clutch SSANGYONG MUSSO 2003 User Guide

OM600 ENGINE MECHANICAL 1B3-19
33. Disconnect the exhaust pipe flange from the exhaustmanifold. Installation Notice
35. Remove the shift control cable.
36. Remove the transmission.
Tightening TorqueAxle 70 ~ 80 Nm T/C 81 ~ 89 Nm
Tightening Torque 20 - 34 Nm
31. Separate the exhaust pipe flange from the turbo charger.
Installation Notice
32. Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder. Installation Notice
Tightening Torque 30 Nm
Tightening Torque 30 Nm
34. Remove the propeller shaft from the transmission. Installation Notice

1B3-64 OM600 ENGINE MECHANICAL
8. Remove the guide pulley bracket (24).
Tools Required
116 589 03 07 00 Socket Wrench Removal Procedure
1. Remove the fan clutch and cooling fan belt pulley.
2. Drain the engine oil completely.
3. Remove the oil dipstick tube bracket bolts.
4. Remove the crankshaft pulley.
5. Loosen the bolt (1) and then remove the cylinder head cover(2) and gasket.
6. Remove the vacuum pump.
7. Detach the closing cover (20). Remove the bolts(21) and then remove the guide pulley (22).

1B3-70 OM600 ENGINE MECHANICAL
15. Install the guide pulley (22) and fit the closing cover (20).
16. Replace the gasket (3) and install the cylinder head cover(2).
17. Install the cooling fan belt pulley and fan clutch.
18. Install the belt tensioning device and then install the belt.
19. Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.
Tightening Torque 23 Nm
Tightening Torque 10 Nm

OM600 ENGINE MECHANICAL 1B3-93
FLYWHEEL
Preceding Work : Removal of the transmissionRemoval of the clutch
1 Oil Pan
2 Straight Pin
3 Flywheel 4 12-Sided Stretch Bolt
............ Check, 45Nm + 90 °
5 Drive Plate (Automatic Transmission)
6 Flywheel (Automatic Transmission)

OM600 ENGINE MECHANICAL 1B3-97
MACHINING OF FLYWHEEL
1 Flywheel
Machining of Flywheel Notice Flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding orprecision-turning. If the scores or cracks are severe thanpermissible specifications, replace the flywheel.
When machining the clutch surface ‘A’, the mounting
surface (B) for the clutch pressure plate should also be machined in accordance with ‘A’ to keep the distance ‘a’.
Do not machine under ‘b’ value.
When machining, fix the flywheel exactly not to exceed the standard runout.
OM662LA
OM662LA
Max. axial runout
Distance ‘a’
New
Repair up to 19.3 - 19.5 mm16.6 mm
15.6 mm
0.05 mmDistance ‘b’

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

1D1-2 M162 ENGINE COOLINGFASTENER TIGHTENING SPECIFICATIONS
N

 m
30
22.5 - 27.5
9 - 11
9 - 11
9 - 11
40.5 - 49.5
3 - 73 - 7
Application
Coolant Drain PlugEngine Hanger Bracket and Coolant OutletPort Bolt Thermostat Cover Bracket Bolt Oil Cooler Pipe Line BoltCooling Fan BoltViscous Clutch Bolt
Automatic Transmission Oil Cooling Hose Bolt Cooling Fan Shroud Bolt

1D1-12 M162 ENGINE COOLING COOLING FAN AND VISCOUS CLUTCH Preceding Work : Removal of cooling fan shroud
1 Cooling Fan Pulley
2 Viscous Clutch
3 Cooling Fan4 Bolt (M6 X 12, 4 pieces)
.........................9-11 Nm
5 Bolt (M10 X 45, 1 piece) .................40.5-49.5 Nm

M162 ENGINE COOLING 1D1-13
Tools Required 603 589 00 40 00 Counter Holder Removal & Installation Procedure
1. Hold the cooling fan pulley using the counter holder (special tool : 603 589 00 40 00) and remove the cooling fan after unscrewing the four bolts (4). Installation Notice
2. Remove the bolt (5) from the viscous clutch and remove the viscous clutch from the cooling fan pulley.Installation Notice
Tightening Torque 9 - 11 Nm
Tightening Torque 40.5 - 49.5 Nm
3. Installation should follow the removal procedure in the reverse order.

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)