alternator belt SSANGYONG MUSSO 1998 Workshop Repair Manual

SECTION 1B1
M162 ENGINE MECHANICAL
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 otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B1-2
Fastener Tightening Specifications . . . . . . . . 1B1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8
Crankcase Ventilation System . . . . . . . . . . 1B1-16
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59
TABLE OF CONTENTS
Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Cylinder Head Mating Surface . . . . . . . . . 1B1-115

1B1-2 M162 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N
· ·· ·
·m
35 - 40
10 - 15
5 - 10
21 - 25
30
56 - 66
50 - 60
10 - 15
41.5 - 49.5
22.5 - 27.5
22.5 - 27.5
9 - 11
9 - 11
22.5 - 27.5
9 - 11
22.5 - 27.5
10
+90°
55
+90°
+90°
22.5 - 27.5
22.5 - 27.5
9 - 10
9 - 10
200
+90°
40
+90°
45
+90°
35
9 - 11
20
+90°
20
+90°
20 / + 90°
20 / + 90°
22.5 - 27.5Application
Power Steering Hydraulic Lines
A/C High Pressure and Liquid Hose
Radiator Support Menber Bolt
Fuel Supply and Return Hose to Fuel Distributor
Exhaust Manifold and Pipe
Propeller Shaft to Transmission
Engine Mounting Nut
Alternator Carrier Bolt
Belt Pulley Bolt
Steering Pump Bolt
A/C Bracket Bolt
Intake Air Duct Bolt
Ignition Cable Cover Bolt
Cylinder Head Cover Bolt
Camshaft Adjuster Bolt
Cylinder Head Front Cover Bolt
Flange Bolt in Exhaust Camshaft Sprocket
Cylinder Head Bolt
Cooling Fan Bracket Bolt
Timing Gear Case Cover Bolt M8
M6
Crankshaft Rear Cover Bolt
Vibration Damper Center Bolt
Connecting Rod Bearing Cap Bolt
Flywheel Stretch Bolt
Amarture Bolt in Flywheel
Ring and Seal Cover Nut in Flywheel
Sprocket Bolt to Exhaust Camshaft
Camshaft Adjuster Flange Bolt
Intake Flange Shaft Bolt
Exhaust Camshaft Sprocket Bolt
Camshaft Bearing Cap Bolt

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 Notice4 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.

1B1-26 M162 ENGINE MECHANICAL
Poly V-Belt Arrangement
1 Belt Tensioning Pulley
2 Crankshaft Belt Pulley
3 A/C Compressor Pulley
4 Cooling Fan Pulley5 Alternator Pulley
6 Idler
7 Power Steering Pump Pulley
8 Cooling Fan and Water Pump Pulley

1B1-38 M162 ENGINE MECHANICAL
TIMING GEAR CASE COVER
Preceding Work : Removal of cylinder head front cover
Removal of alternator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper
1 Bolt (M8 x 60, 3 pieces).................22.5-27.5 Nm
2 A/C Bracket
3 Bolt (M8 x 65, 3 pieces).................22.5-27.5 Nm
4 Bolt (M8 x 40, 1 piece)...................22.5-27.5 Nm
5 Bolt (M8 x 60, 1 piece)...................22.5-27.5 Nm6 Seal
7 Timing Gear Case Cover
8 Roll Pin
9 Bolt (M6 x 22, 6 pieces)......................... 9-11 Nm
Removal & Installation Procedure
1. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
2. Unscrew the A/C bracket bolts (1) and remove the bracket.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm

