2003 SSANGYONG MUSSO Service Manual

OM600 ENGINE CONTROLS 1F3-23
Tools Required
000 589 14 27 00 Tester Notice When testing the injection nozzle, do not place your hand into the spray of a nozzle. The spray will penetrate deep into the skin and destroy the tissue.
1. Connect the fuel injection nozzle to the tester (2).
Tester 000 589 14 27 00
2. Close the valve (3) and pump 5 times strongly.
3. Chatter test :
Slowly operate the hand lever at tester (approx. 1 stroke per second). The nozzle must spray with a gentle chattering.
4. Spray pattern test : Operate the hand lever at tester rapidly (approx. 2~3 strokesper second).
GoodThe spray pattern shows closed and well atomized.
Poor
The spray pattern shows split, too wide and stringy.(Repair the fuel injection nozzle)

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 NozzleDifference Between Nozzles 115 - 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 morethan 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 andpush 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 Insert000 589 00 68 00 Cleaning Set Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzletensioning 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 thenozzle 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 pressureif 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 Device 10 Washer
11 Bolt (Left-Hand Thread) .............................46Nm
12 Camshaft Sprocket
13 Washer
14 12-Sided Stretch Bolt ............Check, 25Nm + 90 °
15 Timing Chain
16 Seal
17 Chain Tensioner ......................................... 80Nm