply Loctite 573 2 Clean the groove of radial seal 3 Apply Loctite 573 on the bolts and install the end cover Tightening Torque 10 Nm Notice Be careful not to damage the oil pan gasket 4 Install the inner oil seal assembler to the crankshaft flange...

Page 73: ...ler on he seal and by tightening the bolts press the radial seal into the end cover as far as the stop Notice The seal must be positioned exactly at right angles in the end cover to ensure that it provides a proper seal Oil Seal Assembler 601 589 03 43 00 A Standard Radial Seal BRepairRadialSeal 5 Coat a little oil on the sealing lip of new radial seal and contacting surface Notice Don t use greas...

Page 74: ...ON DAMPER AND HUB Preceding Work Removal of the cooling fan Removal of poly V belt 1 Bolt 10Nm 2 Cooling Fan Belt Pulley 3 Socket Bolt 23Nm 4 Crankshaft Belt Pulley 5 Vibration Damper 6 Bolt 200Nm 90 7 Washer 8 Straight Pin 9 Hub 10 Oil Pan ...

Page 75: ... 5 Vibration Damper 6 Bolt 7 Washer 8 Straight Pin Notice The mounting position of vibration damper is fixed by straight pin 8 Tools Required 602 589 00 40 00 Engine Lock 103 589 00 30 00 Puller 9 Hub 11 Radial Seal 12 Timing Gear Case Cover 13 Key 14 Crankshaft Sprocket 16 Crankshaft ...

Page 76: ...el ring gear Engine Lock 602 589 00 40 00 2 Remove the poly V belt 3 Remove the cooling fan Notice Keep the fan in vertical position 4 Remove the cooling fan belt pulley 2 5 Place alignment marks arrow on the vibration damper 5 and crankshaft belt pulley 4 6 Remove the timing sensor bracket Notice Remove if necessary ...

Page 77: ...ECHANICAL 1B3 77 7 Remove the socket bolts 3 and then remove the belt pulley 4 and vibration damper 5 8 Remove the washer and bolt 9 Remove the hub by using a puller Puller 103 589 00 33 00 10 Replace the radial seal ...

Page 78: ...lign the woodruff key and the groove of hub arrow 2 Install the washer 7 and tighten the bolt 6 Washer new 1 EA 200 Nm 90 3 Install the vibration damper Notice Exactly align and insert onto the straight pin 4 Install the belt pulley Tightening Torque 25 Nm Notice Align the alignment marks ...

Page 79: ...E MECHANICAL 1B3 79 5 Install the timing sensor bracket Notice See the TDC setting 6 Install the cooling fan pulley Tightening Torque 10 Nm 7 Install the cooling fan 8 Install the fan belt 9 Remove the engine lock ...

Page 80: ...1B3 80 OM600 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL 1 Radial Seal 2 Timing Case Cover Tools Required 601 589 03 14 00 Sleeve 3 Woodruff Key ...

Page 81: ...rd Radial Seal B RepairRadialSeal Replacement Procedure 1 Pull out the radial seal 1 and be careful not to damage the sealing surface of timing case cover 2 Thoroughly clean the mounting bore of the radial seal 3 Coat a little oil on the sealing lip of new radial 1 and contact surface Notice Don t use grease 4 Install the radial seal 1 by using a sleeve 4 Notice Align the groove of sleeve and wood...

Page 82: ...rnal Extractor Removal Installation Procedure 1 Remove the manual transmission 2 Using a puller pull out the locking ring and ball bearing together Counter Support 000 589 33 33 00 Internal Extractor 000 589 25 33 00 3 Apply Loctite 241 on the new ball bearing and then insert the ball bearing to be stopped at the spacer ring by using a proper mandrel 3 Ball Bearing 4 Bolt 45Nm 90 ...

Page 83: ... 3 Crankshaft Main Bearing Shells Upper 4 Trust Bearings Upper 5 Crankshaft 6 Crankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower 8 Crankshaft Bearing Cap 9 Crankshaft Bearing Cap Fit Bearing 10 12 sided Stretch Bolts 55Nm 90 Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension ...

Page 84: ...ankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower A Radial Bearings B Radial and Axial Bearings Thrust Bearing Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other Refer to service data Thrust Washer and Bearing Arrangement OM662LA Engine ...

Page 85: ...r 5 Crankshaft 6 Crankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower A Radial Bearings B Radial and Axial Bearings Thrust Bearing Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other Refer to service data OM661LA Engine ...

