oil SSANGYONG MUSSO 1998 Workshop Repair Manual

6A-2 POWER STEERING SYSTEM
Checks
Damaged or Binding Steering Ball Joint
Improper Preload of Steering Pinion
Damaged Wheel or Tire
Faulty Suspension SystemChecks
Worn Steering Gear
Worn or Damaged Steering Ball Joint
Loosened Steering Gearbox BoltsChecks
Damaged Steering Linkage
Damaged Wheel and Tire
Faulty Brake System
Faulty Suspension SystemChecks
Lack of Lubrication
Abnormal Wear or Binding of Steering Ball Joint
Damaged or Faulty Steering Gear
Improper Preload of Steering Pinion
Faulty Steering Shaft Joint
Steering Fluid Leaks
Lack of Fluid or Air-in System
Faulty Steering Oil Pump
Damaged or Loosened Pump Drive Belt
Clogging Oil Line
Damaged Wheel or Tire
Faulty Suspension System
DIAGNOSIS
HARD STEERING
Action
Lubricate
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed
Replace
Adjust or replace
Repair or replace
Repair or replace
Repair or replace
STEERING PULLS TO ONE SIDE
Action
Repair
Repair or replace
Repair or replace
Repair or replace
EXCESSIVE WHEEL PLAY
Action
Replace gear assembly
Replace
Retighten
POOR RETURN OF STEERING WHEEL
Action
Replace
Replace gear assembly
Repair or replace
Repair or replace

POWER STEERING SYSTEM 6A-3
Checks
Loosened Steering Gearbox Mounting Bolt
Faulty Steering Gear
Steering Column Linterference
Loosened Steering Linkage
Damaged or Loosened Oil Pump Drive Belt
Loosened Oil Pump Bracket
Loosened Oil Pump Mounting Bolt
Air-in System
Faulty Oil PumpChecks
Damaged Steering Linkage
Loosened Steering Gearbox Mounting Bolt
Damaged or Binding Steering Ball Joint
Worn or Damaged Front Wheel Bearing
Damaged Wheel or Tire
Faulty Suspension System
STEERING WHEEL SHIMMY
Action
Replace
Retighten
Replace
Replace
Repair or replace
Repair or replace
ABNORMAL NOISE FROM STEERING SYSTEM
Action
Retighten
Replace gear assembly
Replace
Retighten
Adjust or replace
Retighten
Retighten
Bleed
Replace

6A-4 POWER STEERING SYSTEM
1 Steering Wheel
2 Steering Column Shaft
3 Steering Gear Box
4 End Ass'y - Tie Rod
COMPONENT LOCATOR
STEERING SYSTEM
5 Lower Shaft
6 Oil Reservoir
7 Oil Pump
8 Steering Knuckle

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK
Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect a
pressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering
wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
Notice
Do not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure
hose.
6. Do bleeding procedure.
BLEEDING OF POWER STEERING
SYSTEM
Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the
engine and turn the steering wheel from lock to lock 5 or 6
times.
Notice
Do bleeding with engine cranking. If bleed with idling, there
can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no
more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level
change.
Notice
lIf oil is not changes more than 5mm, do bleeding again.
lIf oil level rises suddenly when stopped engine, again.
Relief Pressure75 - 82 kg/cm2

6A-8 POWER STEERING SYSTEM
Tightening Torque 35 - 45 Nm
Removal & Installation Procedure
1. Remove the cotter pin and nut and separate the steering
gear box tie rod from the steering knuckle arm using the
puller.
Installation Notice
2. Remove the bolt and separate the lower sha from the
steering gear box.
Installation Notice
Tightening Torque 30 - 40 Nm
3. Remove the oil pipe from the steering gear box and drain
the oil.
Installation Notice
4. Remove the clamp bolts and remove the steering gear box
assembly.
Installation Notice
Tightening Torque 12 - 18 Nm
Notice
lBe careful not to damage the rubber(1).
lWhen installing tighten the bolt (3) with the rubber
(2)being inserted to the hole of clamp.
5. Bleed the air from system.
6. Check the toe-in.
Tightening Torque 70 - 90 Nm Tighten the bolt toward threadless side of lower shaft
coupling.

