SSANGYONG OM600 Service Manual
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SSANGYONG OM600 Service Manual

SSANGYONG OM600 Service Manual

Engine mechanical
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OM600 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
Specifications. . . . . . . . . . . . . . . . . . . . . . . 1B3-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B3-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B3-4
Maintenance and Repair . . . . . . . . . . . . . 1B3-12
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B3-12
Engine Assembly . . . . . . . . . . . . . . . . . . . . 1B3-12
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-21
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B3-23
Prechamber . . . . . . . . . . . . . . . . . . . . . . . . 1B3-29
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B3-37
Timing Case Cover . . . . . . . . . . . . . . . . . . . 1B3-63
Crankshaft End Cover . . . . . . . . . . . . . . . . 1B3-71
Vibration Damper and Hub . . . . . . . . . . . . . 1B3-74
Crankshaft Front Radial Seal . . . . . . . . . . . 1B3-80
Crankshaft Ball Bearing . . . . . . . . . . . . . . . 1B3-82
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-83
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-93
Machining of Flywheel . . . . . . . . . . . . . . . . 1B3-97
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . 1B3-98
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . 1B3-103
Valve Spring Check . . . . . . . . . . . . . . . . . 1B3-105
Valve Springs (Cylinder Head Removed) . 1B3-106
SECTION 1B3

TABLE OF CONTENTS

Valve Stem Seals . . . . . . . . . . . . . . . . . . . 1B3-112
Valve Seat Rings . . . . . . . . . . . . . . . . . . . 1B3-122
Check and Machining of Valves . . . . . . . . 1B3-127
Machining of Valve Seat . . . . . . . . . . . . . . 1B3-132
Camshaft Timing Test . . . . . . . . . . . . . . . . 1B3-137
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-139
Chain Tensioner . . . . . . . . . . . . . . . . . . . . 1B3-145
Timing Chain. . . . . . . . . . . . . . . . . . . . . . . 1B3-147
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . 1B3-151
Cylinder Head Guide Rail . . . . . . . . . . . . . 1B3-152
Timing Case Cover Guide Rail . . . . . . . . . 1B3-156
Crankshaft Sprocket . . . . . . . . . . . . . . . . . 1B3-158
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-163
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-169
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-171
Oil Spray Nozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-175
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B3-177
Oil Gallery Steel Ball . . . . . . . . . . . . . . . . . 1B3-183
Cylinder Bore Measurement . . . . . . . . . . . 1B3-187

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  • Page 1: Table Of Contents

    SECTION 1B3 OM600 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 2: Specifications

    1B3-2 OM600 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Engine Assembly N• • • • • m Application 28 - 47 Skid Plate Bolt Drain Plug Bolt Coolong Fan Shroud Bolt 3 - 7 8 - 18 Control Linkage Nut 20 - 34...
  • Page 3 OM600 ENGINE MECHANICAL 1B3-3 Cylinder Head N• • • • • m Application Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt 25 / 90° Exhaust Pipe Bolt& Nut Chain Tensioner Injection Nozzle Intake Manifold Not Injection Nozzle Pipe Not Oil Dipstick Tube Bolt Screw Plug M18 x 15 Cam Support &...

  • Page 4: Special Tools

    1B3-4 OM600 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 603 589 00 09 00 603 589 00 40 00 Serration Wrench Counter Holder 657 589 03 63 00 000 589 77 03 00 Sliding Hammer Box Wrench Insert 601 589 00 66 00...
  • Page 5 OM600 ENGINE MECHANICAL 1B3-5 SPECIAL TOOLS TABLE (Cont’d) 116 589 03 07 00 115 589 34 63 00 T Type Socket Wrench 601 589 00 10 00 Cylinder Head Bolt 102 601 589 00 25 00 102 589 12 15 00 φ...
  • Page 6 1B3-6 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 601 589 08 15 00 103 589 00 33 00 Drift Puller 001 589 53 21 00 601 589 03 14 00 Dial Gauge Sleeve 601 589 07 21 00 601 589 03 43 00...
  • Page 7 OM600 ENGINE MECHANICAL 1B3-7 SPECIAL TOOLS TABLE (Cont’d) 363 589 02 21 00 116 589 07 15 00 Dial Gauge Holder Drift 000 589 33 33 00 000 589 04 14 00 Counter Support Tensioning Strap 000 589 25 33 00...
  • Page 8 1B3-8 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 601 589 02 59 00 667 584 02 63 00 Supporting Bridge Supporting Bar 667 589 00 31 00 104 589 00 37 00 Press Lever Pliers 116 589 06 63 00...
  • Page 9 OM600 ENGINE MECHANICAL 1B3-9 SPECIAL TOOLS TABLE (Cont’d) 601 589 02 23 00 601 589 05 15 00 Go/No Go Gauge Drift (for Intake) 105 589 03 15 00 601 589 06 15 00 Drift (for Intake) Drift (for Exhaust)
  • Page 10 1B3-10 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 001 589 32 21 00 124 589 15 21 00 Dial Gauge Tester 001 589 53 21 00 667 589 02 21 00 Dial Gauge TDC Pulse Generator 000 589 58 43 00...
  • Page 11 OM600 ENGINE MECHANICAL 1B3-11 SPECIAL TOOLS TABLE (Cont’d) 000 589 14 21 00 601 589 00 08 00 Tester Flange 001 589 65 09 00 116 589 02 34 00 Serration Wrench Thread Bolt 000 589 00 68 00 667 589 04 63 00...

