check engine light SSANGYONG MUSSO 1998 Workshop Repair Manual

0B-12 GENERAL INFORMATION
OWNER INSPECTIONS
AND SERVICES
WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal
travel or repeated puling to one side when braking. Also,
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes in the sound of the system or
the smell of the fumes. These are signs that the system
may be leaking or overheating. Have the system
inspected and repaired immediately.
Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the
seats at normal highway speeds. This may mean a wheel
needs to be balanced. Also, a pull right or left on a
straight, level road may show the need for a tire pressure
adjustment or a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or
has too much free play, or is unusual sounds are noticed
when turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system
may indicate a problem. Have the system inspected and
repaired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best
time to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil level
on it.5. Add oil, if needed, to keep the oil level above the
lower mark. Avoid overfilling the engine, since this
may cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.
If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the
pan fast enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank
and add coolant if necessary. Inspect the coolant.
Replace dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST TWICE A MONTH
Tire And Wheel Inspection and Pressure
Check
Check the tire for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold ( check the spare also, unless it is a
stowaway). Maintain the recommended pressures. Refer
to “Tire and Wheel” is in section 0B.
AT LEAST MONTHLY
Light Operation
Check the operation of the license plate light, the
headlights (including the high beams), the parking lights,
the fog lights, the taillight, the brake lights, the turn
signals, the backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air
conditioning system after use is normal. If you notice
fuel leaks or fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to
Section 6A,
Power Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low
fluid level can indicate worn disc brake pads which may
need to be serviced. Check the breather hole in the
reservoir cover to be free from dirt and check for an
open passage.

GENERAL ENGINE INFORMATION 1A1-7
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating
conditoins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange must
be repaired also. Before attempting to repair a leak,
check for the following conditions and correct them as
they may cause a leak.
Gaskets
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe fasteners are tightened improperly or the threads
are dirty or damaged.
lThe flanges or the sealing surface is warped.
lThere are scratches, burrs or other damage to the
sealing surface.
lThe gasket is damaged or worn.
lThere is cracking or porosity of the component.
lAn improper seal was used (where applicable).
Seals
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe seal bore is damaged (scratched, burred or
nicked).
lThe seal is damaged or worn.
lImproper installation is evident.
lThere are cracks in the components.
lThe shaft surface is scratched, nicked or damaged.
lA loose or worn bearing is causing excess seal wear.
DIAGNOSIS

1A2-8 GENERAL ENGINE INFORMATION
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating
conditoins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange must
be repaired also. Before attempting to repair a leak,
check for the following conditions and correct them as
they may cause a leak.
Gaskets
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe fasteners are tightened improperly or the threads
are dirty or damaged.
lThe flanges or the sealing surface is warped.
lThere are scratches, burrs or other damage to the
sealing surface.
lThe gasket is damaged or worn.
lThere is cracking or porosity of the component.
lAn improper seal was used (where applicable).
Seals
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe seal bore is damaged (scratched, burred or
nicked).
lThe seal is damaged or worn.
lImproper installation is evident.
lThere are cracks in the components.
lThe shaft surface is scratched, nicked or damaged.
lA loose or worn bearing is causing excess seal wear.
DIAGNOSIS

1A3-10 GENERAL ENGINE INFORMATION
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following
procedures may help you in locating and repairing
most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine
oil, automatic transmission fluid, power steering
fluid, etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large
sheet of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be
necessary to clean the suspected area with a
degreaser, steam or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at
normal operating temperature and varying
speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot
powder) to the suspected area.
3. Operate the vehicle under normal operating
conditions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer
to the manufacturer's directions when using the kit.1. Pour the specified amount of dye into the engine
oil fill tube.
2. Operate the vehicle normal operating conditions
as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must
be determined n order for it to be repaired properly. If
a gasket is replaced, but the sealing flange is bent,
the new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
leak, check for the following conditions and correct
them as they may cause a leak.
Gaskets
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe fasteners are tightened improperly or the
threads are dirty or damaged.
lThe flanges or the sealing surface is warped.
lThere are scratches, burrs or other damage to the
sealing surface.
lThe gasket is damaged or worn.
lThere is cracking or porosity of the component.
lAn improper seal was used (where applicable).
Seals
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe seal bore is damaged (scratched, burred or
nicked).
lThe seal is damaged or worn.
lImproper installation is evident.
lThere are cracks in the components.
lThe shaft surface is scratched, nicked or damaged.
lA loose or worn bearing is causing excess seal
wear.
DIAGNOSIS

1B1-74 M162 ENGINE MECHANICAL
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece13 Chain Tensioner Housing
1 4 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole 5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

M161 ENGINE MECHANICAL 1B2-79
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece13 Chain Tensioner Housing
1 4 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole 5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

1B3-102 OM600 ENGINE MECHANICAL
Checking
Notice
The noise which continues short time during short travel
(frequent starting of the engine) or engine starting after a
long time storage is normal operating conditions. So, it does
not need to be repaired. Determine the malfunctions in valve
clearance compensation device with noise through following
tests. If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4 minutes.
2. Stop the engine. After 5minutes, check the engine oil level
and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cylinders.
5. Using a drift, lightly press the valve tappet and measure
clearance between the cam and valve tappet.
Notice
If the clearance exceeds 0.4mm, replace the valve tappet.
6. If a valve tappet moves down too far in comparison to the
others, replace the valve tappet.
7. Rotate the engine and check the remaining valve tappets.
Notice
lUnnecessary rotation of the engine will damage the valve
tappets.
lDo not rotate the engine by using the camshaft sprocket
bolt or to the opposite direction of the engine rotation.

M162 ENGINE CONTROLS 1F1-47
3. Disconnect the vacuum hose.
4. Disconnect the circlip and remove the fuel pressure
regulator.
5. Apply the oil to O-ring lightly and then replace it.
6. Installation should follow the removal procedure in the
reverse order.
7. Check for fuel pressure and internal leaks by operating the
engine. 2. Discharge the pressure in fuel supply system by pressing
the service valve.
Removal & Installation Procedure
1. Remove the fuel pressure test connector.

1F2-46 M161 ENGINE CONTROLS
3. Disconnect the vacuum hose.
4. Disconnect the circlip and remove the fuel pressure
regulator.
5. Apply the oil to O-ring lightly and then replace it.
6. Installation should follow the removal procedure in the
reverse order.
7. Check for fuel pressure and internal leaks by operating the
engine. 2. Discharge the pressure in fuel supply system by pressing
the service valve.
Removal & Installation Procedure
1. Remove the fuel pressure test connector.

1F3-38 OM600 ENGINE CONTROLS
Tools Required
617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a
suitable vessel.
2. Install the position sensor (1) into the governor housing of
the injection pump to be the guide pin of the position sensor
facing up.
3. Connect the battery terminal of position sensor (1) to positive
terminal (+) of battery.
Position Sensor 617 589 08 21 00
4. Rotate the crankshaft by hand (in direction of engine rotation)
until the lamp ‘B’ lights up. Rotate the crankshaft carefully
further until both lamps ‘A and B’ come on. In this position,
check the Rl value on the crankshaft vibration damper.
Notice
If only lamp ‘A’ lights up, repeat the test and if out of
specification, adjust start of delivery.
Specification ATDC 14° - 16°