battery SSANGYONG MUSSO 2003 User Guide

SECTION 1D1
M162 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D1-1General Specifications . . . . . . . . . . . . . . . . . 1D1-1
Fastener Tightening Specifications . . . . . . . . 1D1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D1-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D1-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-4 System Leakage Test . . . . . . . . . . . . . . . . . . 1D1-4
Maintenance and Repair . . . . . . . . . . . . . . 1D1-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1D1-5Coolant Drain and Fill Up . . . . . . . . . . . . . . .
1D1-5
Coolant Connection Fitting . . . . . . . . . . . . . . 1D1-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-10
Oil Cooler Pipe Line . . . . . . . . . . . . . . . . . . 1D1-11
Cooling Fan and Viscous Clutch . . . . . . . . . 1D1-12
Cooling Fan Shroud . . . . . . . . . . . . . . . . . . 1D1-14
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS
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 otherwisenoted.
TABLE OF CONTENTS
Description
Water Cooling Forced Circulation Double Cross Flow
70,000 kcal/h
580 x 482 x 45 mm
460, Six Blades
ALUTEC - P78
50 : 50
11.3 L 3.4 L
1.4 bar
Application
Cooling Type Radiator Dimension(Width ×Height ×Thickeness)
Cooling Fan Anti-Freeze Agent
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water)Coolant CapacityReservoir Capacity
Cap Operating Pressure (Reservoir Tank Pressure Cap)
Circulation Type Radiation Capability

Circulation Type RadiationCapabilitySECTION 1D2
M161 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D2-1
General Specifications . . . . . . . . . . . . . . . . . 1D2-1
Fastener Tightening Specifications . . . . . . . . 1D2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D2-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D2-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D2-4 System Leakage Test . . . . . . . . . . . . . . . . . . 1D2-4
Maintenance and Repair . . . . . . . . . . . . . . 1D2-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1D2-5Coolant Drain and Fill Up . . . . . . . . . . . . . . .
1D2-5
Cooling Fan and Viscous Clutch . . . . . . . . . . 1D2-7
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D2-9
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D2-11
Thermostat Housing Assembly . . . . . . . . . . 1D2-12
Removal and Installation of Cooling Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . 1D2-14
Removal and Installation of Radiator . . . . . 1D2-15
SPECIFICATIONS
GENERAL SPECIFICATIONS
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 otherwisenoted.
TABLE OF CONTENTS
Description
Water Cooling Forced Circulation Down Flow
61,500 kcal/h 58,000 kcal/h
680 x 415 x 25 mm680 x 415 x 28 mm
460, 9 Blades
ALUTEC-P78, Dragon Power Coolant A 50 : 5010.5 L 3.4 L
1.4 bar
Application
Cooling TypeRadiator Dimension(Width ×Height ×Thickeness)
Cooling Fan Anti-Freeze Agent
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water) Coolant Capacity Reservoir Capacity
Cap Operating Pressure (Reservoir Tank Pressure Cap)

SECTION 1D3
OM600 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D3-1General Specifications . . . . . . . . . . . . . . . . . 1D3-1
Fastener Tightening Specifications . . . . . . . . 1D3-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-2 Cooling Circulation . . . . . . . . . . . . . . . . . . . . 1D3-2
Thermostat Operation . . . . . . . . . . . . . . . . . 1D3-3
Cooling System Leakage Test . . . . . . . . . . . 1D3-4
Maintenance and Repair . . . . . . . . . . . . . . 1D3-5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . .
1D3-5
Drain and Filling of Coolant . . . . . . . . . . . . . 1D3-5
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D3-6
Coolant Pump Housing . . . . . . . . . . . . . . . . . 1D3-8
Cooling Fan Clutch . . . . . . . . . . . . . . . . . . . 1D3-10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-12
Cooling Sub-System . . . . . . . . . . . . . . . . . . 1D3-14
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-16
TABLE OF CONTENTS
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 otherwisenoted.
Application
Coolant
Mixing Ratio (Water : anticorrosion) Capacity
Description
ALUTEC P- 78 50 : 50
10.5L - 11L 9.5L - 10L
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Coolant Pump Bolt Belt Pulley BoltCoolant Pump Housing Return Pipe BoltThermostat Bolt Cooling Fan Clutch Socket Bolt (Center) Cooling Fan Clutch Socket Bolt (Side)Radiator BoltCoolant Sub-tank BoltN 

 m
10 101010 45 10
3 - 73 - 7
FASTENER TIGHTENING SPECIFICATIONS
662LA 661LA

SECTION 1E1
M162 ENGINE ELECTRICAL
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E1-1Alternator Specifications . . . . . . . . . . . . . . . . 1E1-1
Starting Motor Specifications . . . . . . . . . . . . 1E1-2
Battery Specifications . . . . . . . . . . . . . . . . . . 1E1-2
Fastener Tightening Specifications . . . . . . . . 1E1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1E1-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1E1-3
Maintenance and Repair . . . . . . . . . . . . . . 1E1-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
1E1-4
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-4
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 1E1-5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-6
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-7
Ignition Cable . . . . . . . . . . . . . . . . . . . . . . . . 1E1-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 1E1-12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-12
SPECIFICATIONS
ALTERNATOR SPECIFICATIONS
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 cablewill help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
TABLE OF CONTENTS
Application
Output Voltage CurrentResistance Between Rotor Core and Slip Ring Description
12 - 14 V115 A