Page 86: ...earing 47 700 47 715 47 450 47 650 47 200 47 215 46 950 46 965 57 500 57 715 57 450 57 465 57 200 57 215 56 950 56 965 Repair size 1 Repair size 2 Repair size 3 Repair size 4 Bearing Clearances Thrust bearing Crankshaft bearing 0 026 0 068 Max 0 080 0 027 0 051 Max 0 070 0 100 0 254 Max 0 300 Matching Fit Bearing Journal Width to Thrust Bearings Fit bearing journal width Thrust bearings thickness ...

Page 87: ...ic bearing bore in lower Color code of relevant crankshaft parting surface 1 punch mark or blue 2 punch marks or yellow 3 punch marks or red bearing shell Blue or white blue Yellow or white yellow Red or white red Marking of bearing journals on crank webs Color code of relevant crankshaft Blue or white blue Yellow or white blue Red or white blue Blue or white blue Yellow or white yellow Red or whi...

Page 88: ...t bearing caps are marked with stamped numbers Remove the bearing cap from the vibration damper side 3 Remove the crankshaft bearing caps 9 and lower thrust bearings 7 4 Remove the lower thrust bearings 6 from the bearing cap 9 5 Remove the crankshaft 5 6 Remove the upper thrust bearings 4 7 Remove the upper bearing shells 3 from crankcase ...

Page 89: ... and into the crankshaft bearing caps Notice Do not mix up upper and lower crankshaft bearing shells 11 Install the bearing caps according to marking and tighten the 12 sided stretch bolts Tightening Torque 35 40 Nm Notice No 1 is vibration damper side 12 Measure crankshaft bearing diameters E Extension 366 589 00 21 05 13 Measure at 3 points A B and C and if the average value of B and C is less t...

Page 90: ...ap 17 Measure width of thrust bearing journal H and adjust with proper thrust bearings see table Notice The same thickness of thrust washers should be installed on both sides of the thrust bearing 18 Coat the upper thrust bearing 4 with oil and insert into the crankcase so that the oil grooves are facing the crank webs arrow 19 Coat the lower thrust bearing 7 with oil and insert into the crankshaf...

Page 91: ... 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 th...

Page 92: ... 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 the connecting rod ...

Page 93: ...1B3 93 FLYWHEEL Preceding Work Removal of the transmission Removal of the clutch 1 Oil Pan 2 Straight Pin 3 Flywheel 4 12 Sided Stretch Bolt Check 45Nm 90 5 Drive Plate Automatic Transmission 6 Flywheel Automatic Transmission ...

Page 94: ...1B3 94 OM600 ENGINE MECHANICAL l Manual transmission flywheel l Automatic transmission flywheel OM661LA OM662LA ...

Page 95: ...ctly align the position of dowel pin 2 Tools Required 602 589 00 40 00 Engine Lock Removal Installation Procedure 1 Install the engine lock Engine Lock 602 589 02 40 00 2 Remove the 12 sided stretch bolts 4 Installation Notice Tightening Torque 45 Nm 90 Notice If the length L of bolts exceeds 22 5mm replace the bolts ...

Page 96: ...ANICAL 4 Remove the flywheel 6 and driven plate 5 if equipped with automatic transmission Installation Notice Correctly align the position of dowel pin 2 5 Installation should follow the removal procedure in the reverse order ...

Page 97: ...s are severe than permissible specifications replace the flywheel l When machining the clutch surface A the mounting surface B for the clutch pressure plate should also be machined in accordance with A to keep the distance a l Do not machine under b value l When machining fix the flywheel exactly not to exceed the standard runout OM662LA OM662LA Max axial runout Distance a New Repair up to 19 3 19...

Page 98: ... OM600 ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work Removal of flywheel 1 Ring Gear 2 Flywheel 3 Centering Collar Diameter Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder ...

Page 99: ...p with a chisel 2 Thoroughly clean the collar surfaces of ring gear 3 Measure diameter a of centering collar Notice If out of standard replace the flywheel 4 Heat up the new ring gear up to 220 C by using a heating device Notice Use temperature measuring chalk 5 Install the new ring gear 1 onto the flywheel by using a drift ...

Page 100: ...MECHANICAL 6 Measure axial runout of ring gear 1 on a surface plate Limit Max 0 4mm Notice For correct measurement put the flywheel on the flat measuring board Dial Gauge 001 589 53 21 00 Dial Gauge Holder 363 589 02 21 00 ...

