SSANGYONG MUSSO 2003 Service Manual

M161 ENGINE MECHANICAL 1B2-49
BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutchRemoval of fan shroud Removal of drive belt
1 Center Bolt(M18 X 55) ....................... 1st step 200-220 Nm
2nd step 90° + 10 ° rotation added
2 Vibration Damper Disk 5 Vibration Damper Assembly
6 Key

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)

M161 ENGINE MECHANICAL 1B2-51
Engine Lock 602 589 00 40 00
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in thereverse order. Notice If possible, don ’t separate the vibration damper and the
pulley. Tightening Torque
1st step 180 - 220 Nm2nd step + 90
°

1B2-52 M161 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper
1 Center Bolt (M18 x 50)............................... 1st step 200-220 Nm
2nd step 90° +10 °
2 Center Bolt Washer
3 Sleeve (Special Tool)
4 Crankshaft Front Seal
5 Key
Tools Required
601 589 03 14 00 Sleeve Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.
5. Remove the sleeve and install the belt pulley and thevibration damper.
6. Check for leaks while operating the engine.
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk stop in the movement. Installation Notice
Tightening Torque 1st step 200 - 220Nm
2nd step 90
° + 10 °

M161 ENGINE MECHANICAL 1B2-53
CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate
1 Special Tool
2 Special Tool3 Crankshaft Rear Seal
Tools Required
601 589 03 43 00 Sleeve Replacement Proceudre
1. Remove the radial seal with a screw driver.
Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
NoticeDo not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.

1B2-54 M161 ENGINE MECHANICAL CRANKSHAFT Preceding Work : Removal of engineRemoval of cylinder head Removal of timing gear case cover Removal of crankcase sealing rear coverRemoval of oil panRemoval of baffle plateRemoval of oil pump
1 Bearing Cap Bolt(M8 X 55-10 pieces) ............ 1st step 50-60 Nm 2nd step 90°+5 ° rotation added
2 Bearing Cap
3 Upper Main Bearing
4 Lower Main Bearing
5 Upper Thrust Bearing
6 Lower Thrust Bearing
8 Crank Shaft

M161 ENGINE MECHANICAL 1B2-55
Arrangement of the Thrust Bearing and the Main Bearing1 - 8 Weight Balance/Color Marking Point
j1 - j5 Journal Main Bearing #1 - #5 Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6
, 8 , and it indicates the diameter of crankshaft journal
by color as below. A Crankcase Side
B Bearing Cap Side (Oil Pan Side)
1 Upper Main Bearing
2 Upper Thrust Bearing
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

1B2-56 M161 ENGINE MECHANICAL Selection of Crankshaft Main Bearing
1. Crankcase SideThere 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 themarking letter on the crankshaft main journal whenrepaired.
Color Dot Marking
Blue
Yellow
Red
White VioletCrankshaft Journal Diameter (mm)
57.960 - 57.965 57.955 - 57.960 57.950 - 57.95557.945 - 57.95057.940 - 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 Data Unit : mm
Crankshaft
Bearing Jour- nal Diameter Crankshaft
Bearing
Diameter Crankshaft
Journal Width at fit bearing Connecting Rod
Bearing Journal Diameter Connecting
Rod Bearing
Jourmal Width
Standard size
1st repair size
2nd repair size 3rd repair size4th repair size 57.950-57.965 57.700-57.71557.450-57.46557.200-57.215
56.950-56.965 58 24.50-24.533 47.94-47.96
47.75 47.5047.25 47.0027.958-28.042
Crankshaft Standard
and Repair Size
-
--

M161 ENGINE MECHANICAL 1B2-57
Installation Notice
Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the leftside (intake manifold side).
Assemble so that the projected part of the cap and
crankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap. Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice
Remove the bearing cap from front (pulley side) to
rear.
Make sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the bearing cap.
There are five kinds of thrust washers by thickness.
Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the reverse order.
5. After completion of the installation, check for the rotating condition of the crankshaft.
Make sure that the upper and lower bearing shells do
not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
Tightening Torque 40 Nm + 90 °
Tightening Torque 55 Nm + 90°

1B2-58 M161 ENGINE MECHANICAL Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaftbearing. Notice
Measure at 2 points (1, 2).
Measure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft bearing journal. Notice
Record the mean value when measured at 3 points
(A, B, C).
Measure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data, replace the bearing shell.