  • Page 12: Maintenance And Repair

    1B3-12 OM600 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY...
  • Page 13 OM600 ENGINE MECHANICAL 1B3-13 Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the hood. 3. Remove the skid plate. Installation Notice Tightening Torque 28 - 47 Nm 4. Remove the radiator drain cock and drain the coolant.
  • Page 14 1B3-14 OM600 ENGINE MECHANICAL 8. Disconnect the upper coolant hose from the radiator. 9. Loosen the bolt and remove the coolant pipe and cooling fan shroud. Tightening Torque 3 -7 Nm 10. Remove the hoses (air intake to intercooler, intercooler to intake duct).
  • Page 15 OM600 ENGINE MECHANICAL 1B3-15 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. 15. Remove the air-conditioner lines from the compressor.
  • Page 16 1B3-16 OM600 ENGINE MECHANICAL 16. Remove the power steering pump lines. Notice 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).
  • Page 17 OM600 ENGINE MECHANICAL 1B3-17 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 1B3-18 OM600 ENGINE MECHANICAL 27. Disconnect the preheating time 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)
  • Page 19 OM600 ENGINE MECHANICAL 1B3-19 31. Separate the exhaust pipe flange from the turbo charger. Installation Notice Tightening Torque 30 Nm 32. Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder. Installation Notice Tightening Torque 20 - 34 Nm 33.
  • Page 20 1B3-20 OM600 ENGINE MECHANICAL 37. Loosen the engine mounting bracket nut. Installation Notice Tightening Torque 50 - 75 Nm 38. Remove the engine assembly from the vehicle by using a hoist or crane. 39. Installation should follow the removal procedure in the...

  • Page 21: Poly V-Belt

    OM600 ENGINE MECHANICAL 1B3-21 POLY V-BELT 1 Nut ............. 23Nm 4 Spring 2 Tensioning Lever 5 Tensioning Lever 3 Bolt 6 Poly V-Belt...
  • Page 22 1B3-22 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the nut. 2. Push the tensioning lever in direction of arrow with a rod (F12 ´ 180mm) and pull out the bolt to the rear. 3. Push back the tensioning lever (arrow direction) to release the spring tension and remove the belt.

  • Page 23: Tensioning Device

    OM600 ENGINE MECHANICAL 1B3-23 TENSIONING DEVICE Preceding Work : Removal of cooling fan 1 Bolt ............21Nm 10 Tensioning Pulley 2 Damper 11 Socket Bolt ..........29Nm 3 Nut ............. 21Nm 12 Closing Cover 4 Tensioning Lever 13 Washer 5 Guide Rail Pin...
  • Page 24 1B3-24 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the nut. Installation Notice Tightening Torque 10 Nm 2. Push the tensioning lever in direction of arrow with a rod ( F12 ´ 180mm ) and push out the bolt to the rear.
  • Page 25 OM600 ENGINE MECHANICAL 1B3-25 6. Pull off the tensioning lever (4) from guide rail pin. 7. Remove the spring (17). Installation Notice Insert spring (17) with color coding (blue/violet) facing up. 8. Pry off the closing cover (12) and remove the socket bolt (11) and then remove the tensioning pulley (10).

  • Page 26: Poly V-Belt Alignment & Inspection

    1B3-26 OM600 ENGINE MECHANICAL POLY V-BELT ALIGNMENT & INSPECTION Without Air Conditioner With Air Conditioner...
  • Page 27 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.
  • 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: Prechamber

    OM600 ENGINE MECHANICAL 1B3-29 PRECHAMBER Preceding Work : Removal of glow plug Removal of fuel injection nozzle 1 Threaded Ring ........130 Nm 3 Cylinder Head 2 Prechamber...
  • Page 30 1B3-30 OM600 ENGINE MECHANICAL Tools Required 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer Removal & Installation Procedure 1. Using the serration wrench (4), remove the threaded ring (1). Serration Wrench 603 589 00 09 00 2.
  • Page 31 OM600 ENGINE MECHANICAL 1B3-31 Assembly Procedure Notice In case the prechambers are reused, inspect the prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used. 1. Clean the sealing surface of the prechamber.

  • Page 32: Milling Of Prechamber Sealing Surface

    1B3-32 OM600 ENGINE MECHANICAL MILLING OF PRECHAMBER SEALING SURFACE 1 Drift 4 Counter Sink (Special Tool - 601 589 00 66) 2 Sleeve 5 Cylinder Head 3 Milling Cutter Tools Required 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge...
  • Page 33 OM600 ENGINE MECHANICAL 1B3-33 1. Remove the injection 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.
  • Page 34 1B3-34 OM600 ENGINE MECHANICAL 8. Remeasure size ‘X’ and compare it with the first measurement and determine the thickness of spacer ring. Size before machining 25.7 mm Size after machining 25.5 mm The spacer ring should be selected so that it is at least 0.1mm and not more than 0.3mm thicker than the...

  • Page 35: Tdc (Tdc Sensor Bracket) Setting

    OM600 ENGINE MECHANICAL 1B3-35 TDC (TDC SENSOR BRACKET) SETTING Preceding Work : Removal of No.1 cylinder prechamber 1 Measuring Device 2 Dial Gauge 3 Cylinder Head 4 Piston ..........Set at TDC Tools Service 001 589 32 21 00 Dial Gauge...
  • Page 36 1B3-36 OM600 ENGINE MECHANICAL Setting (with cylinder head installed) 1. Remove the prechamber of No. 1 cylinder. 2. Position the piston of No.1 cylinder at BTDC 10. 3. Install the measuring device into the prechamber bore and position the dial gauge with a preload of 5mm.