Page 101: ...OM600 ENGINE MECHANICAL 1B3 101 HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK 1 Cylinder Head Cover 2 Bolt 10Nm 3 Gasket Replace 4 Valve Tappet 5 Cylinder Head ...

Page 102: ... After 5minutes check the engine oil level and adjust if necessary 3 Remove the cylinder head cover 4 Check the valve tappets at TDC position of each cylinders 5 Using a drift lightly press the valve tappet and measure clearance between the cam and valve tappet Notice If the clearance exceeds 0 4mm replace the valve tappet 6 If a valve tappet moves down too far in comparison to the others replace ...

Page 103: ...OM600 ENGINE MECHANICAL 1B3 103 VALVE TAPPETS Preceding Work Removal of camshaft 1 Valve Tappet 2 Cylinder Head 3 Oil Gallery 4 Seal Replace 5 Screw Plug Tools Required 102 589 03 40 00 Magnetic Bar ...

Page 104: ...ic Bar 102 589 03 40 00 2 Remove the plug 5 and blow compressed air into the oil gallery 3 At this time check that the outlet bores arrow at the seat of the valve tappet are clear 3 Replace the seal 4 and tighten the plug 5 4 Insert the new valve tappet Notice Coat the valve tappet with oil ...

Page 105: ...B3 105 VALVE SPRINGS CHECK Preceding Work Removal of valve spring 1 Valve Spring Service Data Outer diameter 33 1mm Wire diameter 4 20mm Free length 50 0mm At preloaded Length Tension new 680 740N 27mm Limit 612N 2 Spring Scale ...

Page 106: ...CAL VALVE SPRINGS CYLINDERHEADREMOVED Cylinder Head Removed 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Cylinder Head 6 Stud Bolt 12Nm 7 Washer 8 Nut Replace 25Nm 9 Exhaust Manifold ...

Page 107: ... 589 06 63 00 Magnetic Finger 601 589 01 59 00 Assembling Board 601 589 02 59 00 Supporting Bridge 667 589 00 31 00 Press Lever Replace the gasket and tighten the nuts 8 2 Install the assembling board 11 to the cylinder head with 4 cylinder head blots 10 Assembling Board 601 589 01 59 00 3 Pull out the valve tappet 1 with magnetic bar 12 Notice Place the valve tappets upside down open end upward M...

Page 108: ...reful not to damage guide bore of the valve tappet Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 6 Remove the spring retainer 3 and spring 4 Installation Notice Install the valve spring with the color coding arrow facing down 7 Check the valve spring and replace if necessary 8 Installation should follow the removal procedure in the reverse order ...

Page 109: ...otters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Timing Chain 6 Cylinder Head Notice Remove the valve springs only when the piston is at TDC Tools Required 102 589 03 40 00 Magnetic Bar 116 589 06 63 00 Magnetic Finger 603 589 01 40 00 Holding Wheel 667 589 00 31 00 Press Lever 667 589 02 63 00 Supporting Bar ...

Page 110: ...0 31 00 Magnetic Finger 116 589 06 63 00 Removal Installation Procedure 1 Remove the valve tappet 1 with magentic lifter Notice Place the valve tappets upside down open end upward Magentic Liter 102 589 03 40 00 2 Install the holding wheel 7 into the timing chain of camshaft sprocket piston Holding Wheel 603 589 01 40 00 3 Position the piston of relevant cylinder at TDC 4 Install the supporting ba...

Page 111: ...and insert valve spring Retainer 3 9 By press the spring retainer 3 with press lever 90 install the valve cotters with magnetic finger 10 Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 10 Remove the supporting bar 11 Remove the holding wheel 7 from the timing chain 5 Holding Wheel 603 589 01 40 00 13 Coat the valve tappet with oil and install it Magnetic Bar 102 589 03 40 00 ...

Page 112: ...VE STEM SEALS Preceding Work Removal of camshaft 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Valve Stem Seal 6 Valve Notice Remove the valve stem seals when the piston is positioned at TDC ...

Page 113: ...etic Lifter 603 589 01 40 00 Holding Wheel 601 589 02 43 00 Drift 116 589 06 63 00 Magnetic Finger 667 589 02 63 00 Supporting Bar A Intake valve stem seal B Exhaust valve stem seal Chamfer Inner diameter d Color Wire ring Intake valve stem seal Offset 7 3mm Brown Black Exhaust valve stem seal All round 8 2mm Green Yellow ...

