Vacuum SSANGYONG MUSSO 1998 Workshop Workshop Manual

OM600 ENGINE CONTROLS 1F3-17
6. After adjustment, tighten the locking nut and place the
position 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

1F3-30 OM600 ENGINE CONTROLS
REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE
Preceding Work : Removal of vacuum pump
1 Cylinder Head Cover
2 Bolt............................................................10Nm
3 Gasket ................................................... Replace
4 Fuel Injection Pump
5 Seal....................................................... Replace
6 Screw Plug.................................................30Nm
7 Oil Pan
8 Locking Pin
9 Injection Timing Device10 Washer
11 Bolt (Left-Hand Thread).............................46Nm
12 Camshaft Sprocket
13 Washer
14 12-Sided Stretch Bolt............Check, 25Nm + 90°
15 Timing Chain
1 6 Seal
17 Chain Tensioner.........................................80Nm

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 Screw
601 589 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
1 9 Seal....................................................... Replace
20 Bolt(Left-Hand Thread)..............................46Nm
21 Washer
2 2 Bolt............................................................23Nm
2 3 Seal....................................................... Replace24 Oil Pan
25 Fuel Injection Pump
2 6 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).

OM600 ENGINE CONTROLS 1F3-51
12. Connect the vacuum line (13, 14).
13. Connect the connecting rod (9).
14. Connect the accelerator control damper (10).
(Manual transmission vehicle)
15. Install the chain tensioner.
16. Install the vacuum pump.
17. Check the start of delivery.
18. Adjust the idle speed.
11. Assemble the plastic clip (8).

1G1-6 M162 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
lUpper Intake Manifold
1. Disconnect the vacuum hose (8,9).
2. Loosen the clip (22).
3. Remove the upper intake manifold (5) after unscrewing the
bolt (6).
Installation Notice
Notice
Check the gasket and replace it if necessary.
4. Installation should follow the removal procedure in the
reverse order.
lLower Intake Manifold
Preceding work : removal of upper intake manifold
1. Remove the hose of brake booster vacuum line and idle
speed connector.
2. Disconnect the hot water inlet pipe from the bottom of lower
intake manifold.
3. Unscrew the bolt (17) and remove the lower intake manifold
(16).
Installation Notice
4. Start the engine and check for leaks at each connection
part.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 22.5 - 27.5 Nm

M162 ENGINE INTAKE & EXHAUST 1G1-7
RESONANCE FLAP
1 Soft Cap (2)
2 Bolt (M6 x 25, 4 pieces)......................... 9-11 Nm
3 O-ring
Removal & Installation Procedure
1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after removing
4 bolts (2).
Notice
Connect carefully the vacuum hose (4) for installation.
3. Check the O-ring (3) and replace it if necessary.
4. Remove the lower resonance flap (5).
5. Replace the gasket (6).
6. Installation should follow the removal procedure in the
reverse order.4 Vacuum Hose
5 Resonance Flap
6 Gasket ................................................... Replace

1G2-8 M161 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
1. Disconnect the battery ground cable.
2. Remove idle speed control plug connector (arrow).
3. Disconnect the brake booster vacuum line and other
vacuum lines.
4. Disconnector the rod from bearing bracket assembly and
remove the connection piece (8).
Installation Notice
Tightening Torque 36 - 44 Nm
5. Unscrew the three bolts (4) and remove the idle regulator
and intermediate flange (6).
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
6. Unscrew the two bolts (M8 X 16) and remove the support
assembly (arrow).
Installation Notice
7. Unscrew the intake manifold assembly mounting bolts (1)
and remove the intake manifold and gasket.
Installation Notice
Notice
Replace the gasket with new one.
8. Installation should follow the removal procedure in the
reverse order.
9. Start the engine and check for leaks in each connection.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 22.5 - 27.5 Nm

M/T
M/T
A/T (MB)
M/T
A/T (BTRA)
M/T
A/T (BTRA)
M/T
A/T (MB)
M/T
A/T (MB)
A/T (BTRA)
M/T
A/T (MB)
A/T (BTRA)
SECTION 3A
FRONT DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
General Specifications . . . . . . . . . . . . . . . . . . 3A-1
Fastener Tightening Specifications . . . . . . . . . 3A-2
Component Locator . . . . . . . . . . . . . . . . . . . 3A-3
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3
Auto-Locking Hub . . . . . . . . . . . . . . . . . . . . . . 3A-4
Vacuum Circuit . . . . . . . . . . . . . . . . . . . . . . . . 3A-5
Maintenance and Repair . . . . . . . . . . . . . . . 3A-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3A-6
Vacuum Line . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Steering Knuckle and Drive Shaft . . . . . . . . . . 3A-8
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Application
Drive Shaft Type
Axle Housing Type
Differential Type
Differential Gear
CV Joint
Build - up
Conventional
Hypoid Gear
4.56
4.56
3.73
4.56
5.38
4.27
4.89
4.89
4.55
4.55
4.55
5.86
3.73
3.73
4.89
1.4 L
SAE 80W/90, API GL - 5
Description
661NA
662NA
661LA
662LA
E20
E23
E32 Reduction Ratio
Oil Capacity
Oil Specification