1998 SSANGYONG MUSSO fuel pressure

SECTION 1F3
OM600 ENGINE CONTROLS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F3-1
Fastener Tightening Specifications . . . . . . . . 1F3-1
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15Idle Speed Adjustment . . . . . . . . . . . . . . . . 1F3-16
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F3-18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-21
Injection Nozzle Test . . . . . . . . . . . . . . . . . . 1F3-22
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . 1F3-25
Injection Nozzle Repair . . . . . . . . . . . . . . . . 1F3-27
Removal and Installation of
Injection Timing Device . . . . . . . . . . . . . . 1F3-30
Injection Timing Device . . . . . . . . . . . . . . . . 1F3-35
Start of Delivery Test
(Position Sensor, RIV Method) . . . . . . . . . 1F3-37
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 1F3-46
TABLE OF CONTENTS
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
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Tank Mounting Nut
Fuel Pump Pressure Line
Fuel Injection Nozzle
Fuel Injection Pipe
Nozzle Tensioning Nut
Screw Plug
Left-Hand Thread BoltN·m
28 - 47
13
35 - 40
18
80
30
46

OM600 ENGINE CONTROLS 1F3-5
VACUUM CONTROL SYSTEM TEST
2 Engine Cut-Off Valve (Ignition Key Switch)
3 Auto-locking Hub Solenoid Valve
4 Engine Stop Valve Unit
5 PLA Vacuum Unit (Idle Speed Adjustment)
6 Engine
7 Vacuum Pump8 30° Thermovalve
9 Fuel Injection Pump
10 Filter with Restriction
11 Check Valve
12 Modulating Pressure Line (Automatic T/M)
Test Data
Idle Speed Increase
Permissible Pressure Drop of SystemAt least 100 rpm at approx. 500mbr
400 - 500mbar approx. 1 min.

1F3-12 OM600 ENGINE CONTROLS
Test Procedure
1. Remove the fuel filter (1) and keep the filter not to be
damaged from running engine.
2. Remove the vacuum line (2) from ancillaries connection (3).
3. Connect the vacuum tester (4) to the ancillaries connection
(3).
Vacuum Tester 201 589 13 21 00
4 Run the engine at idle and check vacuum pressure after 30
sec.
Notice
If out of standard, replace the vacuum pump.
5. Remove the vacuum tester.
6. Connect the vacuum line to the ancillaries connection.
7. Install the fuel filter.
Standard > 70 mbar

OM600 ENGINE CONTROLS 1F3-19
Fuel Pressure Test

1F3-20 OM600 ENGINE CONTROLS
Tools Required
617 589 04 21 00 Tester
1. Disconnect the fuel line (2) from the fuel filter.
2. Remove the banjo bolt (4) from the fuel injection pump and
remove the seals (3) and fuel line (2).
3. Connect the tester (5).
4. Start the engine and read off the fuel pressure on tester
(5).
Notice
If out of standard, replace the fuel feed pump.
Tester 617 589 04 21 00
5. Stop the engine.At Idle Speed
At Full load
> 0.3bar
> 0.5bar
6. Remove the tester.
7. Replace the seal and connect the fuel line (2).

OM600 ENGINE CONTROLS 1F3-21
FUEL PUMP
1 Fuel Injection Pump
2 Pressure Line............................................13Nm
3 Suction Line
4 Hose Clip............................................... Replace5 Gasket ................................................... Replace
6 Spring Lock Washer
7 Hexagon Nuts
8 Fuel Pump

1F3-24 OM600 ENGINE CONTROLS
5. Opening pressure test :
Open the valve (3) and slowly operate the hand lever at
tester (approx. 1 stroke / second) and measure opening
pressure.
Notice
If out of standard, repair the injection nozzle.
New Nozzle
Used Nozzle
Difference Between Nozzles115 - 125bar
Min. 100bar
Max. 5bar
6. Leak test
Slowly operate the hand lever at the tester until get a
pressure of approx. 90bar. Maintain this pressure for more
than
20 seconds and within this period no drop of fuel should
build up at the nozzle tip.

OM600 ENGINE CONTROLS 1F3-29
7. Check the fuel injection nozzle and adjust opening pressure
if necessary.
Opening pressure adjustment
Disassemble the fuel injection nozzle and replace the steel
washer (2).
Notice
Each 0.05mm thickness of the washer results in a pressure
difference of approx. 3bar.