Page 114: ...89 03 40 00 2 Install the holding wheel 7 into the timing chain 11 Holding Wheel 603 589 01 40 00 3 Position the piston of relevant cylinder at TDC 4 Install the supporting bar 8 Supporting Bar 667 589 02 63 00 5 Using press lever 9 press the spring retainer 3 downward and remove the valve collets with magnetic finger 10 Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 ...

Page 115: ...ert the cap 12 onto the valve 6 and install the new valve stem seal 5 and then remover the cap Drift 601 589 02 43 00 9 By pressing the spring seat with press lever 9 install the valve cotters 2 with magnetic finger 10 Notice Be careful not to damage guide bore of the valve tappet Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 ...

Page 116: ...size 1 Repair size 2 Outer Diameter D 14 251 14 440 14 451 14 240 14 251 14 440 14 451 Color Code 14 200 14 211 14 400 14 411 14 200 14 211 14 400 14 411 Overlap D a Valve Guide InnerDiameter A 37 7 Length L CHECK AND REPLACEMENT OF VALVE GUIDES Preceding Work Removal of cylinder head Removal of valve spring Removal of valve 1 Cylinder Head 2 Valve Guide 3 Valve Seat Ring a Basic Bore Diameter ...

Page 117: ... 346 589 00 63 00 Super Cooling Box 601 589 02 23 00 GO NO GO Gauge 601 589 05 15 00 Drift for Intake Notice Measure center arrow of the valve guide and if the inner diameter A exceeds standard value replace the guide 601 589 06 15 00 Drift for Exhaust Matching Valve Seat Broaching Tools Guide Sleeves Valve Seat Intake Exhaust Intake Exhaust Broaching Tool No 115 589 00 53 00 14 2mm 115 589 01 53 ...

Page 118: ...ge into the valve guide bore If the NO GO side is inserted fully replace the valve guide Intake 8mm Exhaust 9mm GO NOGOGauge601589022300 Replacement Procedure 1 Drive out the valve guide 2 by using a drift 5 Notice The valve guide must be driven out upward of the cylinder head Drift for Intake 103 589 03 15 00 Drift for Exhaust 103 589 02 15 00 Checking 1 Thoroughly clean the valve guide bore usin...

Page 119: ...ching tool must be cleared of swarf with a stiff plastic brush Lubricate the basic bore guide sleeve and broaching tool with petroleum Push broaching tool 6 in broaching direction arrow into the guide sleeve 7 far enough so that the first cut of the broaching tool is positioned in the basic bore when guide sleeve is fitted onto the valve seat ring 3 6 Broaching tool 7 Guide sleeve See the standard...

Page 120: ...r Intake 102 589 00 23 00 GO NO GO Gauge for Exhaust 117 589 03 23 00 6 Cool down the new valve guide 2 with liquid nitrogen Notice Do not touch the cooled valve guide by hand Super Cooling box 346 589 00 63 00 7 Drive in new valve guide with drift 8 until the wire ring makes contact Notice The valve guide must be driven in from the cylinder head cover Drift for Intake 601 589 05 15 00 Drift for E...

Page 121: ...ENGINE MECHANICAL 1B3 121 9 If necessary ream the valve guide bore evenly Notice Never turn the reamer against the direction of rotation Reamer for Exhaust 000 589 10 53 00 Reamer for Intake 000 589 21 53 00 ...

Page 122: ...Surface B Height cylinder Head Cover Surface Seat of Valve Seat Ring D Valve Seat Ring Outer Diameter D1 Valve Seat Ring Inner Diameter D2 Basic Bore Diameter H Height of Valve Seat Ring Service Data Item D2 D D1 H Overlap U D D2 B A Intake 40 000 40 016mm 40 084 40 100mm 33 400 33 600mm 6 955 7 045mm 0 068 0 100mm 133 4mm 142 5mm Exhaust 37 000 37 016mm 37 084 37 100mm 30 400 30 600mm 6 955 7 045...

Page 123: ...ectrically Heated Water Tank CommercialTools Hunger D 8000 München 70 Type Ventilknecht K2000 Order No 221 00 100 Hunger D 8000 München 70 Type VDS 1A Order No 236 03 308 Hunger D 8000 München 70 Type RDS 1 Order No 219 00 100 Hunger D 8000 München 70 Type PVM 1 Hunger D 8000 München 70 Order No 250 15 250 Hunger D 8000 München 70 Order No 217 93 601 Hunger D 8000 München 70 Order No 216 69 210 Ma...

