ABS SSANGYONG MUSSO 1998 Workshop Repair Manual

GENERAL INFORMATION 0B-3
662LA
MB
W4A040
3.871
2.247
1.436
1.000
5.586
5.38
9 - 9.5
Auto Transmission (MB)
Application
Maker
Type or Model
Gear Ratio : 1st
2nd
3rd
4th
Reverse
Final Drive Ratio
Oil Capacity (L)2.3L DOHC
MB
W4A040
3.871
2.247
1.436
1.000
5.586
4.27
9 - 9.53.2L DOHC
MB
W4A040
3.871
2.247
1.436
1.000
5.586
3.73
9 - 9.5
661LA
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
5.38
9
Auto Transmission (BTRA)
Application
Maker
Type or Model
Gear Ratio : 1st
2nd
3rd
4th
Reverse
Final Drive Ratio
Oil Capacity (L)662LA
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
4.89
92.3L DOHC
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
5.86
93.2L DOHC
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
4.89
9
Tire and Wheel
Specifications
P235/75 R15, 255/70 R15
7JJ ´ 15
30 Psi
30 Psi
30 Psi
30 Psi Application
Standard Tire Size
Standard Wheel Size
Inflation Pressure At Full Lode
P235 / 75 : Front
Rear
P255 / 75 : Front
Rear Application
Booster Size
Master Cylinder Diameter (mm)
Booster Ratio
Front Brake : Disc Type
Rear Brake : Disc Type
Specifications
8inch + 9inch
7inch + 8inch
8inch + 9inch
f 25.4
5.6 : 1
Ventilated
Solid
Brake
non-ABS
ABS 5.0
ABS 5.3

SECTION 1B2
M161 ENGINE MECHANICAL
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 . . . . . . . . . . . . . . . . . . . . . . . 1B2-2
Fastener Tightening Specifications . . . . . . . . 1B2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B2-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B2-4
Maintenance and Repair . . . . . . . . . . . . . . 1B2-9
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B2-9
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B2-9
Crankcase Ventilation System . . . . . . . . . . 1B2-17
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-21
Power Steering Pump and A/C Bracket . . . 1B2-22
Hydraulic Engine Mounting Insulator . . . . . . 1B2-25
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-28
Tensioning Deivce . . . . . . . . . . . . . . . . . . . . 1B2-30
Tensioning Device Shock Absorber . . . . . . 1B2-31
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B2-32
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B2-35
Cylinder Head Front Cover . . . . . . . . . . . . . 1B2-37
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B2-39
Timing Gear Case Cover . . . . . . . . . . . . . . 1B2-44
Crankshaft Sealing Rear Cover . . . . . . . . . 1B2-47
Belt Pulley and Vibration Damper . . . . . . . . 1B2-49
Crankshaft Front Radial Seal . . . . . . . . . . . 1B2-52
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B2-53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-54
Flywheel/Driven Plate . . . . . . . . . . . . . . . . . 1B2-60
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B2-62
TABLE OF CONTENTS
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B2-65
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-66
Camshaft Timing Position . . . . . . . . . . . . . . 1B2-69
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B2-72
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B2-76
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B2-77
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B2-80
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B2-85
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B2-86
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B2-87
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B2-88
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-90
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B2-93
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-95
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-97
Engine Oil and Oil Filter Element . . . . . . . . 1B2-99
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-101
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B2-103
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B2-104
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B2-105
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B2-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B2-106
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B2-108
Crankcase Mating Surface . . . . . . . . . . . . 1B2-110
Cylinder Head Mating Surface . . . . . . . . . 1B2-112

1B2-30 M161 ENGINE MECHANICAL
TENSIONING DEVICE
Preceding Work : Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) +
Washer ..........................................22.5-27.5 Nm
2 Bolt (M8 x 25, 1 pieces) +
Washer ..........................................22.5-27.5 Nm
Removal & Installation Procedure
1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in tensioning
arm.
3. Unscrew the bolts (1, 2) and remove the tensioning device.
Installation Notice
4. Installation should follow the removal procedure in the
reverse order.3 Tensioning Device
4 Stud bolt
5 Tensioning Arm
Tightening Torque 22.5 - 27.5 Nm

M161 ENGINE MECHANICAL 1B2-31
TENSIONING DEVICE SHOCK ABSORBER
1 End Cover
2 Nut .................................................40.5-49.5 Nm
3 Tensioning Pulley
4 Bolt (M8 X 25) + Washer................22.5-27.5 Nm
Removal & Installation Procedure
1. Remove the end cover (1).
2. Remove the nut (2) and remove the tensioning pulley (3).
Installation Notice5 Tensioning Device
6 Bolt (M8 X 35) + Washer................22.5-27.5 Nm
7 Shock Absorber
Tightening Torque 40.5 - 49.5 Nm
3. Unscrew the bolts (4,6) and remove the shock absorber
(7).
Installation Notice
Tightening Torque 22.5-27.5 Nm

