1998 SSANGYONG MUSSO check engine

1G1-10 M162 ENGINE INTAKE & EXHAUST
Tools Required
103 589 01 39 00 Caulking Bolt
Removal & Installation Procedure
1. Remove the flange bolt from the exhaust manifold, and
disconnect the front exhaust pipe.
Installation Notice
Notice
Check for nut damages and replace the nut if necessary.
2. Remove the 23 nuts (1) from the stud bolt, and remove the
exhaust manifold.
Installation Notice
3. Replace the gasket (2).
4. Installation is reverse order of the removal.
Replacement of Rivet Nut
1. Pull out the rivet nut from the connecting point of the exhaust
manifold and the exhaust pipe using a proper bolt (arrow).
2. Insert a new rivet nut into the exhaust manifold hole, and
tighten with a special tool (Caulking Bolt).
Installation Notice
Caulking Bolt 103 589 01 39 00
Tightening Torque 30 Nm
Tightening Torque 26 - 34 Nm
Tightening Torque 30 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 other
vacuum 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 regulator
and 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 Nm5 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.

OM600 ENGINE INTAKE & EXHAUST 1G3-7
Removal & Installation Procedure
1. Remove the bolt from the exhaust manifold and then remove
the front exhaust pipe.
Installation Notice
Tightening Torque 15 - 18 Nm
Notice
When tightening the nut(3), maintain the clearance between
exhaust manifold(1) and front exhaust pipe.
2. Remove the nut from the front of center muffler and then
remove the front exhaust pipe.
Installation Notice
3. Remove the nut from the rear of center muffler and then
remove the tail muffler.
Installation Notice
4. Remove the muffler mounting hanger from the rubber pad
and remove the center muffler and tail muffler.
Notice
Check the gasket, if necessary, replace the new one.
5. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 28 - 47 Nm
Tightening Torque 28 - 47 Nm

2A-12 SUSPENSION DIAGNOSIS
SELF DIAGNOSIS TEST
DIAGNOSIS TEST
Special Tool Requirements : Scanner
1. Position the ignition switch to 'OFF'.
2. Connect Scanner harness connector to the engine
compartment diagnosis socket.
3. Turn the ignition switch to 'ON' position.
4. Select "Electronic control vehicle diagnosis" from function
selection display and press "Enter".
5. Select "Musso ('98 model year)" from vehicle model selection
display and press 'Enter'.
6. Select "Electronic suspension system (ECS)" from control
system selection display and press 'Enter'.
7. Select "Self-diagnosis" from diagnosis item selection display.
Notice
Check sensor value output display, if necessary.
8. Determine the fault code and check defective component.
Notice
Refer to self-diagnosis list.

WHEEL ALIGNMENT 2B-9
GENERAL DESCRIPTION AND SYSTEM OPERATION
FOUR WHEEL ALIGNMENT
CASTER
Caster is the tilting 91 the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is
positive, and a forward tilt is negative. Caster influences
directional control of the steering but does not affect
tire wear. Weak springs or overloading a vehicle will affect
caster. One wheel with more positive caster will pull
toward the center of the car. This condition will cause
the car to move or lean toward the side with the least
amount of positive caster. Caster is measured in degrees.
CAMBER
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the
tires tilt outward, the camber is positive. When the tires
tilt inward, the camber is negative. The camber angle is
measured in degrees from the vertical. Camber
influences both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear. The first responsibility of engineering is to design safe
steering and suspension systems. Each component
must be strong enough to withstand and absorb extreme
punishment. Both the steering system and the front and
the rear suspension must function geometrically with
thebody mass.
The steering and the suspension systems require that
the front wheels self-return and that the tire rolling effort
and the road friction be held to a negligible force in order
to allow the customer to direct the vehicle with the least
effort and the most comfort.
A complete wheel alignment check should include
measurements of the rear toe and camber.
Four-wheel alignment assures that all four wheels will
be running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and
performance are maximized.
TOE
Toe-in is the turning in of the tires, while toe-out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling
forward. The specified toe angle is the setting which
achieves 0 degrees of toe when the vehicle is moving.
Incorrect toe-in or toe-out will cause tire wear and
reduced fuel economy. As the individual steering and
suspension components wear from vehicle mileage,
additional toe will be needed to compensate for the wear.
Always correct the toe dimension last.

FRONT DRIVE AXLE 3A-5
VACUUM CIRCUIT
1 Engine
2 Vacuum Pump
3 3-way Connector
4 T-connector
5 Check Valve6 Auto locking Hub Solenoid Valve
7 T-connector Hose
8 Hub Hose (left)
9 Hub Hose (right)

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BLEEDING THE BRAKES
For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times
to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the
master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no
more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and
wheel if pressure building is not enough by depressing the
pedal only after above air bleeding.
For Caliper and Brake Hose Replacement
1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a
container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown
in right figure if pressure building is not enough by depressing
the pedal after above air bleeding.
Tightening Torque
9 - 14 Nm
Item
Front Bleeder Screw
Rear Bleeder Screw
Notice
lDo not reuse the bled brake fluid.
lAlways bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
lAlways operate in normal order.