SSANGYONG MUSSO 1998 Workshop Repair Manual

1B2-102 M161 ENGINE MECHANICAL
Removal & Installation Procedure
1. Unscrew the bolt (6) from the oil pump drive sprocket and
separate the oil pump drive chain.
Installation Notice
Tightening TorqueBolt (4) 9 - 11 Nm
Bolt (5) 9 - 11 Nm
Tightening Torque 29 - 35 Nm
2. Unscrew the bolts (4,5) and remove the oil strainer assembly
(3).
Installation Notice
Insert the steel gasket into the oil pump and bolt (4) mounting
surface.
3. Unscrew the six bolts (11) and remove the haffle plate.
Installation Notice
Tightening Torque 9 - 11 Nm
4. Unscrew the three bolt (1) and remove the oil pump.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm

M161 ENGINE MECHANICAL 1B2-103
OIL PRESSURE RELIEF VALVE
Preceding Work : Removal of oil pan
1 Screw Plug................................................ 50 Nm
2 Compression Spring
Removal & Installation Procedure
1. Remove the screw plug (1).
Installation Notice
2. Remove the spring (2), guide pin (3) and the piston (4).
3. Installation should follow the removal procedure in the
reverse order.
Notice
Don’t use the seal for the screw plug.3 Guide Pin
4 Piston
Tightening Torque 50 Nm

1B2-104 M161 ENGINE MECHANICAL
OIL NON-RETURN VALVE
Preceding Work : Removal of timing gear case cover
1 Oil Non-Return Valve
Functions
The non-return valve prevents the oil in the chain tensioner
from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As a
result, the chain tensioner can be activated with oil in itself.
Replacement Procedure
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

M161 ENGINE MECHANICAL 1B2-105
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge
2 Oil Dipstick Guide Tube
3 O-ring
Removal & Installation Procedure
1. Pull out the oil dipstick level gauge (1).
2. Unscrew the bolt (4) and remove the oil dipstick guide
tube (2).
Installation Notice4 Bolt (M6 X 16, 1 piece)........................... 9-11 Nm
5 Clamp
Tightening Torque 9 - 11 Nm
It is very hard to remove the oil dipstick guide tube without
special tool. If it is not necessary, do not remove the guide
tube.
3. Installation should follow the removal procedure in the
reverse order.
4. Check for leaks by starting the engine.

1B2-106 M161 ENGINE MECHANICAL
UNIT REPAIR
CORE PLUGS IN CRANKCASE
Preceding Work : Draining of the coolant
1 Core Plug............................................... Replace

M161 ENGINE MECHANICAL 1B2-107
Tools Required
102 589 00 15 00 Drift
Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
5. Press in new plug using a drift.
Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 241 hardens.
6. Warm up the engine and check the coolant for leaks. 4. Clean the sealing surface and apply Loctite 241.

1B2-108 M161 ENGINE MECHANICAL
Group Code Letter and Cylinder Bore Size
CYLINDER BORE
Group Code Letter of Cylinder
A
X
B
X + 5
X + 10
A
X
B
X + 5
X + 10Piston Type to be Used
A or X
A, X or B
X or B
X + 5
X + 10
A or X
A, X or B
X or B
X + 5
X + 10Cylinder Bore Size (mm)
f 90.906 - f 90.912
f 90.906 - f 90.912
f 90.912 - f 90.918
f 90.950 - f 90.968
f 91.000 - f 91.018
f 89.900 - f 90.906
f 89.906 - f 89.912
f 89.912 - f 89.918
f 89.950 - f 89.968
f 90.000 - f 90.018
Engine
E23
E20

M161 ENGINE MECHANICAL 1B2-109
Service Data Standard
Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points
A . Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
Wear Limit in Longitudinal and Transverse Direction
Permissible Deviation of Cylinder Out-of-round
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)
Basic Peak-to-valley Height After Final Honing and Brushing
Chamfer Angle
Honing AngleWhen new
Wear limit0.1 mm
0.007 mm
0.05 mm
0.05 mm
0.003 - 0.006 mm
75°
50° ± 10°
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.Type
Standard Size
E20 :
f 89.9
E23 :
f 90.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5)Group Code Letter
1)
A
X
B
A
X
B
A
X
BCylinder Bore Size (mm)f 89.900 - f 90.906
f 89.906 - f 89.912
f 89.912 - f 89.918
f 90.150 - f 90.156
f 89.156 - f 90.162
f 90.162 - f 90.168
f 90.400 - f 90.406
f 90.406 - f 90.412
f 90.412 - f 90.418

1B2-110 M161 ENGINE MECHANICAL
CRANKCASE MATING SURFACE
Service Data Standard
Height of the Crankcase “H” (When New)
Minimum Height After Milling
Flatness
Permissible Deviation of Parallelism of the
Upper to Lower Mating Surface
Peak-to-valley HeightCrankcase Upper Mating Surface
Crankcase Lower Mating Surface
Axial Direction
Transverse Direction
Crankcase Upper Mating Surface
Crankcase Lower Mating Surface289.35 - 289.45mm
289.05mm
0.03mm
0.04mm
0.1mm
0.05mm
0.012 - 0.009mm
0.025 - 0.020mm

M161 ENGINE MECHANICAL 1B2-111
Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder after
finishing the chamfering with a suitable tool (e.g., hand milling
cutter).