SSANGYONG MUSSO 2003 Service Manual

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

1F3-42 OM600 ENGINE CONTROLS
After Testing Preceding Work : Start of delivery test Position Sensor (RIV method)
1 Adjusting Screw
2 Bolt ............................................................ 23Nm
3 Fuel Injection Pump 4 Bolt
............................................................ 23Nm
5 Scale .......... Rl start of delivery = 14 ° - 16 ° ATDC

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

1F3-44 OM600 ENGINE CONTROLS
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 With Pulse Generator
Without Pulse Generator Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3 Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875
Digital tester (RIV Method)
1 Bolt
............................................................ 23Nm
2 Adjusting Screw ....... To the right : start of delivery retarded
To the left : start of delivery advanced 3 Bolt
............................................................ 23Nm
Service Data
Start of Delivery (RIV) Ldling Speed
ATDC 14 ° - 16 °
OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm

OM600 ENGINE CONTROLS 1F3-45
Adjustment Procedure
1. Remove the bolt (3) at the supporting bracket.
2. remove the bolts (1) at the timing case cover.
3. Run the engine at idle speed.
4. Turn the adjusting screw (2) until the specification (15° ± 1 °
ATDC) is indicated on the digital tester.
To the Right
To the Left Start of Delivery Retarded
Start of Delivery Advanced

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 1F3-47
2. Remove the connecting rod (9).
3. Disconnect the vacuum lines (13, 14).
4. Remove the accelerator control damper (10).(Manual transmission vehicle)
5. Remove the suction line (16) and pressure line (4).
6. Remove the banjo bolt (1) and then remove the seal (2) and fuel line (3).
7. Remove the plastic clip (8) on the injection line.
Removal Procedure
1. Position then no.1 cylinder at 15
° ATDC.
Notice Do not rotate the engine in opposition direction of engine rotation.
8. Disconnect the injection lines (15) from the injection pump (25).
9. Remove the banjo bolt (1) and then remove the seal (7) and return line (5).

1F3-48 OM600 ENGINE CONTROLS
10. Install the assembly cage (29) and remove the bolt (20)and pull off the washer (21). Notice Be careful that the bolt (20) is left hand thread.
Assembly Cage 601 589 05 14 00
11. Remove the chain tensioner (18) and seal (19).
12. Remove the bolt (12) and pull off the washer (11).
13. Remove the bolt (22) and pull off the square nut (28).
14. Pull out the fuel injection pump (25) and seal (23).

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