1D2-12 M161 ENGINE COOLING
THERMOSTAT HOUSING ASSEMBLY
Preceding Work : Removal of viscous clutch
1a Bolt (M6 X 95, 2 pieces)......................... 9-11 Nm
1b Bolt (M8 X 75, 2 pieces).................22.5-27.5 Nm
1c Bolt (M8 X 35, 1 piece)...................22.5-27.5 Nm
2 Thermostat Housing Assembly
3 O-ring4 De-aeration Hose
5 Coolant Outlet Hose
6 Coolant Bypass Hose
7 Tensioning Device Shock Absorber
8 Engine Hanger Brocket

M161 ENGINE COOLING 1D2-13
Removal & Installation Procedure
1. Drain the coolant.
2. Remove the de-aeration hose (4), coolant outlet hose (5)
and coolant bypass hose (6).
3. Disconnect the coolant temperature sensor connector.
4. Unscrew the bolt (1c) and pry off the tensioning device shock
absorber (7).
Installation Notice
6. Replace the O-ring with new one.
7. Installation should follow the removal procedure in the
reverse order.
8. Check for leaks in cooling system. 5. Unscrow the bolts (1a, 1b) and remove the engine
hanger bracket and thermostat housing.
Installation Notice
Tightening Torque9 - 11 Nm
22.5 - 27.5 Nm
(1a)
(1b)
Tightening Torque 22.5 - 27.5 Nm

1F1-6 M162 ENGINE CONTROLS
DIAGNOSIS
SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS
1 Ground
2 Ignition 1
3 Battery Power Supply (Fuse NO.17)
4 REKES :PIN 6
5 Engine Speed Signal :MSE PIN 60
6 TCCU(Part-time)
7 STICS(PIN 26)
8-
9-
10 Air Bag(PIN 20)11 Remote Engine Start Unit(PIN 10)
12 -
13 Brake System
(ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46)
14 MSE 3.62S/3.53S(ECU Data Output:PIN 58)
15 TOD(PIN 20)
1 6 Immobilizer
17 -
1 8 TCU(PIN 23)
19 -
2 0 K-LINE(ECS:PIN 23)

M162 ENGINE CONTROLS 1F1-19
Failure
codeItem
Þ 22.1
Checking method Test
stepRequirementSpecified
valuePossible cause
38 37115 - 125 W
· ·· ·
· CAN module
resistance in
ABS, ABD,
ASR control
unit· Cable
· ABS, ABD, ASR
control unit
· Ignition:OFF
- disconnect the
coupling "No.1" from
ECU.
Þ 22.2
38 37115 - 125 W
· ·· ·
· CAN module
resistance in
ECU control
unit· ECU· Ignition:OFF
- disconnect the
coupling "No.1" from
ECU.
Þ 23.0
55811 - 14 V· ·· ·
· Diagnosis
cable
operating· ECU
· Cable
· Ignition:ON
22,23,
24,26,
27,29,
30,31,
59,60,

M162 ENGINE CONTROLS 1F1-45
Removal & Installation Procedure
lwhen removing the ECU only
1. Turn the ignition switch to "OFF" position.
2. Disconnect the negative battery cable.
3. Disconnect the couplings from ECU.
4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly
bracket and remove the auxiliarly bracket from the bracket
assembly (2).
Installation Notice
5. Unscrew the four bolts (5) and disconnect the ECU (6) from
the bracket assenbly.
Installation Notice
6. Installation should follow the removal procedure in the
reverse order.
Tightening Torque6 - 8 Nm
5 - 7 Nm(1)
(3)
Tightening Torque 5 - 7 Nm
8. Unscrew the bolts (5) and disconnect the ECU (6) from the
bracket assenbly.
Installation Notice lWhen Removing the ECU with ABS or ABS/ASR Unit
1. Turn the ignition switch to "OFF" position.
2. Disconnect the negative battery cable.
3. Disconnect the couplings from ECU.
4. Disconnect the coupling from ABS or ABS/ASR unit.
5. Unscrew the bolt (1) and the left and right flange nuts.
6. Remove the ECU with ABS or ABS/ASR unit assembly.
7. Unscrew the left and right bolt (3) on the auxiliary bracket
and remove the auxiliary bracket from the bracket assembly.
Installation Notice
Tightening Torque 6 - 8 Nm
Tightening Torque 5 - 7 Nm
Tightening Torque 5 - 7 Nm
9. Installation should follow the removal procedure in the
reverse order.

1F1-62 M162 ENGINE CONTROLS
PURGE SWITCHOVER VALVE
1 Purge Switchover Valve
2 Line to Engine
3 Line to Canister
4 Canister
Functions
The fuel vaporization control system is installed to inhibit the
fuel vaporized gas from discharging into the atmosphere. The
fuel vaporized gas that is accumulated in the canister abstracts
through the purge switchover valve purification during the
engine combustion (except the decreasing mode) and coolant
temperature of over 80°C. For this reason, the ECU transacts
the engine speed, air inflow quantity, coolant temperature, and
intake temperature.
The purge switchover valve is activated by the ECU frequency
according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the
continuous valve opening interval.
The purge switchover valve is activated by the ECU for the
following conditions :
lCoolant temperature of over 80°C
lEngine speed of over 1000rpm
l2 Minutes after starting
lWhen the fuel cut-off mode is not activated