  • Page 37: Cylinder Head

    OM600 ENGINE MECHANICAL 1B3-37 CYLINDER HEAD 1 Fuel Injection Pipe ........18Nm 21 Camshaft Drive Sprocket ....... Replace 2 Cylinder Head 22 Washer 3 Gasket ........... Replace 23 Bolt(12-Sided)........25Nm + 90° 4 Bolt ............25Nm 24 Sliding Rail 5 Washer...
  • Page 38 1B3-38 OM600 ENGINE MECHANICAL Tightening Torque stage1 10 Nm Cylinder Bolts (12-sided socket head) (Engine cold) stage2 35 Nm stage3 180° M8 Cylinder Head Bolts 25 Nm Tools Required 000 589 77 03 00 Box Wrench Insert 001 589 65 09 00 Socket Wrench Insert...
  • Page 39 OM600 ENGINE MECHANICAL 1B3-39 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 the table.
  • Page 40 1B3-40 OM600 ENGINE MECHANICAL Disassembly Procedure 1. Completely drain the coolant from the radiator and cylinder block. 2. Remove the cooling fan shroud. 3. Hold the fan with counter holder and remove the bolt and then remove the cooling fan.
  • Page 41 OM600 ENGINE MECHANICAL 1B3-41 8. Remove the air cleaner cover and element and then remove 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.
  • Page 42 1B3-42 OM600 ENGINE MECHANICAL 14. Pull out the accelerator control linkage. 15. 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.
  • Page 43 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.
  • Page 44 1B3-44 OM600 ENGINE MECHANICAL 22. Remove 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...
  • Page 45 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 nozzle washer(11). Socket Wrench Insert 001 589 65 09 00...
  • Page 46 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.
  • Page 47 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.
  • Page 48 1B3-48 OM600 ENGINE MECHANICAL 38. Remove the camshaft bearing cap bolts according to the numerical sequence. Notice Remove the No.1 bolts first and then remove 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.
  • Page 49 OM600 ENGINE MECHANICAL 1B3-49 41. Remove the bolt(32). 42. Separate the spring and pull 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).
  • Page 50 1B3-50 OM600 ENGINE MECHANICAL 45. Remove the vacuum line from the vacuum pump. 46. Disconnect the vacuum pipe from 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.
  • Page 51 OM600 ENGINE MECHANICAL 1B3-51 OM 661LA 49. Remove the cylinder head(2) and gasket(3).
  • Page 52 1B3-52 OM600 ENGINE MECHANICAL Assembly Procedure 1. Replace the cylinder head gasket. 2. Install the cylinder head onto the crankcase. Notice Align the cylinder head holes with the guide pins. 3. Measure the length(L) of cylinder head bolts. Notice If the max. length is exceeded, replace the bolts.
  • Page 53 OM600 ENGINE MECHANICAL 1B3-53 5. Tighten the cylinder head bolts to specified torque and torque angle. Stage 1 15 Nm Stage 2 35 Nm Torque angle 90° Wait for 10 minutes Torque angle 90° OM 662LA OM 661LA 6. Install the socket bolts in the chain box.
  • Page 54 1B3-54 OM600 ENGINE MECHANICAL 8. Connect the vacuum lines to the vacuum pump. 9. Install the fuel filter and connect the pipe. Tightening Torque 25 Nm Notice Be careful not to be confused the connections and hoses. 10. Connect the fuel pipe to the injection pump.
  • Page 55 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.
  • Page 56 1B3-56 OM600 ENGINE MECHANICAL 17. Coat the camshaft with oil and install the camshaft on the cylinder head to be TDC mark(arrow) upward. 18. Measure the axial end play of the camshaft. End Play 0.06 - 0.21mm Notice If out of standard, adjust it with the proper thickness of locking washer.
  • Page 57 OM600 ENGINE MECHANICAL 1B3-57 21. Position the camshaft on marking and install the camshaft sprocket. Notice Align the alignment marks on the chain and sprocket. 22. Check the TDC position of the crankshaft. 23. Install the camshaft sprocket bolt. Tightening Torque...
  • Page 58 1B3-58 OM600 ENGINE MECHANICAL Notice Measure the max. length ‘L’ and replace the bolt if it exceeds 53.6mm. 24. Install the exhaust manifold and gasket. 25. Install the turbocharger. 26. Install the exhaust pipe onto the turbocharger. Tightening Torque 25 Nm...
  • Page 59 OM600 ENGINE MECHANICAL 1B3-59 27. Replace the seal and then install the chain tensioner. 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.
  • Page 60 1B3-60 OM600 ENGINE MECHANICAL 33. Replace the gasket and install the cylinder head cover. Tightening Torque 10 Nm 34. Install the blow-by hose. 35. Connect the wires to the coolant temperature sensor and the glow plug sensor. 36. Replace the intake manifold gasket.
  • Page 61 OM600 ENGINE MECHANICAL 1B3-61 38. Replace the O-ring of heater feed pipe and install it to the cylinder 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.
  • Page 62 1B3-62 OM600 ENGINE MECHANICAL 42. Install the poly V-belt. Notice Be careful not to contaminate the belt. 43. By inserting a rod into the tensioning lever upper hole and pulling the rod, install the bolt and then tighten the nut.

  • Page 63: Timing Case Cover

    OM600 ENGINE MECHANICAL 1B3-63 TIMING CASE COVER Preceding Work : Removal of the cooling fan Rmoval of the V-belt tensioning device Removal of the vibration damper and hub Removal of the alternator 1 Bolt ............10Nm 13 Bolt ............32Nm...
  • Page 64 1B3-64 OM600 ENGINE MECHANICAL Tools Required 116 589 03 07 00 Socket Wrench Removal Procedure 1. Remove 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.
  • Page 65 OM600 ENGINE MECHANICAL 1B3-65 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.
  • Page 66 1B3-66 OM600 ENGINE MECHANICAL 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).
  • Page 67 OM600 ENGINE MECHANICAL 1B3-67 Installation Procedure 1. Thoroughly clean the sealing surface and apply sealant. 2. Install the timing case cover. Tightening Torque 10 Nm Notice Bolts arrangement 1.M6 x 60 2.M6 x 70 3.M6 x 40 3. Tighten the socket bolts in the chain box.
  • Page 68 1B3-68 OM600 ENGINE MECHANICAL 5. Install the flange, vibration damper and crankshaft belt pulley. Notice Replace front radial seal if necessary. 6. Install the alternator bracket. 25 Nm Front Tightening Torque Side 25 Nm 7. Install the alternator Upper - 25 Nm...
  • Page 69 OM600 ENGINE MECHANICAL 1B3-69 10. Install the fuel filter. Tightening Torque 25 Nm 11. Install the vacuum pump. Tightening Torque 10 Nm 12. Install the power steering pump. Tightening Torque 23 Nm 13. Install the power steering pump pulley. Tightening Torque 32 Nm 14.
  • Page 70 1B3-70 OM600 ENGINE MECHANICAL 15. Install the guide pulley (22) and fit the closing cover (20). Tightening Torque 23 Nm 16. Replace the gasket (3) and install the cylinder head cover (2). Tightening Torque 10 Nm 17. Install the cooling fan belt pulley and fan clutch.

