lock SSANGYONG MUSSO 2003 Owner's Manual

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 otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2Fastener 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

1B2-6 M161 ENGINE MECHANICALSPECIAL TOOLS TABLE (Co n t ’d)
116 589 20 33 00
Sliding Hammer
602 589 00 40 00 Engine Lock 103 589 00 33 00
Puller
601 589 03 43 00Sleeve
001 589 65 09 00
Socket Wrench Insert
001 589 74 21 00 Torque Wrench 000 589 04 14 00
Clamping Strap
000 589 88 33 00
Puller

M161 ENGINE MECHANICAL 1B2-11
10. Remove the upper mounting bolts of radiator and thenremove the radiator.
7. Loosen the cylinder block drain plug and then drain thecoolant completely. Installation Notice
Tightening Torque 30 Nm
Notice Replace the seal before installation of the drain plug.
8. Remove the cooling fan shroud.
9. Disconnect the each hose from radiator.

M161 ENGINE MECHANICAL 1B2-23
Removal & Installation Procedure
1. Remove the belt pulley after removal of poly v-belt.Installation Notice
2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump. Installation Notice
Notice Pull the tensioning pulley counterclockwise as shown in the figure.
4. Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A/C compressor. Notice Discharge all the refrigerant before removing the pipes.
Tightening Torque 40.5 - 49.5 Nm
Tightening Torque 22.5 - 27.5 Nm

1B2-28 M161 ENGINE MECHANICAL
POLY V-BELT Preceding Work : Removal of cooling fan
1 Poly V-belt (2,155 mm)
2 Belt Tensioning Pulley
Removal & Installation Procedure
1. Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclockwise.
2. Remove the poly v-belt.
Notice Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt after prying the tensioning pulley.3 Belt Tensioner

1B2-30 M161 ENGINE MECHANICAL TENSIONING DEVICE Preceding Work : Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) +Washer .......................................... 22.5-27.5 Nm
2 Bolt (M8 x 25, 1 pieces) + Washer .......................................... 22.5-27.5 Nm
Removal & Installation Procedure
1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in tensioning arm.
3. Unscrew the bolts (1, 2) and remove the tensioning device.
Installation Notice
4. Installation should follow the removal procedure in the reverse order. 3 Tensioning Device
4 Stud bolt
5 Tensioning Arm
Tightening Torque 22.5 - 27.5 Nm

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
°

1B2-58 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.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and removethe roll pin, and remove the armature. Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice
Tightening Torque 60 - 70 Nm
Notice Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step + 95
°
Notice The flange bolt is designed to be used only once, so always replace with new one.
12. Installation should follow the removal procedure in the reverse order.
13. Check and adjust the camshaft timing.