SSANGYONG MUSSO 2003 Service Manual

M161 ENGINE MECHANICAL 1B2-29
Poly V-belt Arrangement
1 Belt Tensioning Pulley
2 Crankshaft Belt Pulley
3 A/C Compressor Pulley5 Alternator Pulley
7 Power Steering Pump Pulley
8 Water Pump Pulley

1B2-30 M161 ENGINE MECHANICAL TENSIONING DEVICE Preceding Work : Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) +Washer .......................................... 22.5-27.5 Nm
2 Bolt (M8 x 25, 1 pieces) + Washer .......................................... 22.5-27.5 Nm
Removal & Installation Procedure
1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in tensioning arm.
3. Unscrew the bolts (1, 2) and remove the tensioning device.
Installation Notice
4. Installation should follow the removal procedure in the reverse order. 3 Tensioning Device
4 Stud bolt
5 Tensioning Arm
Tightening Torque 22.5 - 27.5 Nm

M161 ENGINE MECHANICAL 1B2-31
TENSIONING DEVICE SHOCK ABSORBER
1 End Cover
2 Nut .................................................40.5-49.5 Nm
3 Tensioning Pulley
4 Bolt (M8 X 25) + Washer ................22.5-27.5 Nm
Removal & Installation Procedure
1. Remove the end cover (1).
2. Remove the nut (2) and remove the tensioning pulley (3). Installation Notice 5 Tensioning Device
6 Bolt (M8 X 35) + Washer
................22.5-27.5 Nm
7 Shock Absorber
Tightening Torque 40.5 - 49.5 Nm
3. Unscrew the bolts (4,6) and remove the shock absorber (7). Installation Notice
Tightening Torque 22.5-27.5 Nm

1B2-32 M161 ENGINE MECHANICAL
3. Pointed rib.
4. Belt cord visible in the base of rib.
POLY V-BELT INSPECTION

Make marks on the belt with chalk.
Rotate the engine and check the belt for damage. Notice If one of the following types of damages is found, replace the belt.
1. Rubber lumps in the base of rib.
2. Dirt or grit ingrained.

M161 ENGINE MECHANICAL 1B2-33
5. Cord torn out at the side.
6. Outer cords frayed.
7. Rib detached from the base of belt.
8. Splits across the rib.
9. Sections of rib torn out.
10. Splits across several ribs.

1B2-34 M161 ENGINE MECHANICAL
11. Splits across the back of the belt.

M161 ENGINE MECHANICAL 1B2-35
CYLINDER HEAD COVER
1 Ignition Coil Cover
2 Spark Plug Connector
3 Bolt (M6 X 45 : 4 pieces, M6 X 60 :6 pieces) ............................................. 10 ± 1 Nm 4 Cylinder Head Cover
5 Gasket ................................................... Replace

1B2-36 M161 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the intake air duct.Installation Notice
2. Remove the ignition coil cover. Installation Notice
3. Remove the spark plug connector and ignition cable. Notice Release 3 screws from the ignition cover and remove the cover for M161 Engine coil.
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 10 Nm

M161 ENGINE MECHANICAL 1B2-37
CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head coverRemoval of thermostat housing assembly
Removal of engine hanger bracket
Removal & Installation Procedure
1. Disconnect the camshaft adjuster connector and removethe camshaft adjuster (E23 engine only). Installation Notice
Tightening Torque 9 - 11 Nm
1 Bolt (M6 X 16, 3 pieces) ......................... 9-11 Nm
2 Camshaft Adjuster
3 Bolt (M8 X 35, 2 pieces) .................22.5-27.5 Nm
4 Bolt (M6 X 22, 6 pieces) ......................... 9-11 Nm
5 Front Cover (E23 : M161.973) 6 Front Cover (E20 : M161.943)
7 Sleeve
8 O-ring .................................................... Replace
9 Thermostat Housing

1B2-38 M161 ENGINE MECHANICAL
2. Remove the cylinder head front cover.Installation Notice
Tightening Torque (3) 22.5 - 27.5 Nm
Tightening Torque (4) 9 - 11 Nm
Apply the sealant at the mating surface of the cylinder head
and the front cover.
3. Remove the O-ring. Installation Notice Replace the O-ring with new one and apply the sealant.
4. Installation should follow the removal procedure in the reverse order.