SSANGYONG MUSSO 1998 Workshop Repair Manual

SECTION 1E2
M161 ENGINE ELECTRICAL
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E2-1
Alternator Specifications . . . . . . . . . . . . . . . . 1E2-1
Starting Motor Specifications . . . . . . . . . . . . 1E2-2
Battery Specifications . . . . . . . . . . . . . . . . . . 1E2-2
Fastener Tightening Specifications . . . . . . . . 1E2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1E2-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1E2-3
Maintenance and Repair . . . . . . . . . . . . . . 1E2-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1E2-4
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-4
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 1E2-5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-6
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-7
Ignition Cable . . . . . . . . . . . . . . . . . . . . . . . . 1E2-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 1E2-12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-12
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.
TABLE OF CONTENTS
SPECIFICATIONS
ALTERNATOR SPECIFICATIONS
Application
Output Voltage
Current
Resistance Between Rotor Core and Slip RingDescription
12 - 14 V
115 A
¥ W

1E2-2 M161 ENGINE ELECTRICAL
N·m
14 - 18
4 - 5
45 - 50
12 - 15
6 - 7
35 - 48
12 - 18
12 - 18
12 - 18
9 - 11
9 - 11
25 - 30
STARTING MOTOR SPECIFICATIONS
Application
Voltage
Output PowerDescription
12 V
1.2 KW
BATTERY SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Capacity
Specific Gravity
Max. Tolerance Between CellsDescription
90 Ah
³ 1.24
³ 0.04
Application
Alternator Terminal B+Nut
Alternator Terminal D+Nut
Alternator Combinction Bolt
Battery Cable Nut on Starting Motor
Electric Wire Nut on Starting Motor
Starting Motor Mounting Nut
Battery Mounting Bracket Nut
Battery Negative Cable
Battery Positive Cable
Ignition Cable Cover Bolt
Ignition Cable Bolt
Spark plug

M161 ENGINE ELECTRICAL 1E2-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
120 589 02 09 00
Spark Plug Wrench

1E2-4 M161 ENGINE ELECTRICAL
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ALTERNATOR
Preceding Work : Removal of the drivebelt
Removal & Installation Procedure
1. Disconnect the negative battery terminal.
2. Unscrew the nut and disconnect the terminal (1).
Installation Notice
1 Terminal (B+)
2 Terminal (D+)
3 Combination Bolt
4 Alternator
3. Unscrew the nut and disconnect the terminal (2).
Installation Notice
Tightening Torque 14 - 18 Nm
4. Unscrew the combination bolt (3).
Installation Notice
Tightening Torque 4 - 5 Nm
5. Remove the alternator.
6. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 42 - 50 Nm

M161 ENGINE ELECTRICAL 1E2-5
3 Fixing Bolt
4 Starting Motor
4. Unscrew the mounting bolts (3) of starting motor.
Installation Notice
5. Remove the starting motor.
6. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 35 - 48 Nm
STARTING MOTOR
Removal & Installation Procedure
1. Disconnect the ground cable.
2. Unscrew the nut and disconnect the battery cable(1).
Installation Notice
1 Battery Cable
2 Engine Electric Wire
3. Unscrew the nut and disconnect the engine electric wire
(2).
Installation Notice
Tightening Torque 12 - 15 Nm
Tightening Torque 6 - 7 Nm

1E2-6 M161 ENGINE ELECTRICAL
BATTERY
1 Cable Terminal (-)
2 Cable Terminal Cap (-)
3 Cable Terminal Cap (+)
4 Nut
5 Fuseblink Box
6 Terminal (+)7 Battery holddown Bracket
8 Battery Clamp Bolt
9 Battery
10 Sub Tray
11 Battery Tray
Removal & Installation Procedure
Notice
lDisconnect the battery negative cable first.
lInsert the clamp bolt (8) into the battery tray hole (11)
from inside when installing.

M161 ENGINE ELECTRICAL 1E2-7
SPARK PLUG
Preceding Work : Removal of intake air duct
Tools Required
119 589 01 09 00 Spark Plug Wrence1 Screw (3 pieces).................................. 9 - 11 Nm
2 Adaptor (3 pieces)
3 Ignition Coil Cable Cover
4 Spark Plug Connector
5 Ignition Coil Connector6 Bolts (M6 X 25, 4 pieces)..................... 9 - 11 Nm
7 Ignition Coil (T1/1)
8 Coupling Plug
9 Spark Plug......................................... 25 - 30 Nm
10 Ignition Coil (T1/2)

1E2-8 M161 ENGINE ELECTRICAL
Tightening Torque 9 - 11Nm
Replacement Procedure
1. Unscrew the three screws(1) and remove the ignition coil
cable cover
Installation Notice
Tightening Torque
Clearance25 - 30 Nm
0.8 + 0.1 mm
2. Disconnect the cable from ignition coil and spark plug.
4. Using the special tool, remove the spark plug .
Installation Notice
Spark Plug Wrench 119 589 01 09 00
Notice
lTighten the spark plug with specified torque.
lInstall the ignition coil to number 2 and 4 cylinder, and
connect the cable to number 1, 4 and 2, 3 cylinder
- T1/1 : cylinder 1 and 4
- T1/2 : cylinder 2 and 3
3. Unscrew two bolts(M6 X 25) from each ignition coil and
remove the ignition coil(arrow) .
Installation Notice
Tightening Torque 9 - 11Nm

M161 ENGINE ELECTRICAL 1E2-9
IGNITION CABLE
Preceding Work : Removal of intake air duct
1 Control Cable Connection
2 Ignition Cable
3 Spark Plug Connector
4 Coupling Plug5a, 5b Secondary Voltage Connection
E Iron Core
L1 Secondary Ignition Coil
L2 Primary Ignition Coil

1E2-10 M161 ENGINE ELECTRICAL
Ignition Cable and Cable Lay-out
1. Firing Order : 1-3-4-2
2. T1/1 : Connect the cylinder 1 + 4
3. T1/2 : Connect the cylinder 2 + 3
Removal & Installation Procedure
1. Disconnect the battery negative cable.
2. Unscrew the 3 screws and remove the ignition cable duct
cover.
Installation Notice
3. Seperate the cable from the ignition cable and the spark
plug.
4. Remove the 2 bolts from each ignition cable and remove
the ignition cables.
Installation Notice
Install the ignition cable to the cylinder 2 and 4 and connect
the cable from 1 to 4, and from 2 to 3.
- T1/1 : Cylinder 1 and 4
- T1/2 : Cylinder 2 and 3
5. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 11 Nm