oil SSANGYONG MUSSO 2003 Owner's Manual

SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)
GENERAL ENGINE INFORMATION TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A2-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A2-1
Component Locator . . . . . . . . . . . . . . . . . . 1A2-3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-3
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-4
Performance Curve . . . . . . . . . . . . . . . . . . 1A2-5
E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-5
E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A2-7
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-7Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
1A2-8
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8
Engine Cranking At The Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9
Compression Pressure Test . . . . . . . . . . . . 1A2-10
Cylinder Pressure Leakage Test . . . . . . . . . 1A2-12
General Information . . . . . . . . . . . . . . . . . 1A2-14
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
E20 Engine
M161.940 1998
89.9 x 78.7

9.6:1

135 / 5500
19.3 / 4000
ATDC 13.15° / ABDC 13.57°
BBDC 16.58° / BTDC 17.05°
Application
Engine Model Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition SystemCompression RatioNumber of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type Max. Output (ps/rpm)
Max. Torque (kg m/rpm)Firing Order
Ignition Type
Ignition Timing
Valve Timing Intake Open/Close ExhaustOpen/Close
Valve Clearance Adjustment SPECIFICATIONS
ENGINE SPECIFICATIONS E23 EngineM161.970 2295
90.9 x 88.4
MSE 3.53S 10.4:1
4
DOHC
Chain-Driven 149 / 5500
22.4 / 4000 1-3-4-2
Distributorless
BTDC 6° ± 2 °
ATDC 19.25° / ABDC 28.76°
BBDC 20.62° / BTDC 15.08° Automatic Control

1A2-2 GENERAL ENGINE INFORMATION
E20 Engine
Application
Idle Speed (rpm)
Fuel Injection Pressure (kg/cm²)Oil Capacity (liter)
Lubrication Type
Oil Filter Type Fuel ENGINE SPECIFICATIONS (Cont'd)
E23 Engine750 ± 503.2 - 4.2 7.5
Forced by Gear Pump
Full Flow with Paper Filter Unleaded Gasoline
MSE 3.62S/3.53S (Motors teuer Elektronik : German)
MSE : Engine Control Electronic 3.62S : 6 cylinder version3.53S : 4 cylinder version

Application
Engine Type Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition SystemCompression RatioNumber of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type Max. Output (ps/rpm)
Max. Torque (kg• m/rpm)Firing Order
Injection Timing
Valve Timing Intake Open/Close
(at 2mm lift) Exhaust Open/Close
Valve Clearance Adjustment SECTION 1
ENGINE
SECTION 1A3(OM600 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A3-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A3-1
Sectional View . . . . . . . . . . . . . . . . . . . . . . 1A3-3
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-3
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-5
Performance Curve . . . . . . . . . . . . . . . . . . 1A3-7
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-7
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A3-9
SPECIFICATIONS
ENGINE SPECIFICATIONS
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A3-9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A3-10
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . 1A3-10
Compression Pressure Test . . . . . . . . . . . . 1A3-11
Cylinder Pressure Leakage Test . . . . . . . . . 1A3-13
General Information . . . . . . . . . . . . . . . . . 1A3-15
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A3-15
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A3-15
OM662LA
Four-Stroke Diesel 2874
89 x 92.4
PES 5 M55 C320 RS 168 22:15
SOHC
Chain-Drive 120 / 4000
25.5 / 4000 1-2-4-5-3
BTDC 18°± 10°
ATDC 11.33° / ABDC 17°
BBDC 28° / BTDC 15.25°
Automatic Control OM661LA
Four-Stroke Diesel 2299
89 x 92.4
PES 5 M55 C320 RS 167 22:1
4
SOHC
Chain-Drive 101 / 4000
21.5 / 2400 1-3-4-2
BTDC 18°± 10°
ATDC 11.33° / ABDC 17°
BBDC 28° / BTDC 15.25° Automatic Control

1A3-2 GENERAL ENGINE INFORMATION
OM 662 LA720 - 820 135 - 1438.0 - 9.5
Forced by Gear Pump
Combined Full-Flow and Partial Flow Filter
Diesel
Application
Idle Speed (rpm)Fuel Injection Pressure (bar)Oil Capacity (liter)
Lubrication Type
Oil Filter Type Fuel ENGINE SPECIFICATIONS (Cont'd)OM661LA
750 - 850 135 - 143 6.5 - 8.0
Forced by Gear Pump
Combined Full-Flow and Partial Flow
Filter
Diesel

SECTION 1B1
M162 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 . . . . . . . . . . . . . . . . . . . . . . . 1B1-2Fastener Tightening Specifications . . . . . . . . 1B1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8
Crankcase Ventilation System . . . . . . . . . . 1B1-16
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59
TABLE OF CONTENTS
Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104 Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Cylinder Head Mating Surface . . . . . . . . . 1B1-115

M162 ENGINE MECHANICAL 1B1-3
N

 m
20 / +90 °
40
72 - 88
20 / +90 °
25 - 35
22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 30
26 - 34
30
8 - 10 2525
22.5 - 27.5 29 - 35
22.5 - 27.5 9 - 11
50
9 - 11
15Application
Exhaust Camshaft Sproket Bolt
Chain Tensioner Screw Plug
Chain Tensioner AssemblyExhaust Camshaft Sprocket to CamshaftOil Pump Sprocket Bolt
Tensioning Device Bolt
Water Pump PulleyUpper Intake Manifold BoltLower Intake Mainfold BoltFlange Bolt to Exhaust Mainfold Exhaust Mainfold Nut to Stud Bolt Rivet Nut in Exhuast Mainfold HolePre-silencer BoltOil Drain PlugOil Filter Cover Oil Filter Bolt Oil Pump Drive Sprocket BoltOil Pump Mounting BoltOil Strainer Bracket Bolt
Oil Pressure Relief Valve Screw Plug
Oil Dipstick Guide Tube Bolt Oil Gallery Screw Plug
FASTENER TIGHTENING SPECIFICATIONS (Co n t ’d)

1B1-4 M162 ENGINE MECHANICALSPECIAL TOOLS
SPECIAL TOOLS TABLE
001 589 66 21 00 Torque Wrench
000 589 01 10 00
Box Wrench Insert 124 589 15 21 00
Radiator CapTesting Unit
116 589 02 34 00
Screw-Fixed Pin
000 589 10 99 01 Torque Wrench
112 589 00 72 00 Oil Extractor 000 589 72 21 00
Torque Wrench
000 589 40 37 00
Hose Clamp

M162 ENGINE MECHANICAL 1B1-7
103 589 01 63 00Rivet Set
103 589 02 09 00 Oil Filter
Socket Wrench 102 589 12 15 00
Drift
SPECIAL TOOLS TABLE (Co n t
’d)
615 589 01 33 00
Caulking Bolt
102 589 00 15 00 Drift
000 589 51 37 00 Clamping Strap 001 589 72 21 00
Torque Wrench
601 589 03 14 00
Sleeve

1B1-8 M162 ENGINE MECHANICALMAINTENANCE 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

M162 ENGINE MECHANICAL 1B1-11
12. Discharge the refrigerant from A/C system, and disconnectthe discharge pipe and suction pipe from the compressor.
14. Remove the fuel feed and return line. Notice Before removing the fuel lines, release the pressure in the fuel system. Installation Notice
13. Remove the acceleration control cable and automatic
transmission pressure cable.
11. Remove the hydraulic pipe of power steering.
NoticeCompletely drain the oil.
Tightening Torque 21 - 25 Nm