engine oil SSANGYONG MUSSO 2003 Service Manual

1F3-32 OM600 ENGINE CONTROLS
5. Remove the plug (6) and seal (5) from the fuel injection pump and collect oil in a suitable vessel. Installation Notice
Notice Replace the seal.
Tightening Torque 30 Nm
6. Install the locking screw (18) into the injection pump. Notice Before tightening the bolts for the injection timing device and the camshaft sprocket, always remove the locking screw from the injection pump and reinstall the plug.
Locking Screw 601 589 05 21 00
7. Place alignment marks (arrow) on the timing chain (12) and camshaft sprocket (15).
4. Position the no.1 cylinder at A
TDC 15°.
Notice Do not rotate the engine with camshaft sprocket bolt or opposite direction of the engine rotation.

1F3-38 OM600 ENGINE CONTROLS
Tools Required 617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel.
2. Install the position sensor (1) into the governor housing of
the injection pump to be the guide pin of the position sensor facing up.
3. Connect the battery terminal of position sensor (1) to positive terminal (+) of battery.
Position Sensor 617 589 08 21 00
4. Rotate the crankshaft by hand (in direction of engine rotation) until the lamp ‘B’ lights up. Rotate the crankshaft carefully
further until both lamps ‘A and B ’ come on. In this position,
check the Rl value on the crankshaft vibration damper. Notice If only lamp ‘A’ lights up, repeat the test and if out of
specification, adjust start of delivery.
Specification A TDC 14° - 16 °

OM600 ENGINE CONTROLS 1F3-41
With Pulse Generator
Tools Required 617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Item
Digital Tester
Without Pulse Generator Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3 Bosch, ETD 019.00Sun, DIT 9000
ALV, Diesel - Tester 875
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable vessel.
2. Install the Rl sensor into the governor housing of injection pump (1).
Rl Sensor 617 589 10 21 00
3. Connect the digital tester and TDC pulse sender unit according to connection diagram.
4. Run the engine at idle speed and check the Rl value on the digital tester Notice
If out of standard, adjust the start of delivery.
5. Stop the engine.
6. Remove the Rl sensor, digital tester and TDC pulse sender unit.
7. Replace the seal and tighten the plug.
8. Check engine oil level and adjust if necessary.
Rl value A TDC 14° - 16 °
Tightening Torque 30 Nm

1F3-46 OM600 ENGINE CONTROLS
Tools Required 000 589 77 03 00 Box Wrench Insert 601 589 00 08 00 Flange 601 589 05 21 00 Locking Screw601 589 05 14 00 Assembly CageRemoval
FUEL INJECTION PUMP
Preceding Work : Removal of vacuum pump
Removal of air cleaner housing Removal of intake manifold
18 Chain Tensioner ......................................... 80Nm
19 Seal ....................................................... Replace
20 Bolt(Left-Hand Thread) ..............................46Nm
21 Washer
22 Bolt ............................................................ 23Nm
23 Seal ....................................................... Replace 24 Oil Pan
25 Fuel Injection Pump
26 Seal
....................................................... Replace
27 Screw Plug ................................................. 30Nm
28 Square Nut

OM600 ENGINE CONTROLS 1F3-49
Installation Procedure
1. Remove the screw plug (27) and seal (26) and collect oil ina vessel.
2. Insert flange (31) onto the injection pump camshaft and turn until the cam of the governor is visible in the hole.
Flange 601 589 00 08 00
3. Tighten the locking screw. Locking Screw 601 589 05 21 00
4. Ensure that the No.1 cylinder is positioned at A TDC 15°.

1F3-50 OM600 ENGINE CONTROLS
10. Connect the fuel pipesNotice Replace the seal. Box Wrench Insert 000 589 77 03 00
Return Line Fuel Injection LineFuel feed LineSuction and Pressure Line 46 Nm18 Nm13 Nm13 Nm
5. Coat the new seal (23) with engine oil and install it.
6. Insert the fuel injection pump (25) and tighten the bolts
(22).
7. Remove the locking screw (32).
Tightening Torque 23 Nm
8. Tighten the bolt(12).
9. Insert the washer (21) and tighten the bolts (20) and then remove the assembly cage (29).
Tightening Torque 23 Nm
Tightening Torque 46 Nm

1G3-8 OM600 ENGINE INTAKE & EXHAUST
1 Turbocharger Oil Inlet
2 Turbine Wheel
3 Waste Gate
4 Oil Outlet
5 Compressor Wheel6 Air Inlet
7 Exhaust Gas Outlet
8 Compressed Air Flow
9 Intercooler
10 Cylinder
TURBOCHARGER
CHARGE AIR SYSTEM DIAGRAM

OM600 ENGINE INTAKE & EXHAUST 1G3-11
TURBOCHARGER ASSEMBLY
1 Oil Supply Line
2 Oil Return Line3 Nuts
4 Turbocharger

1G3-12 OM600 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
1. Remove the 2 hoses connected to intercooler.
2. Remove the hose(air cleaner to turbocharger) with blow byhose.
3. Disconnect the oil supply pipe.
4. Remove the oil return pipe.
5. Remove the support assembly.
6. Remove the 3 nuts(arrows).

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
BLEEDING THE BRAKES For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and wheel if pressure building is not enough by depressing the pedal only after above air bleeding.
For Caliper and Brake Hose Replacement
1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown in right figure if pressure building is not enough by depressing the pedal after above air bleeding.
Tightening Torque
9 - 14 NmItem
Front Bleeder Screw
Rear Bleeder Screw
Notice
Do not reuse the bled brake fluid.
Always bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
Always operate in normal order.