1998 SSANGYONG MUSSO Workshop Repair Manual

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 1F3-25
INJECTION NOZZLES
1 Fuel Injection Nozzle.............................35-40Nm
2 Fuel Return Hose
3 Plug
4 Nozzle Washer....................................... Replace
5 Fuel Injection Pipe.....................................18Nm

1F3-26 OM600 ENGINE CONTROLS
Tools Required
001 589 65 09 00 Serration Wrench
Removal & Installation Procedure
1. Remove the plastic clip from the injection pipe
2. Remove the fuel return hose.
3. Disconnect the injection pipes from the injection nozzles and
push them to the side.
4. Remove the fuel injection nozzle.
Serration Wrench 001 589 65 09 00
Notice
Replace the washers.
5. Installation should follow the removal procedure in the
reverse order.
Notice
Pay attention to the installation position of new nozzle washer
and tightening torque

OM600 ENGINE CONTROLS 1F3-27
INJECTION NOZZLE REPAIR
Preceding Work : Removal of fuel injection nozzle
1 Nozzle Holder
2 Steel Washer
3 Compression Spring
4 Thrust Pin5 Intermediate Disc
6 Nozzle Needle
7 Nozzle Body
8 Nozzle Tensioning Nut................................80Nm

1F3-28 OM600 ENGINE CONTROLS
Tools Required
001 589 65 09 00 Socket Wrench Insert
000 589 00 68 00 Cleaning Set
Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzle
tensioning nut (8).
Notice
Use protective jaws for clamping.
2. Disassemble the fuel injection nozzle.
Socket Wrench Insert 001 589 65 09 00
3. Clean the nozzle needle (6) and nozzle body (7) with an
abradant.
4. Clean the nozzle seat with cleaning cutter.
Cleaning Set 000 589 00 68 00
5. Immerse nozzle needle (6) and nozzle body (7) in filtered
diesel fuel. When the nozzle body is held vertical, the weight
of the nozzle needle must cause it to slide down toward the
nozzle needle seat.
6. Assemble the injection nozzle so that the tip of the thrust
(4) pin is facing toward the nozzle holder.
Tightening Torque 80 Nm
Notice
Nozzle needle (6) and nozzle body (7) should always be
replaced as a pair.

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.

1F3-30 OM600 ENGINE CONTROLS
REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE
Preceding Work : Removal of vacuum pump
1 Cylinder Head Cover
2 Bolt............................................................10Nm
3 Gasket ................................................... Replace
4 Fuel Injection Pump
5 Seal....................................................... Replace
6 Screw Plug.................................................30Nm
7 Oil Pan
8 Locking Pin
9 Injection Timing Device10 Washer
11 Bolt (Left-Hand Thread).............................46Nm
12 Camshaft Sprocket
13 Washer
14 12-Sided Stretch Bolt............Check, 25Nm + 90°
15 Timing Chain
1 6 Seal
17 Chain Tensioner.........................................80Nm

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