SSANGYONG KORANDO 1997 Service Repair Manual

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) .....

OM600 ENGINE CONTROLS 1F3 -- 27
D AEW OO M Y_2000
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 Torque80 N∙m (59 lb-ft)
Notice
Nozzle needle (6) and nozzle body (7) should al-
ways be replaced as a pair.

1F3 -- 28 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
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.

OM600 ENGINE CONTROLS 1F3 -- 29
D AEW OO M Y_2000
REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE
Preceding Work : Removal of vacuum pump
1 Cylinder Head Cover
2 Bolt 10N∙m (89 lb-in) .....................
3 Gasket Replace..........................
4 Fuel Injection Pump
5 Seal Replace.............................
6 Screw Plug 30N∙m (22 lb-ft) ................
7OilPan
8 Locking Pin
9 Injection Timing Device10 Washer
11 Bolt (Left -- Hand Thread) 46N∙m (34 lb-ft) ....
12 Camshaft Sprocket
13 Washer
14 12-- Sided Stretch Bolt
Check, 25N∙m (18 lb-ft) +90_ ..............
15 Timing Chain
16 Seal
17 Chain Tensioner 80N∙m (59 lb-ft) ............

1F3 -- 30 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Tools Required
601589000800 Flange
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 Torque10 N∙m(89lb-in)
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
Tightening Torque25N∙m (18 lb-ft) + 90_
Notice
If max. length of bolt exceeds 53.6mm, replace it.
3. Loosen the bolt (11) (left -- hand thread).
Notice
Do not remove the bolt.

OM600 ENGINE CONTROLS 1F3 -- 31
D AEW OO M Y_2000
4. Position the no.1 cylinder at ATDC 15_.
Notice
Do not rotate the engine with camshaft sprocket bolt
or opposite direction of the engine rotation.
5. Remove the plug (6) and seal (5) from the fuel injec-
tion pump and collect oil in a suitable vessel.
Installation Notice
Tightening Torque30 N∙m (22 lb-ft)
Notice
Replace the seal.
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 rein-
stall the plug.
Locking Screw 601 589 05 21 00
7. Place alignment marks (arrow) on the timing chain
(12) and camshaft sprocket (15).

1F3 -- 32 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
8. Remove the chain tensioner (17).
Installation Notice
Tightening Torque80 N∙m (59 lb-ft)
Notice
Replace the seal (16).
9. Pull out the 12-- sided stretch bolt (14) and washer
and remove thecamshaft sprocket (12).
10. Pull out the bolt (11) and washer (10).
Notice
Be careful that the bolt is left -- hand thread.
Installation Notice
Tightening Torque46 N∙m (34 lb-ft)
11. Using special tool (24, 25), remove the locking pin
(8).
Sliding Hammer 116 589 20 33 00
Threaded Bolt 116 589 02 34 00

OM600 ENGINE CONTROLS 1F3 -- 33
D AEW OO M Y_2000
12. Push back the timing chain with retaining plate (26)
and remove the injection timing device (9).
Retaining Plate 667 589 04 63 00
13. Installation should follow the removal procedure in
the reverse order.
14. After assembling the engine, check start of delivery
and adjust if necessary.