belt SSANGYONG MUSSO 2003 User Guide

M162 ENGINE MECHANICAL 1B1-25
POLY V - BELT Preceding Work : Removal of cooling fan
1 Poly V-belt
Removal & Installation Procedure
1. Release the belt tension by turning the belt tensioning pulley nut clockwise.
2. Remove the poly v-belt.
Notice Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley clockwise.2 Belt Tensioning Pulley

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

M162 ENGINE MECHANICAL 1B1-27
TENSIONING DEVICE Preceding Work : Removal of poly v-belt
1 Belt (L = 2245)
2 Bolt Combi(M8 x 14, 3 pieces) + Washer....................................................... 22.5-27.5Nm
Removal & Installation Procedure
1. Remove the poly v-belt.
2. Remove the tensioning pulley by turning its mounting nut counter clockwise as shown in figure. Installation Notice 3 Water Pump Pulley
4 Nut
5 Tensioning Pulley
Tightening Torque 40.5 - 49.5 Nm

M162 ENGINE MECHANICAL 1B1-29
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.
5. Cord torn out at the side.
6. Outer cords frayed.

1B1-30 M162 ENGINE MECHANICAL7. Rib detached from the base of belt.
8. Splits across the rib.
9. Sections of rib torn out.
10. Splits across several ribs.
11. Splits across the back of the belt.

1B1-38 M162 ENGINE MECHANICAL
TIMING GEAR CASE COVER Preceding Work : Removal of cylinder head front coverRemoval 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 Nm 6 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

1B1-42 M162 ENGINE MECHANICAL1 Center Bolt (M18 x 50) ......1st step 200- 220 Nm
2nd step 90 °+10 °
2 Vibration Damper Disk
3 Bolt (M6 x 20, 6 pieces) .....................7.7-9.5 Nm
BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud Removal of drive belt
4 Vibration Damper Assembly
5 Woodruff Key
6 Bolt (M6 x 12, 4 pieces) ......................... 9-11 Nm
7 Cooling Fan Pulley

M162 ENGINE MECHANICAL 1B1-45
CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper
1 Center Bolt (M18 x 50)................................ 1st step 200-220 Nm
2nd step 90 ° +10 °
2 Center Bolt Washer
3 Sleeve (Special Tool)
4 Crankshaft Front Seal
5 Key
Tools Required
601 589 03 14 00 Sleeve Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.
5. Remove the sleeve and install the belt pulley and thevibration damper.
6. Check for leaks while operating the engine.
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk stop in the movement. Installation Notice
Tightening Torque 1st step 200 - 220Nm
2nd step 90
° + 10 °

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 otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2Fastener 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 MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS N

 m
35 - 40 10 - 15 5 - 10
21 - 25 30
56 - 6650 - 60
22.5 - 27.5 41.5 - 49.522.5 - 27.522.5 - 27.5
9 - 11
9 - 11
9 - 11
9 - 11
22.5 - 27.5
10
+90 °
55
+90 °
+90 °
22.5 - 27.522.5 - 27.5 9 - 109 - 10200
+90 °
40
+90 °
45
+90 °
35
9 - 11 20
+90 °
20
+90 °
20 / + 90 °
20 / + 90 °
22.5 - 27.5
Application
Power Steering Hydraulic Lines A/C High Pressure and Liquid HoseRadiator Support Menber BoltFuel Supply and Return Hose to Fuel DistributorExhaust Manifold and Pipe
Propeller Shaft to Transmission Engine Mounting NutAlternator Carrier BoltBelt Pulley BoltSteering Pump Bolt A/C Bracket Bolt Intake Air Duct BoltIgnition Cable Cover BoltCylinder Head Cover BoltCamshaft 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 BoltVibration Damper Center Bolt Connecting Rod Bearing Cap Bolt Flywheel Stretch Bolt Amarture Bolt in Flywheel Ring and Seal Cover Nut in FlywheelSprocket Bolt to Exhaust Camshaft Camshaft Adjuster Flange Bolt Intake Flange Shaft Bolt Exhaust Camshaft Sprocket Bolt Camshaft Bearing Cap Bolt