brake SSANGYONG MUSSO 2003 User Guide

1B1-14 M162 ENGINE MECHANICAL
Tightening Torque 30 Nm
29. Remove the exhaust manifold and exhaust pipe.
Installation Notice
25. Separate the vacuum hose for brake booster.
26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.Installation Notice
28. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate.
Tightening Torque 81 - 89 Nm

M161 ENGINE MECHANICAL 1B2-15
Tightening Torque 30 Nm
29. Remove the exhaust manifold and exhaust pipe.
Installation Notice
25. Separate the vacuum hose for brake booster.
26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.Installation Notice
28. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate.
Tightening Torque 81 - 89 Nm

OM600 ENGINE MECHANICAL 1B3-17
26. Disconnect the starter motor wires and remove the startermotor.
21. Remove the fuel lines from the fuel filter and cover thefilter with plug.
22. Disconnect the brake booster hose from vacuum pump.
23. Disconnect the other vacuum lines.
24. Disconnect the ground cable.
25. Disconnect the alternator wires.

1F1-6 M162 ENGINE CONTROLSDIAGNOSIS
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 -
18 TCU(PIN 23)
19 -
2 0 K-LINE(ECS:PIN 23)

1F1-38 M162 ENGINE CONTROLS
Pin No.Abbreciation
Decription
21 222324252627282930313233343536373839404142434445464748495051525354555657585960 BRS
-----
KLIKU ---
GND
SP1+5V KP
TEV ML -
CAN L
CAN H -- - -
KPI
KLIMAKLIMA -
SP1SSP2S BLS
GND
SP2+2.5V S+BWA
S-B
KSK -
AUS
DIAG
V-SIG
TN-SIG
Brake switch-----Air conditioning clutch relay---Pedal potentiometer 1 groundPedal potentiometer 1 supplyFuel pump relay
Tank purge valveEngine fan (H1)-CAN-LowCAN-High-- - -Clutch switchAir conditioningElectronic traction signal-Pedal potentiometer 1 signalPedal potentiometer 2 signalBrake light switchPedal potentiometer 2 groundPedal potentiometer 2 supplyCruise accelerate/SetCruise resumeCruise decelerate/SetCruise safety contact switch-Cruise off switchDiagnostics (k-line)
Vehicle speed signalEngine speed signal

M162 ENGINE CONTROLS 1F1-41
Application
Pin No.Description
- Starter motor TM.50- - Electronic ground--- Lambda probe 1 heating Power ground TM.31
V-BATTERY TM.87
V-BATTERY TM.30Immobilizer crypto read Immobilizer crypto write -Lambda probe 1 groundLambda probe 1 signal- - -Brake switch-- - --Air conditioning clutch relay- - -1 23 4 5678 9
10 11
12 13 14 15161718 19 20212223 24 25262728 29 30-
TM.50 - -
GND - --
LSH1
TM.31TM.87TM.30
WFS I/O WFS O
-
GND LS1 - - -
BRS -- - --
KLIKU - - - -
--
-- -





-

- - -
-- - --
- - - -
- -
- --






-

- - -
-- - --
- - -
: Standard, : Option Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

1F1-42 M162 ENGINE CONTROLS
Pin No.Description
Pedal potentiometer 1 ground Pedal potentiometer 1 supplyFuel pump relay
Tank purge valve Engine fan -CAN-LowCAN-High - - --Clutch switchAir conditioning Electronic traction signal(ABD) -Pedal potentiometer 1 signalPedal potentiometer 2 signalBrake light switchPedal potentiometer 2 ground Pedal potentiometer 2 supply Cruise accelerate/SetCruise resumeCruise decelerate/SetCruise safety contact switch - Cruise off switchDiagnostics(K-line)
Vehicle speed signalEngine speed signal31 323334 35 363738 39 40 41424344 45 4647484950 51 52535455 56 57585960GND
SP1+5V KP
TEV ML
-
CAN L
CAN H
- - --
KPL
KLIMA ETS
-
SP1SSP2S BLS
GND
SP2+2.5V
S+BWA
S-B
KSK -
AUS
DIAG
V-SIG
TN-SIG




-

- - --


-







-







-

- - --


-







-


Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

OM600 ENGINE CONTROLS 1F3-13
VACUUM PUMP Preceding Work : Remove the poly V-belt
1 Bolt............................................................ 10Nm
2 Vacuum Pump
3 Vacuum Line (Ancillaries) 4 Vacuum Line (Brake Booster)
5 Gasket ................................................... Replace

1G1-6 M162 ENGINE INTAKE & EXHAUST Removal & Installation Procedure
Upper Intake Manifold
1. Disconnect the vacuum hose (8,9).
2. Loosen the clip (22).
3. Remove the upper intake manifold (5) after unscrewing the bolt (6). Installation Notice Notice
Check the gasket and replace it if necessary.
4. Installation should follow the removal procedure in the reverse order.
Lower Intake ManifoldPreceding work : removal of upper intake manifold
1. Remove the hose of brake booster vacuum line and idle speed connector.
2. Disconnect the hot water inlet pipe from the bottom of lower intake manifold.
3. Unscrew the bolt (17) and remove the lower intake manifold (16). Installation Notice
4. Start the engine and check for leaks at each connection part.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 22.5 - 27.5 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