torque SSANGYONG MUSSO 2003 Service Manual

1E1-4 M162 ENGINE ELECTRICALMAINTENANCE 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

M162 ENGINE ELECTRICAL 1E1-5
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

1E1-8 M162 ENGINE ELECTRICAL
Tools Required 120 589 09 00 Spark Plug Wrench Replacement Procedure
1. Remove the seven bolts (2) and remove the ignition cablecover. Installation Notice
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 11 Nm
2. Remove the two bolts (M6 X 25) from each ignition cableand remove the ignition cable. Installation Notice
3. Remove the spark plug using the special tool. Installation Notice
Spark Plug Wrench 120 589 02 09 00

1E1-10 M162 ENGINE ELECTRICAL Functions
1. Firing order : 1-5-3-6-2-4
2. The ignition cables are located on the cylinder head cover.Each ignition coil provides the high voltage to two spark
plugs simultaneously.
- T1/1 : cylinder 2 and 5
- T1/2 : cylinder 3 and 4
- T1/3 : cylinder 1 and 6
Removal & Installation Procedure
1. Disconnect the negative battery cable (1).
2. Remove the ignition cable connector from the ignition cable.
3. Disconnect the secondary spark plug connectors from the each spark plugs and remove the ignition cable. Installation Notice
3. The secondary output voltage (5a) is supplied to the No.2
cylinder spark plug through the spark plug connector. The secondary output voltage (5b) is supplied to the No.5 cylinderspark plug through the ignition cable. The guide pin (W)acts as a ground while the ignition cable is operated.
Make sure that the ignition cables are correctly routed.
Exactly install the ignition cable guide pin into the vehicle
to be grounded.
4. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm

1E2-4 M161 ENGINE ELECTRICALMAINTENANCE 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

1E2-8 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
Clearance 25 - 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
Tighten the spark plug with specified torque.
Install 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

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 ductcover. 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

OM600 ENGINE ELECTRICAL 1E3-5
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the nut (2).
3. Remove the glow plug (4).
4. Install the glow plug (4).
5. Tighten the nut (2).
Tightening Torque 20 Nm
Tightening Torque 4 Nm

OM600 ENGINE ELECTRICAL 1E3-7
Removal & Installation Procedure
1. Disconnect the negative terminal of the battery.
2. Disconnect the plug connection (5).
3. OM 662 EngineAlign the groove of cooling fan with bolt (2) (arrow).
4. Remove the bolts (2, 3) and take out the alternator.
5. Installation should follow the removal procedure in the reverse order.
Tightening Torque 45 Nm