maintenance SSANGYONG MUSSO 2003 Owner's Guide

1F3-2 OM600 ENGINE CONTROLS
FUEL SYSTEM
1 Fuel Injection Pump
2 Fuel Feed Pump
3 Overflow Valve
4 Injection Nozzle
5 Pre-filter 6 Fuel Return Hose
7 Injection Line
8 Fuel Tank
9 Fuel Filter
10 Choke Orifice
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE

SECTION 1G1
M162 ENGINE INTAKE & EXHAUST
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G1-1Fastener Tightening Specifications . . . . . . . . 1G1-1
Maintenance and Repair . . . . . . . . . . . . . . 1G1-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G1-2
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G1-2
TABLE OF CONTENTS
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G1-4
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G1-5
Resonance Flap . . . . . . . . . . . . . . . . . . . . . . 1G1-7
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G1-9
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N m
9 - 11
22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 28 28 - 47
Application
Air Cleaner Housing Cover NutIntake Manifold Bolt (M8 x 20) Intake Manifold Bolt (M8)Exhaust Mainfold Stud BoltExhaust Pipe Nut (Engine) Exhaust Pipe Bolt

1G1-2 M162 ENGINE INTAKE & EXHAUSTMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AIR CLEANER
1 Air - Cleaner Assembly
2 Air - Cleaner Shield Upper Cover
3 Blot4 Blot
5 Air Intake Shield

SECTION 1G2
M161 ENGINE INTAKE & EXHAUST
TABLE OF CONTENTSSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N m
9 - 11
22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 28 28 - 47
Application
Air Cleaner Housing Cover NutIntake Manifold Bolt (M8 x 20) Intake Manifold Bolt (M8)Exhaust Mainfold Stud BoltExhaust Pipe Nut (Engine) Exhaust Pipe Bolt
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G2-1 Fastener Tightening Specifications . . . . . . . . 1G2-1
Maintenance and Repair . . . . . . . . . . . . . . 1G2-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G2-2
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G2-2Air Intake Shield . . . . . . . . . . . . . . . . . . . . . .
1G2-4
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G2-5
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G2-7
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G2-9

1G2-2 M161 ENGINE INTAKE & EXHAUSTMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AIR CLEANER
1 Air Cleaner Assembly
2 Element Assembly
3 Insulator
4 Air Duct Hose5 Air Inlet Duct
6 Bolt (M8 × 30 ) ................................... 22.5-27.5 Nm
7 Bolt (M6 × 35 ) ........................................... 9-11 Nm

SECTION 1G3
OM600 ENGINE INTAKE & EXHAUST
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G3-1Fastener Tightening Specifications . . . . . . . . 1G3-1
Schematic and Routing Diagrams . . . . . . . 1G3-2 EGR Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-2
Maintenance and Repair . . . . . . . . . . . . . . 1G3-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1G3-3 TABLE OF CONTENTS
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 otherwisenoted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Air Cleaner Housing Cover Nut Intake Manifold Bolt (M8 x 20)Intake Manifold Bolt (M8)Exhaust Mainfold Stud BoltExhaust Pipe Nut (Engine) Exhaust Pipe Bolt
N 

 m
9 - 11
22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 2828 - 47
Air Cleaner and Inlet Duct & Hose . . . . . . . . 1G3-3
Intake and Exhaust Manifold . . . . . . . . . . . . . 1G3-5
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 1G3-8
Charge Air System Diagram . . . . . . . . . . . . . 1G3-8
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-9
Turbocharger Assembly . . . . . . . . . . . . . . . 1G3-11

OM600 ENGINE INTAKE & EXHAUST 1G3-3
AIR CLEANER AND INLET DUCT & HOSEMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
1 Air Intake Shield Assembly
2 Air Cleaner Assembly
3 Mounting Bracket
4 Air Cleaner Element ...........Clean : 20,000km
Replace : 60,000km 5 Bolt
......................................................... 9-11Nm
6 House
7 Clamp
8 Engine Cover Assembly (Turbo)
9 Mounting Bracket

SECTION 2B
WHEEL ALIGNMENT
TABLE OF CONTENTSSPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
Application CamberCaster
Toe-in
King Pin Inclination Description
0° ± 30'
2 °30' ± 30'
0 - 4 mm 12 °30'
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Wheel Alignment Specifications . . . . . . . . . . . 2B-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Tire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Radial Tire Lead/Pull . . . . . . . . . . . . . . . . . . . 2B-3
Vibration Diagnosis . . . . . . . . . . . . . . . . . . . . . 2B-5
Maintenance and Repair . . . . . . . . . . . . . . . 2B-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 2B-6Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . 2B-6
General Description and System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Four Wheel Alignment . . . . . . . . . . . . . . . . . . 2B-9
Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9

2B-6 WHEEL ALIGNMENT
MAINTENANCE AND REPAIR ON VEHICLE SERVICE WHEEL ALIGNMENT
Vehicle Height
1. Check the tire for proper inflation.
2. Measure ‘A’ from the center of the lower arm rear mounting
bolt end to the ground.
3. Measure ‘B’ from the center of the steering knuckle shaft to the ground.
4 . If the dif ference between ‘A’ and ‘B’ is not within specification,
adjust vehicle height using torsion bar height control bolt.
‘B’ - ‘A’
Notice Before wheel alignment, adjust vehicle height first.31 - 36mm
Toe-in
1. Measure toe-in.
Specification0 - 4mm
2. If toe-in is not within specification, loosen the tie rod nuts and adjust it by turning the tie rod.

SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTSSPECIFICATIONS
GENERAL SPECIFICATIONS
Type
Spring Type
Torsion Bar Shock Absorber
Stabilizer Type
Double Wishbone
Torsion Bar Spring 1,040 mm
24.5 mm
Cylindrical Reciprocation Type
Torsion Bar Spring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-1General Specifications . . . . . . . . . . . . . . . . . . 2C-1
Fastener Tightening Specifications . . . . . . . . . 2C-2
Component Locator . . . . . . . . . . . . . . . . . . . 2C-3
Front Suspension . . . . . . . . . . . . . . . . . . . . . . 2C-3
Maintenance and Repair . . . . . . . . . . . . . . . 2C-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2C-4
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . 2C-4
Application Description
Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Front Lower and Upper Arm . . . . . . . . . . . . . . 2C-8
Front Shock Absorber . . . . . . . . . . . . . . . . .
2C-10
Axle Vertical Acceleration Sensor (Wheel G Sensor) . . . . . . . . . . . . . . . . . . . 2C-12
Vertical and Lateral Sensor . . . . . . . . . . . . . . 2C-13
ECS (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-14
Length Outer Diameter(
)