Page 124: ...mm and dimension E is approx 6mm 4 Remove the cylinder head from the clamping device and place it onto wooden blocks 5 Remove the valve guide 3 Drift Intake 8mm Drift Exhaust 9mm 6 Insert the tensioning head 4 and extracted wedges arrow by turning the bolt 5 Notice Carefully tighten the bolt 5 otherwise the valve seat ring in the cylinder head will be excessively tensioned 7 Lock the bolt 5 with n...

Page 125: ...value U 0 090mm If overlap value U is out of standard machine the basic bore for the valve seat ring 13 Clamp the cylinder head with clamping device 14 Machining basic bore for valve seat ring repair size Notice Maintain minimum value of B Machine the basic bore Limit Intake Exhaust Max D2 Min B 40 516mm 37 516mm 133 4mm Measure machined basic bore and outer diameter D of valve seat ring repair si...

Page 126: ...ve guide must be driven in from the cylinder head cover Drift Intake 8mm Drift Exhaust 9mm 19 Machine the valve seats 15 Hang the cylinder head 1 to the lifting device and heat in a water tank to approx 80 C 16 Cool down new valve seat ring 2 into the cooling box with liquid nitrogen Notice Do not touch the cooled valve seat rings with hand Super Cooling Box 345 589 00 63 00 ...

Page 127: ...ceding Works Removal of cylinder head Removal of the vale spring Removal of the valve I Valve Length W Camshaft Cam Basic Diameter X Distance Camshaft Basic Bore Valve Stem Y Half Camshaft Basic Bore Diameter Z Distance Cylinder Head Cover Parting Surface Valve Stem ...

Page 128: ...m Exhaust Valve 34 90 35 10 mm 1 7 mm 45 9 945 8 960 mm 106 20 106 60 mm 105 30 105 70 mm 0 03 mm Standard Repair Max Permis Sible Runout at Valve Stem and Valve Seat W 38 0 0 2mm MatchingValves Camshaft Cam Basic Dia Size x Size x Size x 19 5 20 3mm 20 4 21 4mm 21 4 21 97mm W 36 6 0 2mm Camshaft Cam Basic Dia 19 5 20 1mm 20 2 21 2mm 21 2 21 97mm Valve to be Used Use machined valve if needed new r...

Page 129: ...bled valve disc with worn or scored valve stem should be replaced 2 Measure valve disc height h Service data Intake Exhaust 1 7 0 15 mm 1 7 0 15 mm 3 Machine the valve Notice Pay attention to setting angle α Commercial Tool Valve corn grinding machine 4 Measure radial runout between valve stem and valve seat Limit Max 0 03mm Dial Gauge 001 589 32 21 00 ...

Page 130: ...valve guides 6 Coat the valve stem with oil and insert it into valve guide 7 Insert the valves 1 into the valve guides according to marking 8 Measure amount by which the valve arrears a Arrears a 0 1 0 7 mm Notice If out of standard replace the valve seat ring 9 Measure camshaft cam basic diameter w Diameter w 38 0 2 mm or 37 6 0 2 mm ...

Page 131: ...re valve stem x z y Determine the valve to use according to this measurement See matching valves Example Measured value w 38 2 mm Measured value z 36 5 mm Value y 15 5 mm x 36 5 15 5 21 0mm In this case according to Matching valves table the installed valve may be used ...

Page 132: ...VALVE SEAT Preceding Work Removal of prechamber Removal and inspection of valve replace if necessary Inspection of valve guide replace if necessary 1 Valve 2 Valve Seat Ring 3 Cylinder Head 4 Valve Guide a Valve Seat Angle b Valve Seat Free Angle ...

Page 133: ...MatchingValves Camshaft cam basic dia Size x Size x Size x 19 5 20 3mm 20 4 21 4mm 21 4 21 97mm w 37 6 0 2 mm Camshaft cam basic dia 19 5 20 1mm 20 2 21 2mm 21 2 21 97mm Valve to be used Use machined valve if needed use pair valve 1 105 5 0 2mm Reuse valve Use standard size valve I 106 4 0 2mm CommercialTools Hunger D 8000 München 70 Type Ventilknecht K2000 Order No 221 00 100 Hunger D 8000 Münche...

