ignition SSANGYONG MUSSO 1998 Workshop Repair Manual

PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedure are essential
for the safe, reliable operation of all motor vehicles, as well as for the
personal safety of the person doing the repair. There are many
variations in procedures, techniques, tools and parts for servicing
vehicles, as well as in the skills of the people doing the work. This
manual cannot possibly anticipate all such variations and provide advice
or precautions for each. Anyone who deviates from the instructions
provided in this manual must ensure their own safety and preserve
the safety and integrity of the vehicle. The following list contains general
precautions that should always be followed while working on a vehicle.
•Safety stands are required whenever a procedure calls for
underbody work.
•Do not smoke when you work on a vehicle.
•To prevent serious burns, do not touch any hot metal parts.
•Set the parking brake when you work on the vehicle.
•Turn the ignition switch OFF unless a procedure states
otherwise.
•The engine may operate only in a well-ventilated area.
•Avoid moving parts when the engine is running.
•Safety glasses must be worn for eye protection.

0B-2 GENERAL INFORMATION
661LA
4Cylinder
DIESEL
89
92.4
2299
22:1
101/4000
21.5/2400 Application
Engine Type
Bore (mm)
Stroke (mm)
Total Displacement (cc)
Compression Ratio
Maximum Power (ps/rpm)
Maximum Torque (kg.m/rpm)
Engine
662NA
5Cylinder
DIESEL
89
92.4
2874
22:1
95/4000
19.6/2400662LA
5Cylinder
DIESEL
89
92.4
2874
22:1
120/4000
25.5/24002.0L DOCH
4Cylinder
GASOLINE
89.9
78.7
1998
9.6:1
135/5500
19.3/40002.3L DOCH
4Cylinder
GASOLINE
90.9
88.4
2295
10.4:1
149/5500
22.4/40003.2L DOCH
6Cylinder
GASOLINE
89.9
84
3199
10:1
222/5500
31.6/3750
661LA
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.4 Application
Ignition Type
Ignition Timing (BOTH)
Ignition Sequence
Spark Plug Gap (mm)
Spark Plug Maker
Spark Plug Type
Ignition System
Clutch - Manual Type
2.0L DOHC
6° ± 2°
1-3-4-2
0.8 ± 0.12.3L DOHC
6° ± 2°
1-3-4-2
0.8 ± 0.12.0L DOHC
8° ± 2°
1-5-3-6-2-4
0.8 ± 0.1 Distributorless Ignition
Bosch, Chapion, Beru
F8DC4(BOSCH)
C11YCC(CHAMPION)
14F8DU4(BERU)
661LA
225
150
9.2
662NA
225
150
9.2662LA
240
150
9.22.0L DOHC
225
150
9.22.3L DOHC
225
150
9.23.2L DOHC
240
155
9.3 Application
Type
Outside Diameter (mm)
Inside Diameter (mm)
Thickness
Fluid
Single Dry Diaphram
Common use :Brake Fluid
Application
Maker
Type or Model
Gear Ratio : 1st
2nd
3rd
4th
5th
Reverse
Final Drive Ratio
Oil Capacity (L)
Manual Transmission
662NA
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.4662LA
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.27
3.42.0L DOHC
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.42.3L DOHC
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.43.2L DOHC
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
3.73
3.4

0B-8 GENERAL INFORMATION
SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)
Engine
Months
MAINTENANCE
ITEMMAINTENANCE INTERVALKilometers or time in months, whichever comes first
120 105 90 75 60 45 30 15 1
96 84 72 60 48 36 24 12 - x1,000 km
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition. Change
engine oil and the filter every 7,500 km or 6 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving condition.
(3) Refer to “Recommended fluids and lubricants”.
Drive belt
Engine oil & filter (1) (3)
Cooling system hose & connections
Engine coolant (3)
Fuel filter (2)
Fuel line & connections
Air cleaner (2)
Ignition timing
Spark plugs
Charcoal canister & vapor linesI
I
I
I
-
I
-
-I
R
I
I
-
I
I
I
I
-I
R
I
I
-
I
I
I
R
-I
R
I
I
-
I
I
I
I
II
R
I
R
R
I
R
I
R
-I
R
I
I
-
I
I
I
-I
R
I
I
-
I
I
I
R
II
R
I
I
-
I
I
I
I
-I
R
I
R
R
I
R
I
R
-

0B-10 GENERAL INFORMATION
SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)
Engine
Months
-
MAINTENANCE
ITEMMAINTENANCE INTERVAL
Kilometers or time in months, whichever comes first
100 90 80 70 60 50 40 30 20 10 1
60 54 48 42 36 30 24 18 12 6 x1,000 km
NOTE 1 :Injection Timing :
Adjust as required :
- When excessive smoke is visible (black or white)
- Poor performance/economy
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition, change
engine oil every 5,000km or 3 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving conditing.
(3) Refer to “Recommended fluids and lubricants”.
Drive belt
Engine oil & fillter (1) (3)
Cooling system hose & connections
Engine coolant (3)
Fuel filter (2)
Fuel line & connections
Glow plug
Pre - fuel filter
Air cleaner (2)
Ignition timing (see NOTE 1)I
R
II
R
I
I
I
I
I
R
I
I
I
I
I
I
II
R
I
I
I
R
II
R
I
R
I
I
I
I
II
R
I
I
I
I
II
R
I
R
I
I
I
R
II
R
I
I
I
I
II
R
I
I
R
I
I
II
R
I
R
I
I
R
II
R
I
I
I
I
I
I
I

