torque SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE CONTROLS 1F3-43
Tools Required
617 589 08 21 00 Position Sensor
Adjustment Procedure
1. Position the No. 1 cylinder at ATDC 15°
Notice
Do not rotate the engine in opposite direction of engine
rotation.
2. Remove the bolt (2) at the supporting bracket.
3. Remove the bolt (4).
4. Turn the adjusting screw (1) until both lamps ‘A’ + ‘B’ on
the position sensor light up.
Notice
If the adjustment range is not adequate, remove the injection
pump and reinstall.
Position Sensor 617 589 08 21 00
5. After adjusting, retighten all the bolt to the specified torque.
To the right
To the leftStart of delivery retarded
Start of delivery advanced

1F3-50 OM600 ENGINE CONTROLS
10. Connect the fuel pipes
Notice
Replace the seal.
Box Wrench Insert 000 589 77 03 00
Return Line
Fuel Injection Line
Fuel feed Line
Suction and Pressure Line46 Nm
18 Nm
13 Nm
13 Nm
5. Coat the new seal (23) with engine oil and install it.
6. Insert the fuel injection pump (25) and tighten the bolts
(22).
7. Remove the locking screw (32).
Tightening Torque 23 Nm
8. Tighten the bolt(12).
9. Insert the washer (21) and tighten the bolts (20) and then
remove the assembly cage (29).
Tightening Torque 23 Nm
Tightening Torque 46 Nm

M162 ENGINE INTAKE & EXHAUST 1G1-3
Removal & Installation Procedure
1. Release the clamp securing HFM sensor and air cleaner.
2. Disengage the air cleaner assembly and HFM sensor
assembly.
3. Unserew the mounting bolt(6) from the bracket.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
4. Release the clamp from air cleaner assembly housing and
remove the cover.
5. Remove the air cleaner assembly.
6. Remove the air cleaner housing from insulator.
Notice
Make sure the air cleaner to be seated in insulator.
7. Disengage the air duct hose and air cleaner housing and
remove the housing.
8. Remove the air duct hose.
9. Unscrew the two bolts(7) from air inlet duct.
Installation Notice
10. Remove the air inlet duct.
11. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 8 - 9 Nm

1G1-6 M162 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
lUpper Intake Manifold
1. Disconnect the vacuum hose (8,9).
2. Loosen the clip (22).
3. Remove the upper intake manifold (5) after unscrewing the
bolt (6).
Installation Notice
Notice
Check the gasket and replace it if necessary.
4. Installation should follow the removal procedure in the
reverse order.
lLower Intake Manifold
Preceding work : removal of upper intake manifold
1. Remove the hose of brake booster vacuum line and idle
speed connector.
2. Disconnect the hot water inlet pipe from the bottom of lower
intake manifold.
3. Unscrew the bolt (17) and remove the lower intake manifold
(16).
Installation Notice
4. Start the engine and check for leaks at each connection
part.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 22.5 - 27.5 Nm

1G1-8 M162 ENGINE INTAKE & EXHAUST
Function Description
A pneumatically actuated resonance flap (5) is located on the
intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled
by ECU and rpm.
1. Resonance flap closed (at idle/partial load : less than
3,800/rpm)
The switch valve (7) will be adjusted by ECU and resonance
falp will be colosed. By increasing air flow passage through
dividing intaking air flow toward both air collection housing
(8). This leads to a signficant increase in the torque in the
lower speed range.
2. Resonance flap open (at full load : over 3,800/rpm)
The switch valve (7) will not be adjusted by ECU and
resonance falp (5) will be open. The colllected air in the air
collection housing (8) will not be divided and intaking air
passage will be shorten.

1G1-10 M162 ENGINE INTAKE & EXHAUST
Tools Required
103 589 01 39 00 Caulking Bolt
Removal & Installation Procedure
1. Remove the flange bolt from the exhaust manifold, and
disconnect the front exhaust pipe.
Installation Notice
Notice
Check for nut damages and replace the nut if necessary.
2. Remove the 23 nuts (1) from the stud bolt, and remove the
exhaust manifold.
Installation Notice
3. Replace the gasket (2).
4. Installation is reverse order of the removal.
Replacement of Rivet Nut
1. Pull out the rivet nut from the connecting point of the exhaust
manifold and the exhaust pipe using a proper bolt (arrow).
2. Insert a new rivet nut into the exhaust manifold hole, and
tighten with a special tool (Caulking Bolt).
Installation Notice
Caulking Bolt 103 589 01 39 00
Tightening Torque 30 Nm
Tightening Torque 26 - 34 Nm
Tightening Torque 30 Nm

M161 ENGINE INTAKE & EXHAUST 1G2-3
Removal & Installation Procedure
1. Release the clamp securing HFM sensor and air cleaner.
2. Disengage the air cleaner assembly and HFM sensor
assembly.
3. Unserew the mounting bolt(6) from the bracket.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
4. Release the clamp from air cleaner assembly housing and
remove the cover.
5. Remove the air cleaner assembly.
6. Remove the air cleaner housing from insulator.
Notice
Make sure the air cleaner to be seated in insulator.
7. Disengage the air duct hose and air cleaner housing and
remove the housing.
8. Remove the air duct hose.
9. Unscrew the two bolts(7) from air inlet duct.
Installation Notice
10. Remove the air inlet duct.
11. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 8 - 9 Nm

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

M161 ENGINE INTAKE & EXHAUST 1G2-9
EXHAUST MANIFOLD
1 Oxygen Sensor..............................49.5-60.5 Nm
2 Bolt (4 pieces)........................................ 9-11 Nm
3 Upper Cover
4 Nut (11 pieces)...............................31.5-38.5 Nm5 Exhaust Manifold
6 Flange Bolt & Exhaust Pipe
Mounting Nut............................................ 30 Nm
7 Gasket ................................................... Replace
Removal & Installation Procedure
1. Remove the oxygen sensor if necessary.
Installation Notice
Tightening Torque 49.5 - 60.5 Nm
2. Unscrew the bolt (2) and remove the exhaust manifold upper
cover (3).
3. Unscrew the flange bolt (6) of front exhaust pipe and
separate the front exhaust pipe.
Installation Notice
Tightening Torque 30 Nm
Notice
Check the exhaust pipe mounting nut, and replace it with
new one if necessary.

1G2-10 M161 ENGINE INTAKE & EXHAUST
4. Unscrew the eleven nuts (4) and remove the exhaust
manifold (5) and gasket (7).
Installation Notice
Tightening Torque 31.5 - 38.5 Nm
5. Replace the gasket (7) with new one.
6. Installation should follow the removal procedure in the
reverse order.