engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1F3-8 OM600 ENGINE CONTROLS
Detach line downstream of air admission filter (13).
Vacuum drops.
Faulty thermovalve
Fit the line onto air admission filter. Built up vacuum with
vacuum pump. Detach the plug from air admission line.
Vacuum drops.
Faulty filter with restriction.
Go to test step 2. YES
NO YES NO

OM600 ENGINE CONTROLS 1F3-9
Test step 2
Connect vacuum pump (14) with Y adapter to PLA
vacuum unit (5). Run the engine at idle speed.
Vacuum drops to ‘0’ at approx. 30°C of the thermovalve.
Faulty thermovalve.
Defective filter with restriction.
Stop the engine. Detach the filter with restriction.
Filter with restriction is clear.
Defective filter with restriction. YESNO
YES NO

1F3-10 OM600 ENGINE CONTROLS
VACUUM PUMP (SECTIONAL VIEW)
2 Suction Valve
4 Piston
5 Pressure Valve
6 Safety Valve
7 O-Ring
8 Pump Housing
9 Pump Cover
12 Lever
14 Outer Return Spring
15 Inner Spring Retainer16 Roller Cam
17 Piston Rod
21 Inner Return Spring
23 Upper Spring Retainer
28 Piston Ring
30 Seal Ring
31 Oil Return Valve
32 Restrictor
SB To Brake Booster
SK To Vacuum Lines

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 CONTROLS
Idle Speed
750 - 850 rpm
720 - 820 rpm Engine
OM661LA Engine
OM662LA 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 Engine750 - 850rpm
OM 662LA Engine
720 - 820rpm

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