alternator SSANGYONG MUSSO 2003 Service Manual

0B-18 GENERAL INFORMATION
Engine Number Location Diesel Engine The engine number is stamped on the cylinder block in front of injection pump.
IL6 3200 The engine number is stamped on the lower rear side
of the alternator.
Gasolind Engine Number1 6 2 9 9 0 1 0 012345
Serial Number
0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M
99 : 3.2L 97 : 2.3L94 : 2.0L
0 : Common
1 : Left - Hand Drive
2 : Right - Hand Drive
ENGINE TYPE
0 : MUSSO
Diesel Engine Number 662 920 1 0 012345
Serial Number
0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M
910 : Non-Intercooler Engine 920 : Intercooler Engine
0 : Common
1 : Left - Hand Drive
2 : Right - Hand Drive
661 : 2299cc662 : 2874cc

SECTION 1B1
M162 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 . . . . . . . . . . . . . . . . . . . . . . . 1B1-2Fastener Tightening Specifications . . . . . . . . 1B1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8
Crankcase Ventilation System . . . . . . . . . . 1B1-16
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59
TABLE OF CONTENTS
Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104 Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Cylinder Head Mating Surface . . . . . . . . . 1B1-115

1B1-2 M162 ENGINE MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS N

 m
35 - 40 10 - 15 5 - 10
21 - 25 30
56 - 6650 - 60 10 - 15
41.5 - 49.522.5 - 27.522.5 - 27.5
9 - 11
9 - 11
22.5 - 27.5
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

1B1-12 M162 ENGINE MECHANICAL
19. Disconnect the engine ground wire.
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.

1B1-18 M162 ENGINE MECHANICAL
ALTERNATOR
1 Nut (M8)......................................... 22.5-27.5 Nm
2 Bolt (M8 x 30, 3 pieces) .................22.5-27.5 Nm
3 Bolt (M8 x 40, 1 piece) ...................22.5-27.5 Nm
Removal & Installation Procedure
1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts and remove the carrier. Installation Notice 4 Bolt (M8 x 70, 1 piece)
...................22.5-27.5 Nm
5 Bolt (M8 x 75, 1 piece) ...................22.5-27.5 Nm
Tightening Torque 10 - 15 Nm
4. Installation should follow the removal procedure in the reverse order.

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

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

1B1-60 M162 ENGINE MECHANICAL
Tools Required
000 589 01 10 00 Box Wrench Insert104 589 01 01 00Spanner
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30 °.
2. Remove the alternator.
3. Remove the chain tensioner.
4. Remove the cylinder head front cover and the upper guide rail.
6. Unscrew the exhaust camshaft sprocket bolt and remove the sprocket.
7. Separate the chain from the intake camshaft sprocket and put the chain not to be dropped into timing case.
5. Put the alignment marks (arrows) on the camshaft sprocket
(2, 5) and the timing chain (6).

M162 ENGINE MECHANICAL 1B1-63
8. Install the upper guide rail and cylinder head front cover.
9. Install the alternator.

1B1-72 M162 ENGINE MECHANICAL
CHAIN TENSIONER1 Screw Plug ................................................ 40 Nm
2 Seal
3 Filler Pin
4 Compression Spring 5 Snap Ring
6 Thrust Pin
7 Chain Tensioner Housing
.....................72-88 Nm
8 Seal
Removal Procedure
1. Position the No.1 cylinder to TDC (OT). Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam ’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
NoticeIn case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.If the chain tensioner is tightened again without completely reducing its tension, then the detent spring doesn ’t return
to the original position and the tension gets excedded.