  • Page 71: Crankshaft End Cover

    OM600 ENGINE MECHANICAL 1B3-71 CRANKSHAFT END COVER Preceding Work : Removal of flywheel and driven plate. 1 Crankshaft Flange 4 Radial Seal ..........Replace 2 End Cover......Clean, Loctite 573 5 Dowel Sleeve 3 Bolt ......... 10Nm, Loctite 573 6 Bolt ......... 10Nm, Loctite 573...
  • Page 72 1B3-72 OM600 ENGINE MECHANICAL Tools Required 601 589 03 43 00 Oil Seal Assmbler Removal Procedure 1. Remove the bolts (3, 6) from end cover, By pulling out the lugs (arrow), remove the cover. Notice Be careful not to damage the oil pan gasket.
  • Page 73 OM600 ENGINE MECHANICAL 1B3-73 5. Coat a little oil on the sealing lip of new radial seal and contacting surface. Notice Don’t use grease. 6. Insert the new radial seal (4) onto the oil seal assembler (7). Notice The sealing lip of the repair radial seal is offset to the inside...

  • Page 74: Vibration Damper And Hub

    1B3-74 OM600 ENGINE MECHANICAL VIBRATION DAMPER AND HUB Preceding Work : Removal of the cooling fan Removal of poly V-belt 1 Bolt ............10Nm 6 Bolt ..........200Nm + 90° 2 Cooling Fan Belt Pulley 7 Washer 3 Socket Bolt ..........23Nm...
  • Page 75 OM600 ENGINE MECHANICAL 1B3-75 Sectional View 3 Socket Bolt 9 Hub 4 Crankshaft Belt Pulley 11 Radial Seal 5 Vibration Damper 12 Timing Gear Case Cover 6 Bolt 13 Key 7 Washer 14 Crankshaft Sprocket 8 Straight Pin 16 Crankshaft...
  • Page 76 1B3-76 OM600 ENGINE MECHANICAL Removal Procedure 1. Remove the starter motor and install the engine lock into the wheel 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.
  • Page 77 OM600 ENGINE MECHANICAL 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...
  • Page 78 1B3-78 OM600 ENGINE MECHANICAL Installation Procedure 1. Install the hub. Notice Exactly align 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°...
  • Page 79 OM600 ENGINE 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: Crankshaft Front Radial Seal

    1B3-80 OM600 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL 1 Radial Seal 3 Woodruff Key 2 Timing Case Cover Tools Required 601 589 03 14 00 Sleeve...
  • Page 81 OM600 ENGINE MECHANICAL 1B3-81 Notice The sealing lip of the repair radial seal is offset to the inside by 2mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange.

  • Page 82: Crankshaft Ball Bearing

    1B3-82 OM600 ENGINE MECHANICAL CRANKSHAFT BALL BEARING 1 Spacer 3 Ball Bearing 2 Cover ......... Replace 4 Bolt ........45Nm + 90° Notice Manual transmission only. Tools Required 000 589 33 33 00 Counter Support 000 589 25 33 00 Internal Extractor Removal &...

  • Page 83: Crankshaft

    OM600 ENGINE MECHANICAL 1B3-83 CRANKSHAFT Preceding Work : Removal of the end cover Removal of the piston Removal of the crankshaft sprocket 3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower) 4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap...
  • Page 84 1B3-84 OM600 ENGINE MECHANICAL Thrust Washer and Bearing Arrangement OM662LA Engine 3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings 4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower)
  • Page 85 OM600 ENGINE MECHANICAL 1B3-85 OM661LA Engine 3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings 4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower) Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other.
  • Page 86 1B3-86 OM600 ENGINE MECHANICAL Crankshaft Standard and Repair Sizes Crankshaft bearing Thrust bearing Thrust bearing journal diameter journal width journal diameter 24.500 - 24.533 Standard size 50.950 - 57.965 47.950 - 47.965 24.600 - 24.633 24.700 - 24.733 Repair size 1 57.500 - 57.715...
  • Page 87 OM600 ENGINE MECHANICAL 1B3-87 Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft Marking of basic bearing bore in lower Color code of relevant crankshaft parting surface bearing shell Blue or white-blue 1 punch mark or blue Yellow or white-yellow...
  • Page 88 1B3-88 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the bearing cab bolt. 2. Remove the bearing caps (8). Notice The crankshaft 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).
  • Page 89 OM600 ENGINE MECHANICAL 1B3-89 8. Thoroughly clean the oil gallery. 9. Select a proper new bearing shells with reference to table. 10. Coat the new bearing shells with oil and insert into the crankcase and into the crankshaft bearing caps.
  • Page 90 1B3-90 OM600 ENGINE MECHANICAL 15. Measure radial clearance of crankshaft bearing (G). Clearance ‘G’ 0.027 - 0.051mm Notice If ‘G’ is out of standard, replace the bearing shells and adjust the radial clearance of crankshaft bearing. Example) Measured value ‘E’ = 57.700mm Measured value ‘F’...
  • Page 91 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.
  • Page 92 1B3-92 OM600 ENGINE MECHANICAL 24. Insert the new connecting rod bearing shells into the connecting rod and connecting rod bearing cap and tighten the 12-sided stretch bolts (11). Tightening Torque 40 Nm + 90° 25. Measure inner diameter of connecting rod bearing.

