engine SSANGYONG KORANDO 1997 Service Repair Manual

OM600 ENGINE CONTROLS 1F3 -- 17
D AEW OO M Y_2000
FUEL PUMP TEST
Notice
Before test, replace the fuel filter cartridge and fuel pre-
filter.
Fuel Feed Test
1. Disconnect the fuel return line (1) and seal up it with
plug.
2. Insert the plastic hose (5) and put the end into the
measuring beaker (6).
3. Disconnect the vacuum line (4) from vacuum unit
(engine stop) (5) and connect the vacuum pump (7)
to the vacuum unit.
4. To avoid the engine starting, build up vacuum
(approx. 500 mbar).
5. Operate the starter motor for exactly 30 seconds
and measure fuel volume in the beaker.
Min. volume150cm3for 30 seconds

1F3 -- 18 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Fuel Pressure Test

OM600 ENGINE CONTROLS 1F3 -- 19
D AEW OO M Y_2000
Tools Required
617589042100 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
At Idle Speed> 0.3bar
At Full load> 0.5bar
If out of standard, replace the fuel feed pump.
Tester 617 589 04 21 00
5. Stop the engine.
6. Remove the tester.
7. Replace the seal and connect the fuel line (2).

1F3 -- 20 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL PUMP
1 Fuel Injection Pump
2 Pressure Line 13N∙m (10 lb-ft) ..............
3 Suction Line
4 Hose Clip Replace........................5 Gasket Replace..........................
6 Spring Lock Washer
7 Hexagon Nuts
8 Fuel Pump

OM600 ENGINE CONTROLS 1F3 -- 21
D AEW OO M Y_2000
INJECTION NOZZLE TEST
Preceding Work : Removal of fuel injection nozzle
1 Fuel Injection Nozzle New : 115-- 125 bar....
Used : min. 100bar
A Closed Spray = good
B Stringy Spray = poor2Tester
3Valve

1F3 -- 22 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Tools Required
000589142700 Tester
Notice
When testing the injection nozzle, do not place your
hand into the spray of a nozzle. The spraywill 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 nozzlemust spray with a
gentle chattering.
4. Spray pattern test :
Operate the hand lever at tester rapidly (approx.
2~3 strokes per second).
DGood
The spray pattern shows closed and well atom-
ized.
DPoor
The spray pattern shows split, too wide and
stringy.
(Repair the fuel injection nozzle)

OM600 ENGINE CONTROLS 1F3 -- 23
D AEW OO M Y_2000
5. Opening pressure test :
Open the valve (3) and slowly operate the hand le-
ver at tester (approx. 1 stroke / second) and mea-
sure opening pressure.
New Nozzle115 -- 125bar
Used NozzleMin. 100bar
Difference Between NozzlesMax. 5bar
Notice
If out of standard, repair the injection nozzle.
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.

1F3 -- 24 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
INJECTION NOZZLES
1 Fuel Injection Nozzle 35-- 40N∙m(26--30 lb-ft) .
2 Fuel Return Hose
3Plug
4 Nozzle Washer Replace...................
5 Fuel Injection Pipe 18N∙m (13 lb-ft) ..........

OM600 ENGINE CONTROLS 1F3 -- 25
D AEW OO M Y_2000
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 theside.
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.

1F3 -- 26 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
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 80 N∙m (59 lb-ft) .....