SSANGYONG MUSSO 2003 Service Manual

M161 ENGINE MECHANICAL 1B2-99
ENGINE OIL AND OIL FILTER ELEMENT
1 Oil Filter Cover.......................................... 25 Nm
2 O-ring .................................................... Replace
3 Oil Filter Element4 Oil Drain Plug
5 Oil Filter Bypass Valve
6 Oil Filter Cap

1B2-100 M161 ENGINE MECHANICAL9. Fill up engine oil through the engine oil filler opening.
10. Check for oil leaks at normal engine temperature after starting the engine.
11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary.
4. Remove the drain plug (1) and drain the engine oil.
Notice Leave the oil filler cap (3) open to ease the engine oil discharge.
5. Tighten the engine oil drain plug after cleaning it. Installation Notice
Tools Required
103 589 02 09 00 Oil Filter Socket Wrench Replacement Procedure
1. Install the socket wrench ”7” (special tool : 103 589 02 09
00) on the oil filter cover (2). NoticeMake the screw cover removable by tightening the bolt at the side of the socket wrench (special tool).
2. Install the wrench to the upper bolt in the socket wrench and remove the oil cover by turning it.
3. Remove the oil filter element.
Notice Work with a cloth under the vehicle when removing the oil filter element to not drain the oil. Replace the seal washer with new one.
6. Replace the O-ring(5) in the oil filter cover with new one.
Notice Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
Tightening Torque 25 Nm
8. Temporarily tighten the oil filter cover (2). Install the socket wrench “7” (special tool : 103 589 02 09 00), and then
completely tighten it. Installation Notice
2 Oil Filter Cover
5 O-ring
6 Oil Filter Element
7 Special Tool (Socket Wrench)
Tightening Torque 25 Nm

M161 ENGINE MECHANICAL 1B2-101
OIL PUMP Preceding Work : Removal of oil pan
1 Bolt (M8 X 35, 3 piece)...................22.5-27.5 Nm
2 Oil Pump
3 Oil Strainer Assembly
4 Bolt (M6 X 12, 2 pieces) ......................... 9-11 Nm
(In E23 Engine, These Bolts areCombined with Baffle Plate)
5 Bolt (M8 X 20, 1 pieces) ....................... 29-35 Nm 6 Washer
7 Sprocket (Oil Pump Drive)
8 Chain (Oil Pump Drive)
9 Plate-Baffle
10 Bolt (M6 X 12, 6 piece) ........................... 9-11 Nm
(E23 Engine Only : Baffle Plate Mounting Bolt)

1B2-102 M161 ENGINE MECHANICAL
Removal & Installation Procedure
1. Unscrew the bolt (6) from the oil pump drive sprocket andseparate the oil pump drive chain. Installation Notice
Tightening Torque Bolt (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 aresult, 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 Notice 4 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 MECHANICALUNIT 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 outusing 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
AX
B
X + 5
X + 10 AX
B
X + 5
X + 10 Piston Type to be Used
A or X
A, X or B
X or BX + 5
X + 10 A or X
A, X or B
X or BX + 5
X + 10 Cylinder Bore Size (mm)

90.906 - 90.912
90.906 - 90.912
90.912 - 90.918
90.950 - 90.968
91.000 - 91.018
89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
89.950 - 89.968
90.000 - 90.018
Engine
E23 E20