SECTION 1B2
M161 ENGINE MECHANICAL
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 otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2
Fastener Tightening Specifications . . . . . . . . 1B2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B2-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B2-4
Maintenance and Repair . . . . . . . . . . . . . . 1B2-9
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B2-9
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B2-9
Crankcase Ventilation System . . . . . . . . . . 1B2-17
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-21
Power Steering Pump and A/C Bracket . . . 1B2-22
Hydraulic Engine Mounting Insulator . . . . . . 1B2-25
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-28
Tensioning Deivce . . . . . . . . . . . . . . . . . . . . 1B2-30
Tensioning Device Shock Absorber . . . . . . 1B2-31
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B2-32
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B2-35
Cylinder Head Front Cover . . . . . . . . . . . . . 1B2-37
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B2-39
Timing Gear Case Cover . . . . . . . . . . . . . . 1B2-44
Crankshaft Sealing Rear Cover . . . . . . . . . 1B2-47
Belt Pulley and Vibration Damper . . . . . . . . 1B2-49
Crankshaft Front Radial Seal . . . . . . . . . . . 1B2-52
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B2-53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-54
Flywheel/Driven Plate . . . . . . . . . . . . . . . . . 1B2-60
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B2-62
TABLE OF CONTENTS
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B2-65
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-66
Camshaft Timing Position . . . . . . . . . . . . . . 1B2-69
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B2-72
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B2-76
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B2-77
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B2-80
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B2-85
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B2-86
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B2-87
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B2-88
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-90
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B2-93
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-95
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-97
Engine Oil and Oil Filter Element . . . . . . . . 1B2-99
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-101
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B2-103
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B2-104
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B2-105
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B2-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B2-106
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B2-108
Crankcase Mating Surface . . . . . . . . . . . . 1B2-110
Cylinder Head Mating Surface . . . . . . . . . 1B2-112

1B2-2 M161 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N
· ·· ·
·m
35 - 40
10 - 15
5 - 10
21 - 25
30
56 - 66
50 - 60
22.5 - 27.5
41.5 - 49.5
22.5 - 27.5
22.5 - 27.5
9 - 11
9 - 11
9 - 11
9 - 11
22.5 - 27.5
10
+90°
55
+90°
+90°
22.5 - 27.5
22.5 - 27.5
9 - 10
9 - 10
200
+90°
40
+90°
45
+90°
35
9 - 11
20
+90°
20
+90°
20 / + 90°
20 / + 90°
22.5 - 27.5Application
Power Steering Hydraulic Lines
A/C High Pressure and Liquid Hose
Radiator Support Menber Bolt
Fuel Supply and Return Hose to Fuel Distributor
Exhaust Manifold and Pipe
Propeller Shaft to Transmission
Engine Mounting Nut
Alternator Carrier Bolt
Belt Pulley Bolt
Steering Pump Bolt
A/C Bracket Bolt
Intake Air Duct Bolt
Ignition Cable Cover Bolt
Cylinder Head Cover Bolt
Camshaft Adjuster Bolt
Cylinder Head Front Cover Bolt
Flange Bolt in Exhaust Camshaft Sprocket
Cylinder Head Bolt
Cooling Fan Bracket Bolt
Timing Gear Case Cover Bolt M8
M6
Crankshaft Rear Cover Bolt
Vibration Damper Center Bolt
Connecting Rod Bearing Cap Bolt
Flywheel Stretch Bolt
Amarture Bolt in Flywheel
Ring and Seal Cover Nut in Flywheel
Sprocket Bolt to Exhaust Camshaft
Camshaft Adjuster Flange Bolt
Intake Flange Shaft Bolt
Exhaust Camshaft Sprocket Bolt
Camshaft Bearing Cap Bolt

M161 ENGINE MECHANICAL 1B2-21
ALTERNATOR
Removal & Installation Procedure
1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts (1,2,3) and remove the
carrier (4).
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Notice
Apply 3Nm of torque when mounting the bolt (1); apply 25 ±
2.5Nm of torque when mounting the bolts (2), and (3); and
then tighten the bolt (1) with 25 ± 2.5Nm of torque.
4. Installation should follow the removal procedure in the
reverse order. 1 Bolt (M8 X 40, 3 pieces).................22.5-27.5 Nm
2 Bolt (M8 X 70, 2 pieces).................22.5-27.5 Nm3 Bolt (M8 X 85, 1 piece)...................22.5-27.5 Nm
4 Alternator Bracket

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

1B3-22 OM600 ENGINE MECHANICAL
With Air Conditioner
Removal & Installation Procedure
1. Remove the nut.
2. Push the tensioning lever in direction of arrow with a rod
(F12 ´ 180mm) and pull out the bolt to the rear.
3. Push back the tensioning lever (arrow direction) to release
the spring tension and remove the belt.
4. Install the poly V-belt beginning at the tensioning pulley (7).
7 Tensioning Pulley
8 Crankshaft
9 Alternator
10 Coolant Pump
11 Guide Pulley
12 Power Steering Pump
13 Aircon. Compressor
Lengthe of Belt
Length (L)
Without Air Conditioner2,100 mm
2,040 mm