torque SSANGYONG MUSSO 2003 Service Manual

1F3-14 OM600 ENGINE CONTROLS
Removal & Installation Procedure
1. Remove the vacuum line (3, 4).
2. Remove the bolts (1) evenly. Notice
If necessary, rotate the engine until the pressure on the tappet of the vacuum pump is released.
3. Remove the vacuum pump (2).
4. Install the vacuum pump (2).
Tightening Torque 10 Nm
Notice Clean the gasket residues of sealing surface of vacuum pump and replace the gasket(5).
5. Connect the vacuum line (3, 4).

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

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 1F3-31
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.

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.

OM600 ENGINE CONTROLS 1F3-33
9. Pull out the 12-sided stretch bolt (14) and washer andremove the camshaft sprocket (12).
Tightening Torque 46 Nm
11. Using special tool (24, 25), remove the locking pin (8). Sliding Hammer 116 589 20 33 00Threaded Bolt 116 589 02 34 00
8. Remove the chain tensioner (17).
Installation Notice
Tightening Torque 80 Nm
Notice Replace the seal (16).
10. Pull out the bolt (11) and washer (10). Notice Be careful that the bolt is left-hand thread. Installation Notice

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

OM600 ENGINE CONTROLS 1F3-43
Tools Required 617 589 08 21 00 Position Sensor Adjustment Procedure
1. Position the No. 1 cylinder at ATDC 15°
Notice Do not rotate the engine in opposite direction of engine rotation.
2. Remove the bolt (2) at the supporting bracket.
3. Remove the bolt (4).
4. Turn the adjusting screw (1) until both lamps ‘A’ + ‘ B ’ on
the position sensor light up. Notice If the adjustment range is not adequate, remove the injection pump and reinstall.
Position Sensor 617 589 08 21 00
5. After adjusting, retighten all the bolt to the specified torque.
To the right
To the left Start of delivery retarded
Start of delivery advanced

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

M162 ENGINE INTAKE & EXHAUST 1G1-3
Removal & Installation Procedure1. Release the clamp securing HFM sensor and air cleaner.
2. Disengage the air cleaner assembly and HFM sensor assembly.
3. Unserew the mounting bolt(6) from the bracket.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
4. Release the clamp from air cleaner assembly housing and remove the cover.
5. Remove the air cleaner assembly.
6. Remove the air cleaner housing from insulator.
Notice
Make sure the air cleaner to be seated in insulator.
7. Disengage the air duct hose and air cleaner housing and remove the housing.
8. Remove the air duct hose.
9. Unscrew the two bolts(7) from air inlet duct. Installation Notice
10. Remove the air inlet duct.
11. Installation should follow the removal procedure in the reverse order.
Tightening Torque 8 - 9 Nm