  • Page 93: Flywheel

    OM600 ENGINE MECHANICAL 1B3-93 FLYWHEEL Preceding Work : Removal of the transmission Removal of the clutch 1 Oil Pan 4 12-Sided Stretch Bolt ....Check, 45Nm + 90° 2 Straight Pin 5 Drive Plate (Automatic Transmission) 3 Flywheel 6 Flywheel (Automatic Transmission)
  • Page 94 1B3-94 OM600 ENGINE MECHANICAL Manual transmission flywheel OM662LA OM661LA Automatic transmission flywheel...
  • Page 95 OM600 ENGINE MECHANICAL 1B3-95 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°...
  • Page 96 1B3-96 OM600 ENGINE MECHANICAL 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: Machining Of Flywheel

    OM600 ENGINE MECHANICAL 1B3-97 MACHINING OF FLYWHEEL 1 Flywheel OM662LA OM662LA Machining of Flywheel Notice Flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding or precision-turning. If the scores or cracks are severe than permissible specifications, replace the flywheel.

  • Page 98: Flywheel Ring Gear

    1B3-98 OM600 ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work : Removal of flywheel 1 Ring Gear 3 Centering Collar Diameter 2 Flywheel Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder...
  • Page 99 OM600 ENGINE MECHANICAL 1B3-99 Replacement Procedure 1. Drill a hole into the ring gear (1) (arrow) and snap with a chisel. 2. Thoroughly clean the collar surfaces of ring gear. 3. Measure diameter (a) of centering collar. Diameter ‘a’ 275 + 0.5mm Notice If out of standard, replace the flywheel.
  • Page 100 1B3-100 OM600 ENGINE 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: Hydraulic Valve Clearance Compensation Element Check

    OM600 ENGINE MECHANICAL 1B3-101 HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ............10Nm 5 Cylinder Head 3 Gasket ........... Replace...
  • Page 102 1B3-102 OM600 ENGINE MECHANICAL Checking Notice The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it does not need to be repaired. Determine the malfunctions in valve clearance compensation device with noise through following tests.
  • Page 103 OM600 ENGINE MECHANICAL 1B3-103 VALVE TAPPETS Preceding Work : Removal of camshaft 1 Valve Tappet 4 Seal ............Replace 2 Cylinder Head 5 Screw Plug 3 Oil Gallery Tools Required 102 589 03 40 00 Magnetic Bar...
  • Page 104 1B3-104 OM600 ENGINE MECHANICAL Replacement Procedure 1. Pull out the valve tappet (1). Magnetic 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.
  • Page 105 OM600 ENGINE MECHANICAL 1B3-105 VALVE SPRINGS CHECK Preceding Work : Removal of valve spring 1 Valve Spring 2 Spring Scale Service Data At preloaded Outer diameter Wire diameter Free length Length Tension (new) Limit 33.1mm 4.20mm 50.0mm 27mm 680 - 740N...

  • Page 106: Valve Tappets

    1B3-106 OM600 ENGINE MECHANICAL VALVE SPRINGS (CYLINDER HEAD REMOVED) Cylinder Head Removed 1 Valve Tappet 6 Stud Bolt ............ 12Nm 2 Valve Cotters 7 Washer 3 Spring Retainer 8 Nut ..........Replace, 25Nm 4 Valve Spring ... Check, replace if necessary...
  • Page 107 OM600 ENGINE MECHANICAL 1B3-107 Tools Required 102 589 03 40 00 Magnetic Bar 116 589 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 Removal &...
  • Page 108 1B3-108 OM600 ENGINE MECHANICAL 5. Using the press lever (14), press the spring retainer downward and remove the valve cotters (2) with magnetic finger (15). 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 6.

  • Page 109: Valve Spring Check

    OM600 ENGINE MECHANICAL 1B3-109 VALVE SPRINGS (CYLINDER HEAD INSTALLED) Preceding Work : Removal of camshaft 1 Valve Tappet 4 Valve Spring ..Check, replace if necessary 2 Valve Cotters 5 Timing Chain 3 Spring Retainer 6 Cylinder Head Notice Remove the valve springs only when the piston is at TDC.
  • Page 110 1B3-110 OM600 ENGINE MECHANICAL 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.
  • Page 111 OM600 ENGINE MECHANICAL 1B3-111 6. Remove the spring retainer(3) and spring (4). 7. Check the valve spring and replace if necessary. 8. Insert valve spring (4) with the color coding (arrow) facing down 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).

  • Page 112: Valve Stem Seals

    1B3-112 OM600 ENGINE MECHANICAL VALVE STEM SEALS Preceding Work : Removal of camshaft. 1 Valve Tappet 4 Valve Spring ... Check, replace if necessary 2 Valve Cotters 5 Valve Stem Seal 3 Spring Retainer 6 Valve Notice Remove the valve stem seals when the piston is positioned at TDC.
  • Page 113 OM600 ENGINE MECHANICAL 1B3-113 Tools Required 667 589 00 31 00 Press Lever 104 589 00 37 00 Pliers 102 589 03 40 00 Magnetic Lifter 603 589 01 40 00 Holding Wheel 601 589 02 43 00 Drift 116 589 06 63 00 Magnetic Finger...
  • Page 114 1B3-114 OM600 ENGINE MECHANICAL Replacement Procedure 1. Remove the valve tappet (1) with magnetic lifter. Notice Place the valve tappets upside down (open end upward). Magnetic Lifter 102 589 03 40 00 2. Install the holding wheel (7) into the timing chain (11).
  • Page 115 OM600 ENGINE MECHANICAL 1B3-115 6. Remove the spring retainer(3) and valve spring (4). 7. Remove the valve stem seal (5). Pliers 104 589 00 37 00 8. Insert the cap (12) onto the valve (6) and install the new valve stem seal (5) and then remover the cap.

