161 SSANGYONG MUSSO 2003 Service Manual

1G2-4 M161 ENGINE INTAKE & EXHAUST
AIR INTAKE SHIELD Preceding Work : Removal of air cleaner
Removal & Installation Procedure
1. Remove the upper cover (3) from the air intake shield (5)upper mounting pin.
2. Remove the bolts (4 and 6).
3. Remove the air intake shield (5).
4. Installation should follow the removal procedure in the reverse order.
1 Air Cleaner
2 Gasket
3 Air Intake Shield Upper Cover
4 Bolt
5 Air Intake Shield
6 Bolt
7 Bracket

M161 ENGINE INTAKE & EXHAUST 1G2-5
INTAKE AIR DUCT
1 Clamp
2 Sleeve
3 HFM Sensor
4 Intake Air Duct
5 Blow-by Hose
7 Clamp(2 pieces)
8 Intake Air Duct MountingBracket
Removal & Installation Procedure
1. Release the clamp (1) and intake air duct.
2. Remove the Blow-by hose (5) (arrow).

1G2-6 M161 ENGINE INTAKE & EXHAUST
3. Release the clamp (7) and remove the intake air duct.Notice Completely fit the intake air duct with the mounting bracket (8).

M161 ENGINE INTAKE & EXHAUST 1G2-7
INTAKE MANIFOLD Preceding Work : Removal of intake air duceRemoval of fuel distributor and injector
1 Bolt (M6 X 40, 6 pieces) .................22.5-27.5 Nm
2 Intake Manifold
3 Gasket (2 pieces) .................................. Replace
4 Bolt (M8 X 40, 3 pieces) .................22.5-27.5 Nm 5 Idle Regulator
6 Intermediate Flange
7 Bolt (M6 X 35, 4 pieces)
......................... 9-11 Nm
8 Connection Piece With Seal Ring ........ 36-44 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 othervacuum 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 regulatorand 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 Nm 5 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 exhaustmanifold (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.

M161 ENGINE INTAKE & EXHAUST 1G2-11
Removal and Installation of Exhaust Line
1 Heat Protector-Floor
2 Pipe Assembly-Front Exhaust
3 Gasket
4 Heat Protector-Rear Exhaust5 Road Assembly-Muffler Mounting Rear
6 Heat Pro-Tector Dash
7 Heat Pro-Tector Floor
8 Heat Pro-Tector Rear Exhaust

Diesel Gasoline (M161) Gasoline (M162)
Diesel Gasoline
Application
Joint Type Number of Spider Front FrontRear Front Rear
Front (Full-Time)
Front (Part-Time)Rear Front Rear
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 General Specifications . . . . . . . . . . . . . . . . . . 3C-1
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2 M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2 Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
3C-3
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
Single or Single & Double Cardan Single Cardan
Constant Velocity(CV) & Double Carden Single Cardan
3 22
CV Joint : 1, Double Spiders : 1 2
Diesel Gasoline
Shaft Dimensions (L×O.D ×I.D)
When CompressedFully FrontRearFrontRear Front Rear- --M/T & MB A/T
BTRA A/T (2p-Type) TONGIL KSC-
576
×59.5 ×63.5
973 ×
63.5 ×659.5
583.5 ×
44.7×50.8
973 ×
63.5 ×459.5
380.8 ×
63.5×59.5
591.5 ×
63.5×59.5
601.6 ×
50.8×44.7
579.6 ×
50.8×44.7
776.8 ×
63.5×59.5

ANTILOCK BRAKE SYSTEM 4F-15
Description
Check each valve by using SCANNER's solenoid valve overriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check each valve by using SCANNER's solenoid valveoverriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short. (When connector is removed)
Replace the hydraulic modulator.
Check each valve by using SCANNER's solenoid valve overriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short. (When connector is removed)
Replace the hydraulic modulator.
Check each valve by using SCANNER's solenoid valve overriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short.(When connector is removed)
Replace the hydraulic modulator.
Check each valve by using SCANNER's solenoid valveoverriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short.(When connector is removed)
Replace the hydraulic modulator.
Check each valve by using SCANNER's solenoid valveoverriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short.(When connector is removed)
Replace the hydraulic modulator.
Check each valve by using SCANNER's solenoid valveoverriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short.
Application
Front / left INLET Valve
Front / left OUTLET Valve
Front / right INLET Valve
Front / right OUTLET Valve
Rear / left INLET Valve (ABD)
Rear / left OUTLET Valve
Rear / Right INLET ValveDefect Code
13 14 15 1617 18 19