SECTION 1
ENGINE
SECTION 1A1(M162 ENGINE)
GENERAL ENGINE INFORMATION
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A1-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A1-1
Component Locator . . . . . . . . . . . . . . . . . . 1A1-3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-3
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-4
Performance Curve . . . . . . . . . . . . . . . . . . 1A1-5
E32 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A1-6
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A1-6
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-7
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A1-7
Engine Cranking at The
Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A1-8
Compression Pressure Test . . . . . . . . . . . . . 1A1-9
Cylinder Pressure Leakage Test . . . . . . . . . 1A1-11
General Information . . . . . . . . . . . . . . . . . 1A1-13
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A1-13
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A1-13
Application
Engine Model
Displacement (CC)
Cylinder (Bore x Stroke) (mm)
Fuel Injection / Ignition System
Compression Ratio
Number of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type
Max. Output (ps/rpm)
Max. Torque (kg•m/rpm)
Firing Order
Ignition Type
Ignition Timing
Valve Timing Intake Open/Close
ExhaustOpen/Close
Valve Clearance Adjustment
SPECIFICATIONS
ENGINE SPECIFICATIONS
E32 Engine
M162.990
3199
89.9 x 84.0
MSE 3.62S
10 : 1
6
DOHC
Chain-Driven
222 / 5500
31.6 / 3750
1-5-3-6-2-4
Distributorless Double Ignition
BTDC 8° ± 2°
ATDC 11° / ABDC 34°
BBDC 31° / BTDC 14°
Automatic Control
TABLE OF CONTENTS

GENERAL ENGINE INFORMATION 1A1-13
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating of
enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop practice
even if not specifically stated.
Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when they were removed.Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.
ON-ENGINE SERVICE
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.
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against
accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.

SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A2-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A2-1
Component Locator . . . . . . . . . . . . . . . . . . 1A2-3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-3
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-4
Performance Curve . . . . . . . . . . . . . . . . . . 1A2-5
E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-5
E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A2-7
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-8
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8
Engine Cranking At The
Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9
Compression Pressure Test . . . . . . . . . . . . 1A2-10
Cylinder Pressure Leakage Test . . . . . . . . . 1A2-12
General Information . . . . . . . . . . . . . . . . . 1A2-14
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
E20 Engine
M161.940
1998
89.9 x 78.7
¬
9.6:1
¬
¬
¬
135 / 5500
19.3 / 4000
¬
¬
¬
ATDC 13.15° / ABDC 13.57°
BBDC 16.58° / BTDC 17.05°
¬ Application
Engine Model
Displacement (CC)
Cylinder (Bore x Stroke) (mm)
Fuel Injection / Ignition System
Compression Ratio
Number of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type
Max. Output (ps/rpm)
Max. Torque (kg•m/rpm)
Firing Order
Ignition Type
Ignition Timing
Valve Timing Intake Open/Close
ExhaustOpen/Close
Valve Clearance Adjustment
SPECIFICATIONS
ENGINE SPECIFICATIONS
E23 Engine
M161.970
2295
90.9 x 88.4
MSE 3.53S
10.4:1
4
DOHC
Chain-Driven
149 / 5500
22.4 / 4000
1-3-4-2
Distributorless
BTDC 6° ± 2°
ATDC 19.25° / ABDC 28.76°
BBDC 20.62° / BTDC 15.08°
Automatic Control

GENERAL ENGINE INFORMATION 1A2-3
COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor
2 Intake Air Duct
3 Cylinder Head Cover
4 Ignition Coil
5 Spark Plug Connector
6 Fuel Distributor
7 Injector
8 Exhaust Camshaft
9 Intake Camshaft
10 Valve Tappet
11 Intake Valve12 Intake Manifold
13 Cylinder Head
14 Exhaust Manifold
15 Dipstick Guide Tube and Gauge
16 Connecting Rod
17 Crankshaft
18 Engine Mounting Bracket
19 Starter
20 Crankcase
21 Oil Pump Sprocket
22 Oil Pan

1A2-14 GENERAL ENGINE INFORMATION
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating of
enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop practice
even if not specifically stated.
Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable be-
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnect-
ing this cable will help prevent personal injury and
damage to the vehicle. The ignition must also be in
LOCK unless otherwise noted.
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against
accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.

Application
Engine Type
Displacement (CC)
Cylinder (Bore x Stroke) (mm)
Fuel Injection / Ignition System
Compression Ratio
Number of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type
Max. Output (ps/rpm)
Max. Torque (kg•m/rpm)
Firing Order
Injection Timing
Valve Timing Intake Open/Close
(at 2mm lift) ExhaustOpen/Close
Valve Clearance Adjustment
SECTION 1
ENGINE
SECTION 1A3(OM600 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A3-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A3-1
Sectional View . . . . . . . . . . . . . . . . . . . . . . 1A3-3
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-3
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-5
Performance Curve . . . . . . . . . . . . . . . . . . 1A3-7
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-7
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A3-9
SPECIFICATIONS
ENGINE SPECIFICATIONS
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A3-9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A3-10
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . 1A3-10
Compression Pressure Test . . . . . . . . . . . . 1A3-11
Cylinder Pressure Leakage Test . . . . . . . . . 1A3-13
General Information . . . . . . . . . . . . . . . . . 1A3-15
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A3-15
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A3-15
OM662LA
Four-Stroke Diesel
2874
89 x 92.4
PES 5 M55 C320 RS 168
22:1
5
SOHC
Chain-Drive
120 / 4000
25.5 / 4000
1-2-4-5-3
BTDC 18°± 10°
ATDC 11.33° / ABDC 17°
BBDC 28° / BTDC 15.25°
Automatic ControlOM661LA
Four-Stroke Diesel
2299
89 x 92.4
PES 5 M55 C320 RS 167
22:1
4
SOHC
Chain-Drive
101 / 4000
21.5 / 2400
1-3-4-2
BTDC 18°± 10°
ATDC 11.33° / ABDC 17°
BBDC 28° / BTDC 15.25°
Automatic Control