  • Page 116: Check And Replacement Of Valve Guides

    1B3-116 OM600 ENGINE MECHANICAL CHECK AND REPLACEMENT OF VALVE GUIDES Preceding Work : Removal of cylinder head Removal of valve spring Removal of valve 1 Cylinder Head 3 Valve Seat Ring 2 Valve Guide a Basic Bore Diameter Service Data...
  • Page 117 OM600 ENGINE MECHANICAL 1B3-117 Notice Measure center (arrow) of the valve guide and if the inner diameter ‘A’ exceeds standard value, replace the guide. Tools Required 000 589 10 53 00 Reamer (for Exhaust) 000 589 10 68 00 Cylinder Brush...
  • Page 118 1B3-118 OM600 ENGINE MECHANICAL Checking 1. Thoroughly clean the valve guide bore using a cylinder brush. Cylinder Brush 000 589 10 68 00 2. Insert the GO/NO GO gauge into the valve guide bore. If the NO GO side is inserted fully, replace the valve guide (Intake 8mm, Exhaust 9mm).
  • Page 119 OM600 ENGINE MECHANICAL 1B3-119 4. Reaming basic bore in cylinder head (repair size). - Thoroughly remove carbon deposits in cylinder head. Notice Particularly remove the insides of the valve seat rings. - Remove the elevation (arrow) of intake valve seat rings.
  • Page 120 1B3-120 OM600 ENGINE MECHANICAL 5. Heat the cylinder head (1) in a wear tank to approx. 80°C. 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.
  • Page 121 OM600 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: Valve Seat Rings

    1B3-122 OM600 ENGINE MECHANICAL VALVE SEAT RINGS Preceding Work : Removal of valve Checking of valve guide, replace if necessary Removal of prechamber 1 Cylinder Head Valve Seat Ring Outer Diameter 2 Valve Seat Ring D1 Valve Seat Ring Inner Diameter...
  • Page 123 OM600 ENGINE MECHANICAL 1B3-123 Commercial Tools Cylinder Head Clamping Device Hunger D-8000 München 70 Type Ventilknecht K2000 Order No. 221 00 100 Valve Seat Turning Tool Hunger D-8000 München 70 Type VDS 1A Order No. 236 03 308 Ring Seat Turning Tool Hunger D-8000 München 70...
  • Page 124 1B3-124 OM600 ENGINE MECHANICAL Removal Procedure 1. Measure dimension ‘A’ . Limit 142.5mm 2. Clamp the cylinder head with clamping device. 3. Cut groove into the valve seat ring so that dimension ‘C’ is approx. 2mm and dimension ‘E’ is approx. 6mm.
  • Page 125 OM600 ENGINE MECHANICAL 1B3-125 8. Turn over the cylinder head. 9. Remove the tensioning head (4) and valve seat ring (2) with drift (14mm) and removal tool. 10. Clean the basic bore of valve seat ring. 11. Measure the basic bore diameter (D2) and outer diameter (D) of the new valve seat ring (standard size).
  • Page 126 1B3-126 OM600 ENGINE MECHANICAL 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.

  • Page 127: Check And Machining Of Valves

    OM600 ENGINE MECHANICAL 1B3-127 CHECK AND MACHINING OF VALVES Preceding Works : Removal of cylinder head Removal of the vale spring Removal of the valve I Valve Length Y Half Camshaft Basic Bore Diameter W Camshaft Cam Basic Diameter Z Distance (Cylinder Head Cover Parting Surface -...
  • Page 128 1B3-128 OM600 ENGINE MECHANICAL Intake Valve Exhaust Valve Item Intake Valve Exhaust Valve Valve Disc Diameter ‘d’ 37.90 - 38.10 mm 34.90 - 35.10 mm Valve Disc Height ‘h’ 1.7 mm 1.7 mm Setting Angle “α” or Machining the Valve 45°...
  • Page 129 OM600 ENGINE MECHANICAL 1B3-129 Tools Required 001 589 32 21 00 Dial Gauge Commercial Tool Valve corn grinding machine Checking and Machining 1. Clean the valves and do visual check. Valves with wobbled valve disc, with worn or scored valve stem should be replaced.
  • Page 130 1B3-130 OM600 ENGINE MECHANICAL 5. Clean the vales, valve seats and 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’.
  • Page 131 OM600 ENGINE MECHANICAL 1B3-131 11. The distance ‘x’ (camshaft basic bore - 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’...

  • Page 132: Machining Of Valve Seat

    1B3-132 OM600 ENGINE MECHANICAL MACHINING OF VALVE SEAT Preceding Work : Removal of prechamber Removal and inspection of valve, replace if necessary Inspection of valve guide, replace if necessary 1 Valve a Valve Seat Angle 2 Valve Seat Ring b Valve Seat Free Angle...
  • Page 133 OM600 ENGINE MECHANICAL 1B3-133 Service Data Item Intake Exhaust Valve Arrears ‘a’ 0.1 - 0.7 mm 0.1 - 0.7 mm Valve Seat Width ‘b’ 1.2 - 1.7 mm 1.5 - 2.0 mm α Valve Seat Angle ‘ ’ 45° 45°...
  • Page 134 1B3-134 OM600 ENGINE MECHANICAL Machining Procedure Valve machining is required : - When the valve is leaking. - When replacing the valve. - When replacing the valve guide. - When replacing the valve seat or valve seat ring. 1. Machine the valve seat (a=45° ).
  • Page 135 OM600 ENGINE MECHANICAL 1B3-135 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). 38 ± 0.2mm Diameter ‘w’...
  • Page 136 1B3-136 OM600 ENGINE MECHANICAL I Length of Valve y Half Camshaft Basic Bore Diameter w Camshaft Cam Basic Circle Diameter z Distance (Cylinder head cover parting surface -. x Distance (Camshaft basic bore - valve stem) valve stem) 8. Measure ‘x’ (Camshaft basic bore - valve stem).

