SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE CONTROLS 1F3-11
VACUUM PUMP TEST
1 Fuel Filter
2 Vacuum Line3 Ancillaries Connection
4 Vacuum Tester
Tools Required
201 589 13 21 00 Vacuum Tester

1F3-12 OM600 ENGINE CONTROLS
Test Procedure
1. Remove the fuel filter (1) and keep the filter not to be damaged from running engine.
2. Remove the vacuum line (2) from ancillaries connection (3).
3. Connect the vacuum tester (4) to the ancillaries connection (3).
Vacuum Tester 201 589 13 21 00
4 Run the engine at idle and check vacuum pressure after 30 sec. Notice If out of standard, replace the vacuum pump.
5. Remove the vacuum tester.
6. Connect the vacuum line to the ancillaries connection.
7. Install the fuel filter.
Standard > 70 mbar

OM600 ENGINE CONTROLS 1F3-13
VACUUM PUMP Preceding Work : Remove the poly V-belt
1 Bolt............................................................ 10Nm
2 Vacuum Pump
3 Vacuum Line (Ancillaries) 4 Vacuum Line (Brake Booster)
5 Gasket ................................................... Replace

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).

OM600 ENGINE CONTROLS 1F3-15
VACUUM UNIT REPLACEMENT
1 Bracket
2 Bolt
3 Vacuum Unit
4 Vacuum Line
5 Seal.............................................. Replace

1F3-16 OM600 ENGINE CONTROLSIdle Speed
750 - 850 rpm 720 - 820 rpm
EngineOM661LA EngineOM662LA Engine
Tools Required 667 589 00 21 00 TDC Pulse Generato
Commercial Tool
IDLE SPEED ADJUSTMENT Service Data
e.g. Bosch, MOT 001.03
Sun, DIT 9000
Digital Tester
Adjustment Procedure
1. Connect the digital tester (1) and TDC pulse sender unit
(11).
2. Run the engine and warm up the coolant to 60~80 °C.
TDC pulse generator 667 589 02 21 00
3. Disconnect the vacuum hose (4) from the PLA unit to check idle speed with tester.
4. Check idle speed with tester.
Notice
To adjust idle speed, loosen the locking nut (6) of PLA unit.
OM 661LA Engine 750 - 850rpm
OM 662LA Engine
720 - 820rpm

OM600 ENGINE CONTROLS 1F3-17
6. After adjustment, tighten the locking nut and place theposition marking with different color of paint. Notice If there are no changes in idle speed with PLA unit
adjustment, perform the service at a BOSCH Service Center.
7. Connect the vacuum pump to the PLA vacuum unit and build up vacuum approx. 500mbar. If engine rpm increases by approx. 100rpm, It is normal.
Vacuum Pump 001 589 73 21 00
8. Connect the vacuum line (4).
9. Switch on all ancillaries and check the idle speed.
5. Ensure not to damage the idle spring in the governor and adjust idle speed by turning the PLA unit (5) slowly. Notice Do not rotate the PLA unit over ½ turn from the position
marking. If do, idle spring in the governor will be severely damaged. Clockwise
Counterclockwise
RPM Decrease RPM Increase

1F3-18 OM600 ENGINE CONTROLS
Min. volume 150cm for 30 seconds
FUEL PUMP TEST Notice
Before test, replace the fuel filter cartridge and fuel prefilter.
Fuel Feed Test
1. Disconnect the fuel return line (1) and seal up it with plug.
2. Insert the plastic hose (5) and put the end into the measuring
beaker (6).
3. Disconnect the vacuum line (4) from vacuum unit (engine stop) (5) and connect the vacuum pump (7) to the vacuum unit.
4. To avoid the engine starting, build up vacuum (approx. 500 mbar).
5. Operate the starter motor for exactly 30 seconds and measure fuel volume in the beaker.
3

OM600 ENGINE CONTROLS 1F3-19
Fuel Pressure Test

1F3-20 OM600 ENGINE CONTROLS
Tools Required
617 589 04 21 00 Tester
1. Disconnect the fuel line (2) from the fuel filter.
2. Remove the banjo bolt (4) from the fuel injection pump andremove the seals (3) and fuel line (2).
3. Connect the tester (5).
4. Start the engine and read off the fuel pressure on tester (5). Notice If out of standard, replace the fuel feed pump.
Tester 617 589 04 21 00
5. Stop the engine. At Idle Speed
At Full load
> 0.3bar > 0.5bar
6. Remove the tester.
7. Replace the seal and connect the fuel line (2).