service SSANGYONG MUSSO 1998 Workshop Owners Manual

SECTION 1G1
M162 ENGINE INTAKE & EXHAUST
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G1-1
Fastener Tightening Specifications . . . . . . . . 1G1-1
Maintenance and Repair . . . . . . . . . . . . . . 1G1-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G1-2
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G1-2
TABLE OF CONTENTS
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G1-4
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G1-5
Resonance Flap . . . . . . . . . . . . . . . . . . . . . . 1G1-7
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G1-9
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Nlm
9 - 11
22.5 - 27.5
22.5 - 27.5
9.5 - 12.5
15 - 28
28 - 47 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 Bolt

1G1-2 M162 ENGINE INTAKE & EXHAUST
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AIR CLEANER
1 Air - Cleaner Assembly
2 Air - Cleaner Shield Upper Cover
3 Blot4 Blot
5 Air Intake Shield

SECTION 1G2
M161 ENGINE INTAKE & EXHAUST
TABLE OF CONTENTS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Nlm
9 - 11
22.5 - 27.5
22.5 - 27.5
9.5 - 12.5
15 - 28
28 - 47 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 Bolt
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G2-1
Fastener Tightening Specifications . . . . . . . . 1G2-1
Maintenance and Repair . . . . . . . . . . . . . . 1G2-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G2-2
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G2-2Air Intake Shield . . . . . . . . . . . . . . . . . . . . . . 1G2-4
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G2-5
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G2-7
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G2-9

1G2-2 M161 ENGINE INTAKE & EXHAUST
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AIR CLEANER
1 Air Cleaner Assembly
2 Element Assembly
3 Insulator
4 Air Duct Hose5 Air Inlet Duct
6 Bolt (M8
× 30 ) ...................................22.5-27.5 Nm
7
Bolt (M6 × 35 ) ........................................... 9-11 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

OM600 ENGINE INTAKE & EXHAUST 1G3-3
AIR CLEANER AND INLET DUCT & HOSE
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
1 Air Intake Shield Assembly
2 Air Cleaner Assembly
3 Mounting Bracket
4 Air Cleaner Element...........Clean : 20,000km
Replace : 60,000km5 Bolt......................................................... 9-11Nm
6 House
7 Clamp
8 Engine Cover Assembly (Turbo)
9 Mounting Bracket

SUSPENSION DIAGNOSIS 2A-13
Self - Diagnosis List
Fault
CodeDefectsService Hint
01 Vertical Acceleration Sensor
02 Lateral Acceleration Sensor
03 Wheel Acceleration Sensor
04
05 Rear Step Motor
0 6 ECUFront Step Motor1. Check sensor supply voltage
lCondition - IGN ON
lStandard value - voltage between pin 11 and 8 of ECU :
4.5 - 5.0V
2. Check sensor output voltage
lCondition - IGN ON
lStandard value - voltage between pin 20 and 11 of ECU
: 0.5 - 4.5V
3. Check the sensor.
4. Check circuit for open.
5. Check connection of other connectors.
1. Check sensor supply voltage
lCondition - IGN ON
lStandard value - voltage between pin 11 and 8 of ECU :
4.5 - 5.0V
2. Check sensor output voltage
lCondition - IGN ON
lStandard value - voltage between pin 10 and 11 of ECU
: 0.5 - 4.5V
3. Check the sensor.
4. Check circuit for open.
5. Check connection of other connectors.
1. Check step motor supply voltage.
2. Check circuit for open.
3. Check connection of other connectors.
1. Check step motor supply voltage.
2. Check circuit for open.
3. Check connection of other connectors.
1. Check connectors of ECU.
2. Replace the ECU. 1. Check sensor supply voltage
lCondition - IGN ON
lStandard value - voltage between pin 11, 8 and pin
7,11 of ECU : 4.5 - 5.0V
2. Check sensor output voltage
3. Check the sensor.
4. Check circuit for open.
5. Check connection of other connectors.

SECTION 2B
WHEEL ALIGNMENT
TABLE OF CONTENTS
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
Application
Camber
Caster
Toe-in
King Pin InclinationDescription
0° ± 30'
2°30' ± 30'
0 - 4 mm
12°30'
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Wheel Alignment Specifications . . . . . . . . . . . 2B-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Tire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Radial Tire Lead/Pull . . . . . . . . . . . . . . . . . . . 2B-3
Vibration Diagnosis . . . . . . . . . . . . . . . . . . . . . 2B-5
Maintenance and Repair . . . . . . . . . . . . . . . 2B-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 2B-6Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . 2B-6
General Description and System
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Four Wheel Alignment . . . . . . . . . . . . . . . . . . 2B-9
Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9

2B-6 WHEEL ALIGNMENT
MAINTENANCE AND REPAIR
ON VEHICLE SERVICE
WHEEL ALIGNMENT
Vehicle Height
1. Check the tire for proper inflation.
2. Measure ‘A’ from the center of the lower arm rear mounting
bolt end to the ground.
3. Measure ‘B’ from the center of the steering knuckle shaft to
the ground.
4. If the difference between ‘A’ and ‘B’ is not within specification,
adjust vehicle height using torsion bar height control bolt.
‘B’ - ‘A’
Notice
Before wheel alignment, adjust vehicle height first.
31 - 36mm
Toe-in
1. Measure toe-in.
Specification0 - 4mm
2. If toe-in is not within specification, loosen the tie rod nuts
and adjust it by turning the tie rod.

SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Type
Spring Type
Torsion Bar
Shock Absorber
Stabilizer TypeDouble Wishbone
Torsion Bar Spring
1,040 mm
24.5 mm
Cylindrical Reciprocation Type
Torsion Bar Spring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
General Specifications . . . . . . . . . . . . . . . . . . 2C-1
Fastener Tightening Specifications . . . . . . . . . 2C-2
Component Locator . . . . . . . . . . . . . . . . . . . 2C-3
Front Suspension . . . . . . . . . . . . . . . . . . . . . . 2C-3
Maintenance and Repair . . . . . . . . . . . . . . . 2C-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2C-4
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . 2C-4
ApplicationDescription Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Front Lower and Upper Arm . . . . . . . . . . . . . . 2C-8
Front Shock Absorber . . . . . . . . . . . . . . . . . 2C-10
Axle Vertical Acceleration Sensor
(Wheel G Sensor) . . . . . . . . . . . . . . . . . . . 2C-12
Vertical and Lateral Sensor . . . . . . . . . . . . . . 2C-13
ECS (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-14
Length
Outer Diameter(
f)