7B/C-2 MANUAL & SEMIAUTO-HVAC
Application
Type
Capacity
Condenser Fan Motor OutputDescription
Parallel type (Multi Flow Condenser)
11,000 kcal/h
160W
CONDENSER
Application
Desiccant
Type
CapacityDescription
XH - 9 (30g)
Aluminum type
240cc
RECEIVER DRIER
Application
High
LowDescription
OFF: 27±2kgf / cm
2, DIFF : 6±2kgf / cm2
OFF : 1.8±0.2kgf / cm2, ON 1.9±0.3kgf/ cm2
DUAL PRESSURE SWITCH
SPECIFICATIONS
COOLING CAPACITY
Application
Type
Max. Capacity
Max. Blowing Capacity
Refrigerant
Refrigerant AmountDescription
Air mix type
4,500kcal/h
7.Om
3/min
R134a
650 - 75Og
Application
Model
Type
Output
Oil
Magnetic Clutch OutputDescription
FK- ll
Vane rotary type
140.5cc/rev
ZXL 200PG (PAG oil)
45W
COMPRESSOR

MANUAL & SEMIAUTO-HVAC 7B/C-3
Application
Type
Expansion Valve
Resistance
Thermo AmpDescription
Tank laminated
Uniform external pressure type (1.5 RT)
4 stage (Coil resistance)
Sensor type OFF : 2±0.5°C, DIFF : 2±0.5°C
EVAPORATOR
Application
Heater Core Type
Heating Capacity
Heater Core Size (LxWxT)Description
2-ROW
4,600 kcal/h (AT 300 CMH)
219.5 x 151.8 x 52.0
HEATER UNIT
Application
Condenser Bolt
Condenser Fan Nut
Condenser Bolt
Receiver Drier Pipe Bolt
Receiver Drier Pipe Bolt (Condenser)
Pressure Pipe Bolt
Pressure Mounting BoltNlm
4-6
4-6
4-6
5-8
4-6
20-30
20-26
FASTENER TIGHTENING SPECIFICATIONS

MANUAL & SEMIAUTO-HVAC 7B/C-5
Action
Clean oily plate using cleaning agent.
Charge battery or check for cause.
Check wire continuity
Check A/C switch and fan switch for continuity and ground.
DEFECTIVES IN FAN MOTOR CIRCUIT
Fan Motor Does Not Run
Checks
Blown fuse
Battery voltage is low
Faulty wiring
Faulty groundAction
Check for short and replace fuse.
Check battery voltage.
Check connectors’ connection.
Do not apply grease. This can cause voltage down.
Remove body painting and completely ground,
Tighten ground bolts and make sure body ground connection.
Checks
Blown resister temperature fuse
Air leakage in parts connection
Action
Replace resistor.
Check heater, cooling unit and blower for proper connection.
Fan Motor Runs in ‘4’position Only (‘3’, ‘2’, ‘1’ : Does Not Run)
Frosted Evaporator
DEFECTIVES IN COMPRESSOR CIRCUIT
Compressor Does Not Run
Checks
Faulty thermo ampAction
Frosted evaporator reduces cooling capacity.
Off compressor and maximize blowing capacity
Checks
Faulty high/low pressure
Faulty A/C relayAction
Check compressor magnet voltage supply.
A/C relay.
Checks
Oily clutch plate
Low voltage
Faulty electric connection or operation
Magnetic Clutch Slips /Idles
Checks
Clogged or blocked intake grilleAction
Clogged or blocked intake grille reduces blowing capacity.
Motor Runs With Poor Blowing
Checks
Excessive clearance between
Clutch plate and clutch coilAction
Adjust clutch clearance (0.2-0.6mm).
Magnetic Clutch Plays By Hand Only

7B/C-10 MANUAL & SEMIAUTO-HVAC
REFRIGERANT CHARGING
Installation of Manifold Gauge
1. Close both high/low pressure hand valve of gauge before
installation of gauge to the charging valve.
2. Connect the low pressure hose of the gauge to the low
pressure charging valve and the high pressure hose of the
gauge to high pressure charging valve. Tighten the hose
nuts by hand.
Discharging of Refrigerant
1. Connect the manifold gauge to the charging valve.
2. Place the free end of center hose in a shop towel.
3. Slowly open the high pressure hand valve and discharge
refrigerant.
Notice
If refrigerant is allowed to escape too fast, compressor oil
will be drawn out of the system.
MAINTENANCE AND REPAIR

MANUAL & SEMIAUTO-HVAC 7B/C-13
Replacement of Refrigerant Connection (O-ring
Type)
1. When connecting a O-ring type, apply compressor oil to
portions shown in illustration. Be careful not to apply oil to
threaded portion.
Notice
Use specified compressor oil.
2. O-rings must be closely attached to inflated portion of pipe
and always replace used O-rings.
3. After inserting the pipe to the union, tighten the nut by hand
as much as possible and tighten the nut to specified torque.
4. When connecting liquid pipe(B) and low pressure hose(A)
to evaporate pipe, apply compressor oil to the O-ring.
5. When tightening, set the center of pipe and tighten fully.
6. Tighten the nut by specified wrench.
Installation Notice
Tightening Torque Inlet Side to 12 - 15Nm
Low Pressure Hose (A) 30 - 35 Nm