ABS SSANGYONG MUSSO 2003 User Guide

SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
General Specifications . . . . . . . . . . . . . . . . . . 2A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
General Diagnosis . . . . . . . . . . . . . . . . . . . . . 2A-3
Input & Output Devices and Damping Force Control Logic . . . . . . . . . . . . . . . . . 2A-5
Input & Output Devices . . . . . . . . . . . . . . . . . . 2A-5
System Layout . . . . . . . . . . . . . . . . . . . . . . . . 2A-5Damping Force Control Logic . . . . . . . . . . . . . 2A-6
Normal Control . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Actuator Inspection . . . . . . . . . . . . . . . . . . . . . 2A-8
Schematic and Routing Diagrams . . . . . . . . 2A-9
ECS Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9
Self Diagnosis Test . . . . . . . . . . . . . . . . . . 2A-12
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . 2A-12
SPECIFICATIONS
GENERAL SPECIFICATIONS
188
Application
Front
3-stage Variable Damping Force Control Type Rear
ECS Control Type
344 - 350
Shock Absorber517 - 523
Max. Length (mm)
245 ± 3
Compressed Length (mm) 102
Stroke (mm)331 ± 3

SUSPENSION DIAGNOSIS 2A-3
DIAGNOSIS
GENERAL DIAGNOSIS
Checks
Loosened Mountings Damaged or Worn wheel BearingDamaged Shock Absorber
Damaged Tire Action
Retightening ReplaceReplaceReplace
Abnormal Noises
Checks
Broken Stabilizer Bar Faulty Shock Absorber Action
ReplaceReplace
Vehicle Rolling
Checks
Over Inflated Tire Faulty Shock Absorber Loosened wheel Nut Bent or Broken Coil Spring
Damaged TireWorn Bushing Action
Pressure Adjustment
Replace
Tighten as Specified ReplaceReplaceReplace
Poor Riding
Problems in the steering, the suspension, the tires, and the wheels involve several systems. Consider all systems when you diagnose a complaint. Some problems, suchas abnormal or excessive tire wear and scuffed tires,may by the result of hard driving. Always road test the
vehicle first. If possible, do this road test with the
customer. Proceed with the following preliminary checks. Correct any substandard conditions.
Checks
Incorrect Wheel Alignment Excessive Resistance of Lower Arm Ball Joint
Insufficient Tire PressureFaulty Power Steering
Action Repair
Replace Adjust
Repair or Replace
Hard Steering
Checks
Deformed Arm Assembly Worn BushingBent or Broken Coil SpringDifference Between L/H & R/H Heights Action
ReplaceReplaceReplace Adjust
Vehicle Pulls to Right or Left

SUSPENSION DIAGNOSIS 2A-5
INPUT & OUTPUT DEVICES AND DAMPING FORCECONTROL LOGIC
INPUT & OUTPUT DEVICES Damping force of shock absorber will rotate shock absorber control rod in 3 modes by driving actuator on the upper shock absorber when signaled from ECS. Rotary valve in the shock absorber will control hydraulic flow according to rotation of control rod to adjust damping force of shock absorber in SOFT MEDIUM HARD.
SYSTEM LAYOUT
1 ECS (ECU)
2 Body Vertical Acceleration Sensor (Vertical Sensor)
3 Body Lateral Acceleration Sensor (Lateral
Sensor)
Speed Sensor
Axle Vertical Acceleration Sensor (Wheel G Sensor)
Stop Lamp Switch
Body Vertical Acceleration Sensor (Vertical Sensor)
ECS Switch
Indicator Lamp
Actuator
Shock Absorber
Self-Diagnosis Connector
Damping Force Adjustment
ECS
(ECU)
Body Lateral Acceleration Sensor (Lateral Sensor)
4 ECS Mode Switch
5 Stop Lamp Switch
6 Axle Vertical Acceleration Sensor (Wheel G
Sensor)
7 Mode Actuator

WHEEL ALIGNMENT 2B-9
GENERAL DESCRIPTION AND SYSTEM OPERATION
FOUR WHEEL ALIGNMENT CASTER Caster is the tilting 91 the uppermost point of the steering axis either forward or backward from the vertical when viewed from the side of the vehicle. A backward tilt is positive, and a forward tilt is negative. Caster influencesdirectional control of the steering but does not affect
tire wear. Weak springs or overloading a vehicle will affect
caster. One wheel with more positive caster will pull
toward the center of the car. This condition will cause the car to move or lean toward the side with the least
amount of positive caster. Caster is measured in degrees. CAMBER Camber is the tilting of the top of the tire from the vertical when viewed from the front of the vehicle. When thetires tilt outward, the camber is positive. When the tires tilt inward, the camber is negative. The camber angle is measured in degrees from the vertical. Camber
influences both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
The first responsibility of engineering is to design safesteering and suspension systems. Each componentmust be strong enough to withstand and absorb extremepunishment. Both the steering system and the front and the rear suspension must function geometrically with thebody mass. The steering and the suspension systems require that the front wheels self-return and that the tire rolling effortand the road friction be held to a negligible force in orderto allow the customer to direct the vehicle with the least effort and the most comfort. A complete wheel alignment check should include
measurements of the rear toe and camber. Four-wheel alignment assures that all four wheels will be running in precisely the same direction. When the vehicle is geometrically aligned, fuel economy and tire life are at their peak, and steering andperformance are maximized. TOE
Toe-in is the turning in of the tires, while toe-out is the turning out of the tires from the geometric centerline or thrust line. The toe ensures parallel rolling of the wheels. The toe serves to offset the small deflections of the wheel support system which occur when the vehicle is rollingforward. The specified toe angle is the setting whichachieves 0 degrees of toe when the vehicle is moving. Incorrect toe-in or toe-out will cause tire wear and
reduced fuel economy. As the individual steering andsuspension components wear from vehicle mileage,
additional toe will be needed to compensate for the wear. Always correct the toe dimension last.

SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTSSPECIFICATIONS
GENERAL SPECIFICATIONS
Type
Spring Type
Torsion Bar Shock Absorber
Stabilizer Type
Double Wishbone
Torsion Bar Spring 1,040 mm
24.5 mm
Cylindrical Reciprocation Type
Torsion Bar Spring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-1General Specifications . . . . . . . . . . . . . . . . . . 2C-1
Fastener Tightening Specifications . . . . . . . . . 2C-2
Component Locator . . . . . . . . . . . . . . . . . . . 2C-3
Front Suspension . . . . . . . . . . . . . . . . . . . . . . 2C-3
Maintenance and Repair . . . . . . . . . . . . . . . 2C-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2C-4
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . 2C-4
Application Description
Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Front Lower and Upper Arm . . . . . . . . . . . . . . 2C-8
Front Shock Absorber . . . . . . . . . . . . . . . . .
2C-10
Axle Vertical Acceleration Sensor (Wheel G Sensor) . . . . . . . . . . . . . . . . . . . 2C-12
Vertical and Lateral Sensor . . . . . . . . . . . . . . 2C-13
ECS (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-14
Length Outer Diameter(
)

FRONT SUSPENSION 2C-3
COMPONENT LOCATOR
FRONT SUSPENSION
1 Shock Absorber
2 Upper Arm
3 Steering Knuckle
4 Lower Arm
5 Stabilizer Bar Link
6 Stabilizer Bar
7 Suspension Bumper

FRONT SUSPENSION 2C-7
Removal & Installation Procedure
1. Remove the fixing nuts and bolts of the shock absorberand lower arm connection. Installation Notice
2. Remove the connecting nuts of the stabilizer bar link to the lower arm. Installation Notice
3. Turn the height control bolt until the distance between the end of the height control bolt end piece and the bolt end becomes 0-5 mm. Installation Notice Install the torsion bar spring and adjust the distance between the end of the height control bolt and piece end the bolt end to be 50-55 mm. Adjust the vehicle height.
Tightening Torque 60 - 80 Nm
Tightening Torque 16 - 22 Nm
4. Remove the torque arm fixing nuts and bolts and then withdraw the torsion bar spring. Installation Notice
M10 M12
Tightening Torque40 - 60 Nm 60 - 80 Nm
5. Installation should follow the removal precedure in thereverse order.
6. Check and adjust the wheel alignment.

FRONT SUSPENSION 2C-9
Removal & Installation Procedure
1. Remove the shock absorber.Installation Notice
2. Remove the fulcrum pin mounting bolts and nuts and removethe upper arm assembly. Notice Be careful not to damage or lose the adjusting shims.
Upper LowerDistance between the nut end and the screw end
Tightening Torque6 - 9 mm
60 - 80 Nm
3. Remove the lower arm mounting bolts (2). Installation Notice
Tightening Torque 120 - 140 Nm
4. Pull out the cotter pin from the lower arm ball end assembly and remove lower arm after loosening the slotted nut. Installation Notice
Tightening Torque 150 - 180 Nm
Notice Replace the cotter pin with new one.
5. Installation should follow the removal precedure in the reverse order.
Tightening Torque 120 - 180 Nm
Installation Notice

2C-10 FRONT SUSPENSION
FRONT SHOCK ABSORBER1 Front Shock Absorber
2 Washer
3 Bush 4 Center Washer
5 Actuator Mounting Bracket
6 Nut ........................................................
40-60Nm

FRONT SUSPENSION 2C-11
Removal & Installation Procedure
1. Disconnect actuator connector and unscrew bolt and remove
actuator assembly. Notice When installing the actuator to the mounting bracket, the wiring should face the front of the frame.
2. Unscrew the upper nut (6). Notice When screwing the nut, actuator contacting surface of the mounting bracket and rod end should be 0.5 - 1.5mm.
3. Remove the mounting bracket (5). Notice When installing the bracket, it should be vertical to the frame
side member.
4. Remove the bush and check for damage and replace if necessary.
5. Unscrew shock absorber lower bolt and nut and remove the shock absorber. Notice Shock absorber is filled with gas, never attempt to cut or heat.
6. Installation should follow the removal procedure in the reverse order.