service SSANGYONG MUSSO 2003 Workshop Manual
[x] Cancel search | Manufacturer: SSANGYONG, Model Year: 2003, Model line: MUSSO, Model: SSANGYONG MUSSO 2003Pages: 1574, PDF Size: 26.41 MB
Page 451 of 1574
OM600 ENGINE MECHANICAL 1B3-187
Standard size Wear limit in direction of travel and in transverse direction Permissible deviation of cylinder shape Honing angle
CYLINDER BORE MEASUREMENT
a Longitudinal Direction
b Transverse Direction c, d, e. Measuring Point
1 Crankcase Contacting Surface
2 TDC of 1st Piston Ring
4 BDC of Ring
Service Data
Code letter ‘A’
Code letter ‘X’
Code letter ‘B’
When new Wear limit 89.000 - 89.006mm 89.006 - 89.012mm89.012 - 89.018mm
Max. 0.20mm
0.01mm0.05mm
50 ° ± 10 °
Page 452 of 1574
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
Page 456 of 1574
M162 ENGINE COOLING 1D1-5
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. NoticeFor the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 o
C.
2. Loosen the radiator lower drain cock and drain the coolant.
Notice Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose(dia. 14mm) onto the drain bolt on the side of crankcase (exhaust manifold) and by loosening the plug. Notice
Just loosen the drain plug to drain the coolant and do not remove the plug completely.
Collect coolant by using proper container.
4. After complete draining of the coolant, remove the hose connector to drain plug and reinstall the drain plug. Installation Notice
5. Tighten the radiator lower drain cock.
Tightening Torque 30 Nm
Page 468 of 1574
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)
Page 472 of 1574
M161 ENGINE COOLING 1D2-5
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. NoticeFor the risk of scalding, the cap must not be opened unless the coolant temperature is below 90oC.
2. Loosen the radiator lower drain cock and drain the coolant.
Notice
Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose(dia. 14mm) onto the drain bolt on the side of crankcase (exhaust manifold) and by loosening the plug. Notice
Just loosen the drain plug to drain the coolant and do
not remove the plug completely.
Collect coolant by using proper container.
Page 484 of 1574
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
Page 488 of 1574
OM600 ENGINE COOLING 1D3-5
DRAIN AND FILLING OF COOLANT Preceding Work : Removal of skid plate Drain / Filling
1. Loosen the pressure cap of reservoir by 1 notch and removepressure and then loosen the cap. Notice Do not remove radiator cap when coolant is above 90 °C.
2. Open the drain plug and drain the coolant.
Notice Collect the coolant by using the proper bottle.
3. Remove the drain plug(1) and seal(2) of cylinder block and drain the coolant.
4. Replace the seal to new one and tighten the drain plug
Installation Notice
Tightening Torque 30 Nm
5. Tighten the drain plug of the lower radiator.
6. Fill the coolant through coolant reservoir-tank. Notice
A proportion of 50% by volume of water / anticorrosion
must be ensured
7. After engine is running at idle speed, check the level of coolant. If necessary, add enough specified coolant. MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Page 501 of 1574
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
Page 504 of 1574
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
Page 513 of 1574
SECTION 1E2
M161 ENGINE ELECTRICAL
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E2-1Alternator Specifications . . . . . . . . . . . . . . . . 1E2-1
Starting Motor Specifications . . . . . . . . . . . . 1E2-2
Battery Specifications . . . . . . . . . . . . . . . . . . 1E2-2
Fastener Tightening Specifications . . . . . . . . 1E2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1E2-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1E2-3
Maintenance and Repair . . . . . . . . . . . . . . 1E2-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
1E2-4
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-4
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 1E2-5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-6
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-7
Ignition Cable . . . . . . . . . . . . . . . . . . . . . . . . 1E2-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 1E2-12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-12
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
SPECIFICATIONS
ALTERNATOR SPECIFICATIONS
Application
Output Voltage Current Resistance Between Rotor Core and Slip Ring Description
12 - 14 V115 A