1E1-2 M162 ENGINE ELECTRICALNm
14 - 18 4 - 5
45 - 50 12 - 15
6 - 7
35 - 4812 - 1812 - 1812 - 18
9 - 11
9 - 11
25 - 30
STARTING MOTOR SPECIFICATIONS
Application
Voltage Output Power Description
12 V
1.7 KW
BATTERY SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Capacity Specific Gravity
Max. Tolerance Between Cells Description
75 AH
1.24
0.04
Application
Alternator Terminal B+Nut
Alternator Terminal D+NutAlternator Combinction Bolt Battery Cable Nut on Starting Motor Electric Wire Nut on Starting MotorStarting Motor Mounting NutBattery Mounting Bracket Nut Battery Negative Cable Battery Positive CableIgnition Cable Cover BoltIgnition Cable BoltSpark plug

1E1-4 M162 ENGINE ELECTRICALMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ALTERNATOR Preceding Work : Removal of the drivebelt Removal & Installation Procedure
1. Disconnect the negative battery terminal.
2. Unscrew the nut and disconnect the terminal (1). Installation Notice
1 Terminal (B+)
2 Terminal (D+)
3 Combination Bolt
4 Alternator
3. Unscrew the nut and disconnect the terminal (2).Installation Notice
Tightening Torque 14 - 18 Nm
4. Unscrew the combination bolt (3). Installation Notice
Tightening Torque 4 - 5 Nm
5. Remove the alternator.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 42 - 50 Nm

M162 ENGINE ELECTRICAL 1E1-5
3 Fixing Bolt
4 Starting Motor
4. Unscrew the mounting bolts (3) of starting motor.
Installation Notice
5. Remove the starting motor.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 35 - 48 Nm
STARTING MOTOR Removal & Installation Procedure
1. Disconnect the ground cable.
2. Unscrew the nut and disconnect the battery cable(1).
Installation Notice
1 Battery Cable
2 Engine Electric Wire
3. Unscrew the nut and disconnect the engine electric wire
(2). Installation Notice
Tightening Torque 12 - 15 Nm
Tightening Torque 6 - 7 Nm

1E1-6 M162 ENGINE ELECTRICAL
BATTERY
1 Cable Terminal (-)
2 Cable Terminal Cap (-)
3 Cable Terminal Cap (+)
4 Nut
5 Fuseblink Box
6 Terminal (+)7 Battery holddown Bracket
8 Battery Clamp Bolt
9 Battery
10 Sub Tray 11 Battery Tray
Removal & Installation Procedure Notice
Disconnect the battery negative cable first.
Insert the clamp bolt (8) into the battery tray hole (11)
from inside when installing.

1E1-10 M162 ENGINE ELECTRICAL Functions
1. Firing order : 1-5-3-6-2-4
2. The ignition cables are located on the cylinder head cover.Each ignition coil provides the high voltage to two spark
plugs simultaneously.
- T1/1 : cylinder 2 and 5
- T1/2 : cylinder 3 and 4
- T1/3 : cylinder 1 and 6
Removal & Installation Procedure
1. Disconnect the negative battery cable (1).
2. Remove the ignition cable connector from the ignition cable.
3. Disconnect the secondary spark plug connectors from the each spark plugs and remove the ignition cable. Installation Notice
3. The secondary output voltage (5a) is supplied to the No.2
cylinder spark plug through the spark plug connector. The secondary output voltage (5b) is supplied to the No.5 cylinderspark plug through the ignition cable. The guide pin (W)acts as a ground while the ignition cable is operated.
Make sure that the ignition cables are correctly routed.
Exactly install the ignition cable guide pin into the vehicle
to be grounded.
4. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm

1E1-12 M162 ENGINE ELECTRICALUNIT REPAIR
BATTERY
Inspection Notice
When charging the battery, do not leave the inflammable
objects around it.
When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects were found on it.
2. Check if the specific gravity of the electrolyte is within the specified value. Notice
Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
Measure the specific gravity in the approx. 20 °C
of ambient temperature.
3. Replenish the electrolyte if necessary. Battery capacity(Ah)Battery specific gravity Max. tolerance between cells
85
1.24
0.04