maintenance SSANGYONG MUSSO 1998 Workshop Owner's Guide

1F2-34 M161 ENGINE CONTROLS
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ECU
Appearance
1 Cover
2 Plate
3 Connector
4 Flat pin
Vehicle side : number 1 - 12
Engine side : number 61 - 725 Pin
Vehicle side : number 13 - 60
Engine side : number 73 - 120
A Vehicle Connector : Black
B Engine Connector : Gray

M161 ENGINE CONTROLS 1F2-55
Removal & Installation Procedure
1. Remove the O-ring.
Check for damage and replace it if necessary.
2. Remove the injector bracket from the injector.
Installation Notice
Exactly seat the anti-twist lock into the square groove in
injector.
3. Separate the injector from the fuel distributor.
Inspection & Maintenance
Inspection of the Injector operation and spray pattern
1. Connect the contact box to the ECU.
2. Connect the shop made test plug to the injector and place
it into the tank.
3. Position the ignition switch to ON.
4. Connect the pin 63(+) and 69(-) of the contact box with a
test cable.
5. Check the injector spray pattern.
Notice
Replace the injector if the injector spray pattern is abnormal
or the fuel doesn't inject.
Injector Resistance Inspection
1. Remove the injector connector.
2. Measure the injector coil resistance using a resistance
tester.
Notice
Replace the injector if the measured values is out of the
specified values. Check the connector and wire connection
between the ECU and the injector if the measured values
are normal.
Specified Value
14 - 17 W

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

1F3-2 OM600 ENGINE CONTROLS
FUEL SYSTEM
1 Fuel Injection Pump
2 Fuel Feed Pump
3 Overflow Valve
4 Injection Nozzle
5 Pre-filter6 Fuel Return Hose
7 Injection Line
8 Fuel Tank
9 Fuel Filter
10 Choke Orifice
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE

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