SSANGYONG MUSSO 2003 Repair Manual

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

1B1-28 M162 ENGINE MECHANICAL
4. Remove the mounting bolts(M8 x 30, 3 pieces) at thetensioning device, and remove the tensioning device (arrow). Installation Notice
3. Remove the 3 bolts (2) and remove the water pump pulley
(arrow). Installation Notice
5. Installation should follow the removal procedure in the reverse order.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 26 - 32 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.

M162 ENGINE MECHANICAL 1B1-31
CYLINDER HEAD COVER
1 Ignition Cable Dust Cover
2 Bolt (M6 x 65, 8 pieces)......................... 9-11 Nm
3 Bolt (M6 x 50, 4 pieces) ......................... 9-11 Nm
4 Spacer Sleeve
5 Thrust Piece
Composition of The Cylinder Head Cover Bolts A. M6 x 50, 4 Pieces - Bolts + Washers B. M6 x 65, 8 Pieces - Bolts + Washers 6 Cylinder Head Cover
7 Gasket ................................................... Replace
8 Spart Plug Hole Seal
.............................. Replace
9 Camshaft Seal ....................................... Replace

1B1-32 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the intake air duct.Installation Notice
2. Remove the ignition cable cover. Installation Notice
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and the gasket. Installation Notice
Notice Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover. Notice
Replace the gasket with a new one if necessary.
5. Installation should follow the removal procedure in the reverse order.
6. Check for oil leaks by operating the engine.
Tightening Torque 8 - 9 Nm
Tightening Torque 9 - 10 Nm
Tightening Torque 9 - 10 Nm

M162 ENGINE MECHANICAL 1B1-33
CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head coverRemoval of coolant connection fitting
1 Camshaft Position Sensor
2 Magnet Assembly
3 Upper Guide Rail
4 Bolt (M6 x 60, 3 pieces) .................22.5-27.5 Nm 5 Bolt (M8 x 80, 3 pieces)
.................22.5-27.5 Nm
6 Front Cover
7 Rubber Gasket ...................................... Replace
8 Bolt (M6 x 16, 3 pieces) ......................... 9-11 Nm
Removal & Installation Procedure
1. Remove the magnet assembly. Installation Notice
Tightening Torque 9 - 11 Nm

1B1-34 M162 ENGINE MECHANICAL
2. Remove the cylinder head front cover (6).Installation Notice
4. Remove the gasket (arrow). Installation Notice Replace the gasket with new one and apply the sealant.
5. Installation should follow the removal procedure in the reverse order.
Apply the sealant at the mating surface of the cylinder head
and the front cover.
3. Remove the upper guide rail pin and the guide rail (3).
Installation Notice Install it while the chain tensioner is loose.
Tightening Torque 22.5 - 27.5 Nm