engine SSANGYONG MUSSO 2003 Workshop Manual

1B1-12 M162 ENGINE MECHANICAL
19. Disconnect the engine ground wire.
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.

M162 ENGINE MECHANICAL 1B1-13
20. Disconnect following sensors connector.HFM sensor.
Coolant temperature sensor.
2 knock sensors.
Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition coil connector.
22. Remove the harness cover and disconnect the 6 injection valve connectors. Disconnect the main harness
23. Separate the hose toward engine from canister purge solenoid valve.
24. Remove the automatic transmission oil cooler line.

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

M162 ENGINE MECHANICAL 1B1-15
30. Remove the transmission mounting bolts and separatethe transmission from the engine. Installation Notice
Tightening Torque 65 Nm
31. Remove the bolts for engine mounting bracket. Installation Notice
Tightening Torque 50 - 75 Nm
32. Hook the chain to the bracket of engine and by using a hoist or crane, carefully separate the engine assembly from the vehicle.
33. Installation should follow the removal procedure in the reverse order.

1B1-16 M162 ENGINE MECHANICAL
CRANKCASE VENTILATION SYSTEM
1 Crankcase
2 Air Admission Port in Crankcase
3 Oil Drain Port
4 Filter
5 Gasket
6 A/C Bracket
7 Oil Drain Pipe
8 Oil Pan
9 Air Admission Line
10 Vent Line
11 Restriction Hole (Diameter = 2 mm)
12 Intake Manifold 13 Intake Air Duct (Cross Pipe)
14 Cylinder Head Cover
15 Oil Separator
16 Oil Separator
17 Air Admission and Vent Connection
18 Air Admission and Vent Connection
19 Throttle Valve
20 Vent Line
A Fresh Air
B Blowby Gas in Partial Load
C Blowby Gas in Full Load

M162 ENGINE MECHANICAL 1B1-17
Operation at Idling and Mid-Load
It show that the throttle valve (19) is closed or very partially opened and the vacuum pressure in intake manifold is high. The blowby gas in the crankcase in partial load flows into the intake manifold through the vent line (20) after passingthe air conditioner bracket (6) and the filter (4). The air reentered into the intake manifold will be dilluted on the flow
through the restriction hole (11) in the vent line (10). The circulated engine oil is separated at the air conditioner bracket (6) and then returns into the oil pan through thedrain pipe (7). The vacuum pressure generated at the crankcase sucks fresh air from intake air line(13) through the air admissionand vent connection (17,18). The fresh air prevents engine oil from being contami-nated and the air admission and vent connection (17,18) is designed to control the rapid pressure changes in intakeair line (13).
Operation at Full-Load
The throttle valve (19) is fully opened. All the blowby gases flow into the intake air duct (13) after passing through the oil separator (15,16) of the cylinder head cover (14) when fully loaded. This dilluted air will be supplied to the combustion chamber through the intakemanifold (12).

1B1-18 M162 ENGINE MECHANICAL
ALTERNATOR
1 Nut (M8)......................................... 22.5-27.5 Nm
2 Bolt (M8 x 30, 3 pieces) .................22.5-27.5 Nm
3 Bolt (M8 x 40, 1 piece) ...................22.5-27.5 Nm
Removal & Installation Procedure
1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts and remove the carrier. Installation Notice 4 Bolt (M8 x 70, 1 piece)
...................22.5-27.5 Nm
5 Bolt (M8 x 75, 1 piece) ...................22.5-27.5 Nm
Tightening Torque 10 - 15 Nm
4. Installation should follow the removal procedure in the reverse order.

M162 ENGINE MECHANICAL 1B1-19
POWER STEERING PUMP AND A/C BRACKET Preceding Work : Removal of cooling fan and shroud
1 Vent Hose
2 Bolt (M8 x 91, 2 pieces).................22.5-27.5 Nm
3 Power Steering Pump
4 Bolt (M8 x 105, 4 pieces) ...............22.5-27.5 Nm
5 Washer
6 A/C Compressor
7 Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces) ..........................22.5-27.5 Nm 8 A/C Bracket
9 Gasket ................................................... Replace
10 Bracket 11 Bolt (M8 x 22, 2 pieces) .................22.5-27.5 Nm
12 Tensioning Pulley
13 Nut ................................................. 40.5-49.5 Nm

1B1-20 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the belt pulley.Installation Notice
2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump. Installation Notice
Notice Pull the tensioning pulley clockwise as shown in the figure.
4. Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A/C compressor. Notice Discharge all the refrigerant before removing the pipes.
Tightening Torque 40.5 - 49.5 Nm
Tightening Torque 22.5 - 27.5 Nm

M162 ENGINE MECHANICAL 1B1-21
5. Disconnect the vent hose from the A/C bracket.
6. Unscrew all the mounting bolts (arrows) and remove theA/C bracket and the gasket. Installation Notice
7. Clean the sealing surface.
8. Replace the gasket with new one.
9. Installation should follow the removal procedure in the reverse order.
10. Check the oil leakage by operating the engine after installation.
Tightening Torque 22.5 - 27.5 Nm