service SSANGYONG MUSSO 1998 Workshop Owner's Guide

M162 ENGINE MECHANICAL 1B1-115
CYLINDER HEAD MATING SURFACE
Preceding Work : Removal of valves
Service Data Standard
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.Overall Height of Cylinder Head
Minimum Height After Machining
Flatness
Distance ‘T’
(Between Camshaft Bearing
and Valve Stem)Axial Direction
Transverse Direction
Standard Size
Repair Size135.9 - 136.0 mm
135.5 mm
0.08 mm
0.0 mm
24.21 - 24.75 mm
22.21 - 22.75 mm
23.96 - 24.51 mm
21.96 - 22.51 mm
Intake
Exhaust
Intake
Exhaust

1B1-116 M162 ENGINE MECHANICAL
Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard
).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to
Service data standard).
7. Mill the cylinder head valve seat (refer to
Service data
standard
).
Universal Tool
Surface Grinding Machine
Sceledum, Type RTY
Roaro
Schio/Italy

SECTION 1B2
M161 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 otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2
Fastener Tightening Specifications . . . . . . . . 1B2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B2-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B2-4
Maintenance and Repair . . . . . . . . . . . . . . 1B2-9
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B2-9
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B2-9
Crankcase Ventilation System . . . . . . . . . . 1B2-17
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-21
Power Steering Pump and A/C Bracket . . . 1B2-22
Hydraulic Engine Mounting Insulator . . . . . . 1B2-25
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-28
Tensioning Deivce . . . . . . . . . . . . . . . . . . . . 1B2-30
Tensioning Device Shock Absorber . . . . . . 1B2-31
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B2-32
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B2-35
Cylinder Head Front Cover . . . . . . . . . . . . . 1B2-37
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B2-39
Timing Gear Case Cover . . . . . . . . . . . . . . 1B2-44
Crankshaft Sealing Rear Cover . . . . . . . . . 1B2-47
Belt Pulley and Vibration Damper . . . . . . . . 1B2-49
Crankshaft Front Radial Seal . . . . . . . . . . . 1B2-52
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B2-53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-54
Flywheel/Driven Plate . . . . . . . . . . . . . . . . . 1B2-60
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B2-62
TABLE OF CONTENTS
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B2-65
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-66
Camshaft Timing Position . . . . . . . . . . . . . . 1B2-69
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B2-72
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B2-76
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B2-77
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B2-80
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B2-85
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B2-86
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B2-87
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B2-88
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-90
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B2-93
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-95
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-97
Engine Oil and Oil Filter Element . . . . . . . . 1B2-99
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-101
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B2-103
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B2-104
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B2-105
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B2-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B2-106
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B2-108
Crankcase Mating Surface . . . . . . . . . . . . 1B2-110
Cylinder Head Mating Surface . . . . . . . . . 1B2-112

M161 ENGINE MECHANICAL 1B2-9
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 10 99 01 Torque Wrench
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor

M161 ENGINE MECHANICAL 1B2-25
HYDRAULIC ENGINE MOUNTING INSULATOR
Service Data

1B2-50 M161 ENGINE MECHANICAL
Components
Service Data Standard
Permissble Deviation of The Vibration DamperRadial Runout
Axial Runout0.6 mm
0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
001 589 74 21 00 Puller
000 589 88 33 00 Torque Wrench
602 589 00 40 00 Engine Lock
Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.
1 Center Bolt (M18 x 50)
2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

1B2-56 M161 ENGINE MECHANICAL
Selection of Crankshaft Main Bearing
1. Crankcase Side
There are seven punching marks on the mating surface
to oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing
according to the punching mark when repaired.
2. Crankshaft Bearing Cap Side
Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Color Dot Marking
Blue
Yellow
Red
White
VioletCrankshaft Journal Diameter (mm)
57.960 - 57.965
57.955 - 57.960
57.950 - 57.955
57.945 - 57.950
57.940 - 57.945
Punching Mark
·
··
···
Bearing Color Selected
Blue
Yellow
Red
Marking Letter
B
Y
R
W
VBearing Color Selected
Blue
Yellow
Red
White
Violet
Service DataUnit : mm
Crankshaft
Bearing Jour-
nal DiameterCrankshaft
Bearing
DiameterCrankshaft
Journal Width
at fit bearingConnecting Rod
Bearing Journal
DiameterConnecting
Rod Bearing
Jourmal Width
Standard size
1st repair size
2nd repair size
3rd repair size
4th repair size57.950-57.965
57.700-57.715
57.450-57.465
57.200-57.215
56.950-56.96558 24.50-24.533 47.94-47.96
47.75
47.50
47.25
47.0027.958-28.042 Crankshaft Standard
and Repair Size
- --

M161 ENGINE MECHANICAL 1B2-59
Service Data Standard (Crankshaft Main Bearing Gap)
(Connecting Rod Bearing Gap)
Item
Main Bearing Journal
( NO. 1, 5, 7)Measuring Position
Radial
AxialGap (mm)
Static condition :0.015-0.039
Dynamic condition: 0.031-0.051
(Consider the expansion 0.011-0.016)
0.010 - 0.254
Item
Connecting Rod BearingMeasuring Position
RadialGap (mm)
0.020 - 0.065

1B2-60 M161 ENGINE MECHANICAL
FLYWHEEL/DRIVEN PLATE
Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt
(M10 x 22, 8 pieces) ................ 1st Step 45 Nm
2nd Step 90°+10°
2 Plate3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening TorqueM x 1.5
8.5 - 0.2 mm
8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter
When NewD
d
L
1st step 50 Nm, 2nd step 90°

M161 ENGINE MECHANICAL 1B2-93
CONNECTING ROD
Preceding Work : Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 8 pieces)............1st step 40 Nm
2nd step 90°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]
Service Data Standard
Distance (L) from The Connecting Rod Bearing to Bushing Bore Center
Width of The Connecting Rod (B) at Bearing Bore
Width of The Connecting Rod (b) at Bushing Bore
Basic Bore at The Bearing Shell (D1)
Basic Bore at The Bushing (d1)
Bushing Inner Diameter (d)
Clearance Between The Piston Pin and The Bushing
Peak-to-valley Height of Connecting Rod Bushing on Inside
Permissible Wwist of Connecting Rod Bearing Bore to
Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod
Bearing Bore to Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from
Concentricity
Permissible Difference of Each Connecting Rod in WeightE20 : 154 mm
E23 : 149 ± 0.05 mm
21.940 - 22.000 mm
21.940 - 22.000 mm
51.600 - 51.614 mm
24.500 - 24.571 mm
22.007 - 22.013 mm
0.007 - 0.018 mm
0.005 mm
0.1/100 mm
0.045/100 mm
0.01 mm
0.4 g