2003 SSANGYONG MUSSO fuel cap

1B3-2 OM600 ENGINE MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N

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28 - 47 30
3 - 7
8 - 18
20 - 34 30
70 - 80 81 - 8450 - 75
N 

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10 23
200 / 90 °
10
55 / 90 °
45 / 90 °
25 / 90 °
25
N 

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35 / 90 °
N 

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45 / 90 °
Application
Skid Plate Bolt Drain Plug Bolt Coolong Fan Shroud BoltControl Linkage NutClutch Linkage Cylinder NutExhaust Manifold Bolt
Propeller Shaft Bolt & Nut (Axle) Propeller Shaft Bolt & Nut (T/C)
Engine Mounting Nut
Application
Cooling Fan Belt Pulley Bolt Socket Bolt
Tighten The BoltEnd Cover BoltCrankshaft Bearing Cap Bolt Ball Bearing Camshaft Sprocket BoltOil Pump Sprocket Bolt
Application
Connecting Rod Bolt
Application
12-Sided Stretch Bolt
Engine Assembly
Crankshaft Assembly Piston
Flywheel
Cylinder Head
Application
Prechamber Threaded Ring Cylinder Head Cover Bolt Fuel Injsction Pipe NutSocket BoltFuel Filter Pipe BoltIdle Pulley Bolt Damper Bolt N


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130 10 18252523 21

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °

M162 ENGINE CONTROLS 1F1-29
FUEL PRESSURE AND INTERNAL LEAKAGE TEST
01 Pressure Tester
02 Pressure Hose
03 Measuring Beaker
Preparation Connection of the Equipment
1. Turn the ignition switch to "OFF" position.
2. Remove the air cleaner cross pipe.
3. Remove the cap on fuel pressure test plug and connect the
pressure hose and pressure tester.
4. Prepare the beaker for measuring the amount of fuel.
Tools Required
103 589 00 21 00 Pressure Tester
119 589 04 63 00 Pressure Hose

M162 ENGINE CONTROLS 1F1-57
FUEL FILTER
1 Fuel Filter
2 Outlet
Removal & Installation Procedure
1. Open the fuel tank cap and remove the fuel tank pressure.
2. Remove the fuel at (2) and in (3). Installation Notice Notice Place the fuel pump pad. There may be a corrosion due to the contact between the fuel filter and the bracket.
4. Check for leaks by operating the engine.
Notice Installation should follow the removal procedure in the
reverse order.
3. Remove the mounting bracket bolt (4) and remove the fuel
filter (1). Installation Notice 3 Inlet
Tightening Torque
25 - 30 Nm
Tightening Torque 4 - 8 Nm

1F1-60 M162 ENGINE CONTROLS
Tools Required 661 589 00 46 00 Cap Remover Removal & Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the harness connector (1).
3. Disconnect the fuel supply (6) and return (5) pipes.
4. Using a special tool, Unscrew the eight fuel retaining boltsand remove the pump from fuel tank. Notice
Check the condition of the seal and replace if necessary. Drain the fuel before removing the pump.

M162 ENGINE CONTROLS 1F1-61
Notice Replace the fuel pump relay if the measured value is over 9A.
Notice Check the fuel filter and fuel line when the fuel delivery is not within specified value.
Measure the Current Consumption of Fuel Pump
1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to "ON" position.
2. Using a multi-tester, measure the current consumption by connecting the terminal No.1 and No.3 of pump.
Measure the Fuel Delivery From the Fuel Pump
1. Disconnect the return pipe from fuel distributor and insert
the appropriate hose into it.
2 . Place the hose end into the beaker with the minimum capacity of 1Liter.
3. Turn the ignition switch to "ON" position.
4. Connect the terminal No.33 and No.5 of ECU with a service wire.
5. Measure the fuel delivery from the fuel pump.
1Liter/max.35sec.
Specifed Value
5 - 9A
Specifed Value

1F1-64 M162 ENGINE CONTROLS
VACUUM SYSTEM1 Purge Control Valve
2 Molded Hose
3 Insulator
4 Fuel Tube
5 Molded Hose
6 Idle Regulator
7 Resonance Flap
8 Intake Manifold
9 Fuel Pressure Regulator
10 Vacuum Line Rubber Hose11 Vacuum Tube(Gray, 270mm)
12 Molded Hose
13 Rubber Cap
18 Rubber Hose
19 Vacuum Tube(Brown or Black, 770mm)
20 Rubber Hose A To Canicter

1F3-4 OM600 ENGINE CONTROLS
FUEL TANK
1 Fuel Tank
2 The Sender of Fuel Tank
3 2-way Check Valve
4 Pre Filter
5 Front Fuel Filler Neck
6 Rear Fuel Filler Neck
7 Fuel Supply Tube 8 Fuel Return Tube
9 Filter Hose
10 Fuel Tank Hose
11 Fuel Filler Cap
12 Clip
13 Clip