Page 134: ...eplacing the valve guide When replacing the valve seat or valve seat ring 1 Machine the valve seat a 45 2 Measure valve seat width b Valve seat width b 1 2 1 7 mm 1 5 2 0 mm Intake Exhaust 3 If the specification is exceeded the valve seat width has to be corrected at the lower free angle of β 65 4 Measure radial runout Runout Max 0 03mm ...

Page 135: ...5 Insert the valve 1 into the valve guide according to marking and measure amount by which the valve arrears a Arrears a 0 1 0 7mm 6 Measure camshaft cam basic circle diameter w Diameter w 7 Measure distance z cylinder head cover parting surface valve stem ...

Page 136: ...Distance Cylinder head cover parting surface valve stem 8 Measure x Camshaft basic bore valve stem x z y 9 Determine the valve to be used See Matching valves Example Measured value w 38 2 mm Measured value z 36 5 mm Value y 15 5 mm x 36 5 15 5 21 0 mm In the case of a camshaft cam basic circle diameter w 38 2mm and a distance x 21 0mm the installed valve may be used ...

Page 137: ...g 1 Cylinder Head Cover 2 Bolt 10Nm 3 Gasket Replace 4 Valve Tappet 5 Cylinder Head Timing Condition of camshaft New After approx 20 000km Intake valve Open ATDC 11 33 ATDC 12 Close ABDC 17 ABDC 18 Exhaust valve Open BBDC 28 BBDC 27 Close BTDC 15 25 BTDC 14 At 2mm of valve lifting stroke ...

Page 138: ...ot rotate the engine at the bolt of the crankshaft sprocket Do not rotate the engine in the opposite direction of engine rotation If do this will cause serious measuring errors 3 Install the dial gauge holder and dial gauge 7 with the extension 8 to the cylinder head and position the tracer pin 9 onto the valve tappet intake valve of cylinder NO 1 with a preload of min 3mm Notice The tracer pin sh...

Page 139: ...oval of cylinder head cover 1 Bolt 25Nm 2 Washer 3 Camshaft Bearing Cap 4 Camshaft 5 Dowel Pin 6 Locking Washer 7 Timing Chain 8 Cylinder Head 9 Oil Pan 10 Camshaft Sprocket 11 Washer 12 12 Sided Bolt M11 Check 25Nm 90 13 Gasket Replace 14 Chain Tensioner 80Nm ...

Page 140: ...40 00 Engine Lock Removal Procedure 1 Rotate the crankshaft and position the piston of no 1 cylinder at TDC Notice Do not rotate the crankshaft in the opposite direction of engine rotation In this position the markings of the camshaft camshaft bearing cap arrow must be aligned 2 Place alignment marks on the camshaft sprocket and timing chain ...

Page 141: ...cket 5 Remove the chain tensioner 6 Remove the camshaft bearing cap bolts according to the removal order Notice Remove the camshaft bearing cap bolts of 1 dark arrow first and then remove the bolts of 2 light arrow one revolution in stages until the counter pressure is released In order to avoid damaging the camshaft it is essential to adhere to the removal order for the camshaft bearing caps OM66...

Page 142: ...to miss front locking washer 9 Pull out the locking washer Notice Check the condition of locking washer and replace if necessary Installation Procedure 1 Insert the locking washer 2 Check the valve tappet and ensure that tappet moves smoothly 3 Coat the camshaft with oil and install the camshaft onto the cylinder head so that the TDC marking arrow is positioned upward vertically ...

Page 143: ...gned the markings of the camshaft camshaft bearing cap arrow Notice Align the alignment marks on the timing chain and sprocket Tightening Torque 25 Nm Notice Tighten the No 1 bolts light arrow by one revolution in stages first and then tighten the No 2 bolts dark arrow OM661LA OM662LA 7 Tighten the camshaft sprocket bolt Tightening Torque 25Nm 90 ...

Page 144: ...T on the crankshaft 8 Install the chain tensioner Tightening Torque 80 Nm Notice Replace the seal Before installation by pumping in the oil approx 10 times fill the oil 9 Remove the engine lock Notice If max length L of the 12 sided bolt exceeds 53 6mm replace it ...

Page 145: ...OM600 ENGINE MECHANICAL 1B3 145 CHAIN TENSIONER 1 Chain Tensioner 80Nm 2 Seal Replace ...

