engine SSANGYONG MUSSO 2003 Service Manual

OM600 ENGINE CONTROLS 1F3-7
Vacuum 500 mbar
Lines and connections leaking. Faulty PLA vacuum unit.
Test step 1
Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run engine at idle speed.YES NO
(Remove the connection hose from vacuum pump)
Connect vacuum pump (14) direct to PLA vacuum unit(5) and pressurize with vacuum.
Vacuum is built up and idle speed increases approx. 150-200 rpm
YES NO
Faulty PLA vacuum unit
(Coolant Temperature 30 °C)
Stop the engine Seal the air admission line with plug. Connect the vacuum pump to line to thermovalve andpressurize the line with vacuum.
Vacuum is built up.
YES NO
Lines and connectors leaking. Faulty thermovalve.
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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.
YES
NO
YES NO

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