  • Page 137: Camshaft Timing Test

    OM600 ENGINE MECHANICAL 1B3-137 CAMSHAFT TIMING TEST Preceding Work : Removal of glow plug 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ............10Nm 5 Cylinder Head 3 Gasket ........... Replace Timing Intake valve Exhaust valve Condition of camshaft...
  • Page 138 1B3-138 OM600 ENGINE MECHANICAL Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension Measurement Procedure 1. Remove the cylinder head cover. 2. Rotate the engine in the direction of engine rotation until the intake valve of NO.

  • Page 139: Camshaft

    OM600 ENGINE MECHANICAL 1B3-139 CAMSHAFT Preceding Work : Removal of cylinder head cover 1 Bolt ............25Nm 8 Cylinder Head 2 Washer 9 Oil Pan 3 Camshaft Bearing Cap 10 Camshaft Sprocket 4 Camshaft 11 Washer 5 Dowel Pin 12 12-Sided Bolt (M11) ..... Check, 25Nm + 90°...
  • Page 140 1B3-140 OM600 ENGINE MECHANICAL Tools Required 602 589 00 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.
  • Page 141 OM600 ENGINE MECHANICAL 1B3-141 4. Remove the bolt and then remove the camshaft sprocket. Notice During removal, be careful not to drop the sprocket with chain. Remove the chain carefully and then pull out the sprocket. 5. Remove the chain tensioner.
  • Page 142 1B3-142 OM600 ENGINE MECHANICAL 7. Remove the camshaft bearing cap. 8. Pull off the camshaft. Notice Be careful not to miss front locking washer. 9. Pull out the locking washer. Notice Check the condition of locking washer and replace if necessary.
  • Page 143 OM600 ENGINE MECHANICAL 1B3-143 5. Tighten the camshaft bearing cap bolts acccording to installation order. 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).
  • Page 144 1B3-144 OM600 ENGINE MECHANICAL Notice If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm, replace it. 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.

  • Page 145: Chain Tensioner

    OM600 ENGINE MECHANICAL 1B3-145 CHAIN TENSIONER 1 Chain Tensioner ........80Nm 2 Seal ............Replace...
  • Page 146 1B3-146 OM600 ENGINE MECHANICAL Notice Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin 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.

  • Page 147: Timing Chain

    OM600 ENGINE 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 1B3-148 OM600 ENGINE MECHANICAL 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.
  • Page 149 OM600 ENGINE MECHANICAL 1B3-149 7. Insert the new chain link (1) to connect the chain. 8. 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.
  • Page 150 1B3-150 OM600 ENGINE MECHANICAL 11. Place the fitting tool (8) onto the chain link and rivet the chain pins one by one. Tightening Torque 35 - 40 Nm 12. Check the riveting of chain pins and re-rivet if necessary. 13. Remove the wire.

  • Page 151: Tensioning Rail

    OM600 ENGINE 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: Cylinder Head Guide Rail

    1B3-152 OM600 ENGINE MECHANICAL CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of the cooling fan Removal of poly V-belt Removal of chain tensioner 1 Cylinder Head Cover 9 Bearing Pin ......Sealing Compound 2 Bolt ............10Nm 10 Guide Rail 3 Gasket ...........
  • Page 153 OM600 ENGINE MECHANICAL 1B3-153 Tools Required 115 589 02 34 00 Sliding Hammer 116 589 20 33 00 Threaded Pin Removal Procedure 1. Removal the cylinder head cover. 2. Pull off the tensioning lever (7) and remove from the spring (15).
  • Page 154 1B3-154 OM600 ENGINE MECHANICAL 6. Pull out the bearing pins (9, 11) with sliding hammer and remove the guide rail 10. Sliding Hammer 116 589 20 33 00 Threaded Pin 116 589 02 34 00 Installation Procedure 1. Apply collar of both bearing pins with sealing compound.
  • Page 155 OM600 ENGINE MECHANICAL 1B3-155 In this position, the marking 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.

  • Page 156: Timing Case Cover Guide Rail

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

  • Page 157: Crankshaft Sprocket

    1B3-158 OM600 ENGINE MECHANICAL CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of timing case cover 1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90° 11 Bolt ............25Nm 2 Washer 12 Crankshaft Sprocket 3 Camshaft Sprocket...
  • Page 158 OM600 ENGINE MECHANICAL 1B3-159 Special Tools 116 589 07 15 00 Drift 102 589 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 against the crankshaft (13).
  • Page 159 1B3-160 OM600 ENGINE MECHANICAL 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.
  • Page 160 OM600 ENGINE MECHANICAL 1B3-161 Installation Procedure 1. Put the same alignment mark on the new crankshaft sprocket 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.
  • Page 161 1B3-162 OM600 ENGINE MECHANICAL Notice 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.

  • Page 162: Piston

    OM600 ENGINE MECHANICAL 1B3-163 PISTON Preceding Work : Removal of the cylinder head Removal of the oil pump 1 Oil Ring 8 Connecting Rod 2 2nd Ring 9 Connecting Rod Upper Bearing Shell 3 Top Ring 10 Connecting Rod Lower Bearing Shell 4 Snap Ring ..........
  • Page 163 1B3-164 OM600 ENGINE MECHANICAL Service Data Piston clearance Max. 0.12 mm Piston crown protrusion in TDC position 0.735 - 0.965 mm Connecting rod bushing diameter 26.012 - 26.018 mm Connecting Rod Bolt Dimensions Thread M9 x 1 Stretch shaft(C) diameter (new) -0.1...
  • Page 164 OM600 ENGINE MECHANICAL 1B3-165 Removal Procedure 1. Remove combustion residues from the cylinder bores. 2. Remove the connecting 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.
  • Page 165 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.
  • Page 166 OM600 ENGINE MECHANICAL 1B3-167 6. Coat the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and piston with oil. 7. Compress the piston rings with a tensioning strap (7). Tensioning Strap 000 589 04 14 00 8. Insert the piston assembly into the cylinder with a wooden stick (18).
  • Page 167 1B3-168 OM600 ENGINE MECHANICAL 12. Coat the bolts (12) with oil and then tighten the bolts. Tightening Torque 40Nm + 90° 13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft. 14. Measure clearance between the piston crown and cylinder Standard Max.