Page 146: ... 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 ...

Page 147: ...E 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 ...

Page 148: ...ire arrow Tools Required 000 589 58 43 00 Chain Assembling Device Replacement Procedure 1 Cover over the chain box with cleaning rag and grind off both 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 timin...

Page 149: ... Insert the new outer plate 4 into the fitting tool 8 and then 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 the outer plate on as far as the stop 10 Switch over the die 9 of the fitting tool 8 ...

Page 150: ...markings are not aligned the timing chain must be re set and the injection pump 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 the chain 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 ...

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

Page 152: ... 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 23Nm 9 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 ...

Page 153: ...emoval 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 ...

Page 154: ...ve the guide rail 10 SlidingHammer116589203300 Threaded 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 ...

Page 155: ...g 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 ...

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

Page 157: ...iming 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 ...

Page 158: ... 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 against the 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 ...

Page 159: ...2 589 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 ...

Page 160: ...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...

Page 161: ...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 ...

Page 162: ...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 ...

Page 163: ...ushing diameter Max 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 ...

Page 164: ...ecting rod bolts 12 and then remove the 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 ...

Page 165: ...g 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 ...

Page 166: ...inder with a wooden stick 18 Notice The arrow on the piston crown must point toward the front of vehicle 9 Insert the connecting rod bearing shells 9 10 Notice Be careful of the difference in upper and lower bearing shells and not to be changed 10 Position the connecting rod bearings caps Notice Position so that the retaining lugs are on the same side of the connecting rod bearing arrow 11 Measure...

Page 167: ...l clearance between the connecting rod and crankshaft 14 Measure clearance between the piston crown and cylinder Standard Max 0 12mm 15 Position the piston at TDC and measure the distance between the piston crown and the crankcase surface Notice Measure at points marked Dial Gauge 001 589 00 53 21 Dial Gauge Holder 363 589 02 21 00 Standard Max 0 965 mm ...

Page 168: ... ENGINE MECHANICAL 1B3 169 OIL FILTER 1 Nut 25 Nm 2 Oil Filter Cover 3 O Ring Replace 4 Oil Filter Element Replace If necessary 5 Oil Filter Housing 6 Bolt M8 10Nm 7 Oil Pressure Switch 8 Gasket 9 Bolt 25 Nm ...

Page 169: ...stallation Procedure 1 Remove the oil filter cover and then drain the oil 2 Remove the oil pressure switch line 3 Remove the oil filter housing 4 Clean the sealing surface 5 Installation should follow the removal procedure in the reverse order ...

Page 170: ...il Pan 3 Combination Bolt 10 Nm 4 Combination Bolt 10 Nm 5 Gasket Replace 6 Lower Oil Pan 7 Combination Bolt 25 Nm 8 Drain Plug 25 Nm 9 Washer Seal Replace 10 Oil Pan Remove and install as numerical sequence Notice Replace the washer seal with new one OM662LA OM661LA ...

Page 171: ...1B3 172 OM600ENGINE MECHANICAL Oil Circulation ...

Page 172: ...OM600 ENGINE MECHANICAL 1B3 173 Oil Filter a From Oil Pump b To Main Oil Gallery c To Oil Pan ...

Page 173: ... OM600ENGINE MECHANICAL OIL SPRAY NOZZLE 1 Fitting Sleeve 2 Oil Spray Nozzle Disassembly Procedure 1 Remove oil pan or crankshaft 2 Loose the bolt and then remove the nozzle 3 Combination Bolt 10 Nm A Oil Duct ...

Page 174: ...CAL 1B3 175 OIL PUMP 1 Oil Pump 2 Piston 3 Pressure Spring 4 Guide Pin 5 Screw Plug 50 Nm 6 Combination Bolt 25 Nm 7 Oil Strainer 8 Bracket Disassembly Procedure 1 Remove the oil pan 2 Unscrew the mounting bolt of spracket ...

Page 175: ...MECHANICAL Tightening Torque 10 Nm 3 Unscrew the oil strainer bracket bolt 4 Remove the oil pump 5 Unscrew the screw plug and remove the relief valve 6 Installation should follow the removal procedure in the reverse order ...

