1998 SSANGYONG MUSSO battery

SECTION 1F3
OM600 ENGINE CONTROLS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F3-1
Fastener Tightening Specifications . . . . . . . . 1F3-1
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15Idle Speed Adjustment . . . . . . . . . . . . . . . . 1F3-16
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F3-18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-21
Injection Nozzle Test . . . . . . . . . . . . . . . . . . 1F3-22
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . 1F3-25
Injection Nozzle Repair . . . . . . . . . . . . . . . . 1F3-27
Removal and Installation of
Injection Timing Device . . . . . . . . . . . . . . 1F3-30
Injection Timing Device . . . . . . . . . . . . . . . . 1F3-35
Start of Delivery Test
(Position Sensor, RIV Method) . . . . . . . . . 1F3-37
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 1F3-46
TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Tank Mounting Nut
Fuel Pump Pressure Line
Fuel Injection Nozzle
Fuel Injection Pipe
Nozzle Tensioning Nut
Screw Plug
Left-Hand Thread BoltN·m
28 - 47
13
35 - 40
18
80
30
46

OM600 ENGINE CONTROLS 1F3-37
START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD)
1 Position Sensor
2 Battery
3 Fuel Injection Pump4 Seal....................................................... Replace
5 Screw Plug.................................................30Nm
Service Data
Start of Delivery (RIV)
ATDC 14° - 16°

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°

OM600 ENGINE CONTROLS 1F3-39
Digital Tester, RIV Method
(Connection Diagram for Testers Without Adapter)
1 Fuel Injection Pump
2 Rl Sensor
3 Digital Tester4 TDC Pulse Sender Unit
5 Battery

1F3-40 OM600 ENGINE CONTROLS
Start of Delivery (RIV)
Idle Speed (Connection Diagram for Testers With Adapter)
1 Fuel Injection Pump
2 Rl Sensor
3 Digital Tester4 TDC Pulse Sender Unit
5 Battery
6 Rl Pulse Generator
Service Data
ATDC 14° - 16°
OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm

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

SECTION 1G3
OM600 ENGINE INTAKE & EXHAUST
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G3-1
Fastener Tightening Specifications . . . . . . . . 1G3-1
Schematic and Routing Diagrams . . . . . . . 1G3-2
EGR Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-2
Maintenance and Repair . . . . . . . . . . . . . . 1G3-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1G3-3
TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Air Cleaner Housing Cover Nut
Intake Manifold Bolt (M8 x 20)
Intake Manifold Bolt (M8)
Exhaust Mainfold Stud Bolt
Exhaust Pipe Nut (Engine)
Exhaust Pipe BoltN
· ·· ·
·m
9 - 11
22.5 - 27.5
22.5 - 27.5
9.5 - 12.5
15 - 28
28 - 47
Air Cleaner and Inlet Duct & Hose . . . . . . . . 1G3-3
Intake and Exhaust Manifold . . . . . . . . . . . . . 1G3-5
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 1G3-8
Charge Air System Diagram . . . . . . . . . . . . . 1G3-8
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-9
Turbocharger Assembly . . . . . . . . . . . . . . . 1G3-11

2A-8 SUSPENSION DIAGNOSIS
-
ACTUATOR INSPECTION
Output position of the actuator should be changed as below when battery voltage is applied between actuator
connector terminals.
Connector
terminalBattery VoltagePosition of The Actuator OutputRemark
1 (White)
-
2 (Black)OPEN
3 (Red)
+
1 (White)
+
2 (Black)
-
3 (Red)OPEN
1 (White)OPEN
2 (Black)
+
3 (Red)
SOFT Mode
MEDIUM Mode
HARD Mode