  • Page 168: Oil Filter

    OM600 ENGINE MECHANICAL 1B3-169 OIL FILTER 1 Nut ............25 Nm 6 Bolt (M8) ............ 10Nm 2 Oil Filter ............. Cover 7 Oil Pressure Switch 3 O-Ring ........... Replace 8 Gasket 4 Oil Filter ....Element Replace If necessary 9 Bolt ............25 Nm...
  • Page 169 1B3-170 OM600 ENGINE MECHANICAL Removal & Installation 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...

  • Page 170: Oil Pan

    OM600 ENGINE MECHANICAL 1B3-171 OIL PAN OM662LA OM661LA 1 Gasket ........... Replace 6 Lower Oil Pan 2 Upper Oil Pan 7 Combination Bolt ........25 Nm 3 Combination Bolt ........10 Nm 8 Drain Plug ..........25 Nm 4 Combination Bolt ........10 Nm 9 Washer Seal ..........
  • Page 171 1B3-172 OM600 ENGINE 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: Oil Spray Nozzle

    1B3-174 OM600 ENGINE MECHANICAL OIL SPRAY NOZZLE 1 Fitting Sleeve 3 Combination Bolt ........10 Nm 2 Oil Spray Nozzle A Oil Duct Disassembly Procedure 1. Remove oil pan or crankshaft. 2. Loose the bolt and then remove the nozzle.

  • Page 174: Oil Pump

    OM600 ENGINE MECHANICAL 1B3-175 OIL PUMP 1 Oil Pump 5 Screw Plug ..........50 Nm 2 Piston 6 Combination Bolt ........25 Nm 3 Pressure Spring 7 Oil Strainer 4 Guide Pin 8 Bracket Disassembly Procedure 1. Remove the oil pan.
  • Page 175 1B3-176 OM600 ENGINE MECHANICAL 3. Unscrew the oil strainer bracket bolt. Tightening Torque 10 Nm 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: Unit Repair

    OM600 ENGINE MECHANICAL 1B3-177 UNIT REPAIR CYLINDER HEAD PRESSURE LEAKAGE TEST Preceding Work : Removal of the cylinder head Removal of the exhaust manifold Removal of the valve 1 Feed Pipe 2 Bolt 3 Return Connection 4 Gasket ..............Replace 5 Coolant Gallery ...........

  • Page 177: Facing Cylinder Head Mating Surface

    1B3-178 OM600 ENGINE MECHANICAL FACING CYLINDER HEAD MATING SURFACE Preceding Work : Removal of prechamber Cylinder head pressure leakage test 1 Valve B Longitudinal Direction 2 Cylinder Head C Transverse Direction 3 Prechamber a Valve Arrears A Height of Cylinder Head...
  • Page 178 OM600 ENGINE MECHANICAL 1B3-179 Measurement Procedure 1. Measure height ‘A’ . Limit 142.5 mm Notice If the 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.

  • Page 179: Replacement Of Crankcase Core Plug

    1B3-180 OM600 ENGINE MECHANICAL REPLACEMENT OF CRANKCASE CORE PLUG Left Right φ φ Core plug ............34mm Core plug ............34mm OM661LA - 2EA OM661LA - 2EA OM662LA - 3EA OM662LA - 3EA Left Right φ φ Core plug ............
  • Page 180 OM600 ENGINE MECHANICAL 1B3-181 Tools Required 102 589 00 15 00 Drift 102 589 12 15 00 Drift Replacement Procedure 1. Completely drain the coolant. 2. Remove any parts which impede access. (Example : transmission, injection pump) 3. Place the screwdriver to the deepdrawn edge of the core plug and pull forward and then rotate 90°...

  • Page 181: Facing Crankcase Contacting Surface

    1B3-182 OM600 ENGINE MECHANICAL FACING CRANKCASE CONTACTING SURFACE 1 Crankcase B Longitudinal Direction 2 Crankcase Contacting Surface C Transverse Direction H Chamfer Height Y Height (crankcase upper surface - crankcase b Chamfer Angle lower surface) Service Data Height ‘Y’ Min. 299.62 mm...

  • Page 182: Oil Gallery Steel Ball

    OM600 ENGINE MECHANICAL 1B3-183 OIL GALLERY STEEL BALL Preceding Work : Removal of cooling fan Removal of the coolant pump housing Removal of the flywheel and driven plate φ 1 Steel Ball..........15mm 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 1B3-184 OM600 ENGINE MECHANICAL φ 3 Steel Ball..........17mm 5 Screw Plug ..........50Nm 4 Seal 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...
  • Page 184 OM600 ENGINE MECHANICAL 1B3-185 Removal & Installation Procedure 1. Remove the timing case cover. 2. By inserting a round bar (6) approx. 0.7m from the back to the front side through the oil gallery, knock out the steel balls (1,3).
  • Page 185 1B3-186 OM600 ENGINE MECHANICAL Installation of Screw Plug Notice If steel ball leaks again, install the screw plug. 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 ´...

  • Page 186: Cylinder Bore Measurement

    OM600 ENGINE MECHANICAL 1B3-187 CYLINDER BORE MEASUREMENT Longitudinal Direction Transverse Direction c, d, e. Measuring Point Crankcase Contacting Surface TDC of 1st Piston Ring BDC of Ring Service Data Standard size Code letter ‘A’ 89.000 - 89.006mm Code letter ‘X’...

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