Page 176: ...tion 4 Gasket Replace 5 Coolant Gallery Sealing 6 Pressure Measuring Plate Completely tight to the cylinder head 7 Cylinder Head Immerse with pressure measuring plate into warm water of approx 60 C and pressurize with compressed airof 2 bar Notice If air bubbles are seen replace the cylinderhead Tools Required 115 589 34 63 00 Pressure Measuring Plate 601 589 00 25 00 Suspension Device UNIT REPAIR...

Page 177: ...a Prechamber protrusion Service Data In longitudinal direction In transverse direction Intake valve Exhaust valve 142 9 143 1mm 142 5mm 0 08mm 0 0mm Max 0 1mm 0 0017mm 0 1 0 7mm 0 1 0 7mm 7 6 8 1mm FACING CYLINDER HEAD MATING SURFACE Preceding Work Removal of prechamber Cylinder head pressure leakage test 1 Valve 2 Cylinder Head 3 Prechamber A Height of Cylinder Head B Longitudinal Direction C Tra...

Page 178: ...e height is less than 142 5mm replace the cylinder head 2 Insert the valve 1 and measure valve arrears a Valve Arrears a 0 1 0 7 mm Notice If out of standard machine the valve seat 3 Install the prechamber and measure protrusion C Protrusion C 7 6 8 1mm 4 Assemble the engine and check the valve timing ...

Page 179: ...HANICAL REPLACEMENT OF CRANKCASE CORE PLUG Left Right Core plug φ34mm OM661LA 2EA OM662LA 3EA Core plug φ34mm OM661LA 2EA OM662LA 3EA Core plug φ17mm OM661LA 1EA OM662LA 1EA Core plug φ34mm OM661LA 1EA OM662LA 1EA Left Right ...

Page 180: ...pdrawn edge of the core plug and pull forward and then rotate 90 4 Pull out the core plug with pliers 5 Thoroughly clean the sealing surface and apply Loctite 241 6 Install the new core plug by using a drift Drift 102 589 00 15 00 F34 Drift 102 589 12 15 00 F17 7 Install the removed parts and fill the coolant Notice The adhesive must be allowed to harden for about 45 minutes before filling of cool...

Page 181: ...n longitudinal direction Piston protrusion at TDC to crankcase upper surface In longitudinal direction B In transverse direction C Min 299 62 mm 0 06 mm 0 06 mm 0 0006 0 0016 mm 0 05 mm 0 965 mm 0 735 mm Max Min FACING CRANKCASE CONTACTING SURFACE 1 Crankcase 2 Crankcase Contacting Surface Y Height crankcase upper surface crankcase lower surface B Longitudinal Direction C Transverse Direction H Ch...

Page 182: ...receding Work Removal of cooling fan Removal of the coolant pump housing Removal of the flywheel and driven plate 1 Steel Ball φ15mm 2 Screw Plug Loctite 241 50Nm Notice The screw plug 2 has to be installed as a repair solution if the steel ball 1 is leaking ...

Page 183: ...M600ENGINE MECHANICAL 3 Steel Ball φ17mm 4 Seal 5 Screw Plug 50Nm Notice The seal 4 and screw plug 5 have to be installed as a repair solution if the steel ball 3 is leaking Tools Required 601 589 08 15 00 Drift ...

Page 184: ...not to damage the bores of the steel balls 6Shop madetool 3 Thoroughly clean the bores of steel balls 4 Place the steel ball 3 onto the drift 7 with a little grease and position to the bore and then tap until the drift stops Drift 601 589 08 15 00 5 Place the steel ball 1 onto the drift 7 with a little grease and position to the bore and then tap until the drift stops Drift 601 589 08 1500 6 Warm ...

Page 185: ...g 1 Remove the steel ball 2 Tap thread into the bores of the oil gallery Notice Front bore M18 1 5 depth 10mm Rear bore M16 1 5 depth 14mm 3 Thoroughly clean the oil gallery 4 Tighten the front plug 5 with seal 4 5 Apply Loctite 241 and then tighten the rear plug 2 Tightening Torque 50 Nm Tightening Torque 50 Nm ...

Page 186: ...er shape Honing angle CYLINDER BORE MEASUREMENT a Longitudinal Direction b Transverse Direction c d e Measuring Point 1 Crankcase Contacting Surface 2 TDC of 1st Piston Ring 4 BDC of Ring Service Data Code letter A Code letter X Code letter B When new Wear limit 89 000 89 006mm 89 006 89 012mm 89 012 89 018mm Max 0 20mm 0 01mm 0 05mm 50 10 ...