engine oil SSANGYONG MUSSO 2003 Workshop Manual

1B1-48 M162 ENGINE MECHANICAL Arrangement of the Thrust Bearing and the Main Bearing
1 - 12 Weight Balance/Color Marking Point
j1 - j7 Journal Main Bearing #1 - #7 Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6 , 8
, 10 ,12 and it indicates the diameter of crankshaft journal
by color as below. A Crankcase Side
B Bearing Cap Side (Oil Pan Side)
C Axial Fit Bearing (Number 5 Bearing Point)
D Radial Bearing
1 Upper Main Bearing
2 Upper Thrust Bearing
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

M162 ENGINE MECHANICAL 1B1-49
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 the markingletter 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 - 57.95557.945 - 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
47.7547.5047.25 47.00 27.958-28.042
-
Crankshaft Standard
and Repair Size

1B1-50 M162 ENGINE MECHANICALInstallation 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 left side (intakemanifold side).
Assemble so that the projected part of the cap andcrankcase 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 faceoutward and insert the thrust bearing into the bearingcap.
There are five kinds of thrust washers by thickness. Selectthe 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°

1B1-54 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Unscrew the stretch bolt.Installation Notice
Sectional View
1 Oil Pan
2 Cover
3 Crankshaft Front Seal
4 Flywheel MTG Bolt
5 Crankshaft
6 Dowel Pin
7 Plate
8 TGCC
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm.
For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90 ° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for Auto. transmission vehicle.
3. Installation should follow the removal procedure in the reverse order. Tightening Torque
1st step 45+5 Nm
2nd step 90
° + 10 °

M162 ENGINE MECHANICAL 1B1-55
CAMSHAFT ADJUSTER
1 Bolt (M6 x 16, 3 pieces)........................ 9-11 Nm
2 Electromagnetic Actuator (2 Pin Connector)
3 Bolt ........................................................... 35 Nm
4 Armature
5 Roll Pin
6 Nut (M20 x 1.5) .................................... 60-70 Nm
7 Front Cover
8 Seal
9 Camshaft Position Sensor
10 Bolt (M6 x 16, 2 pieces) ......................... 9-11 Nm
11 Seal
12 Seal Cover 13 Camshaft Sprocket and Position Indicator (b)
14 Adjuster piston
15 Flange bolt (M7 x 13, 3 pieces)
.............................................. 1st step 18-22 Nm
2nd step 90 ° ± 5 °
16 Flange Shaft
17 Compression Spring
18 Control Piston
19 Circlip
20 Oil Gallery
21 Pin
22 Intake Camshaft

M162 ENGINE MECHANICAL 1B1-71
VALVE STEM SEAL Preceding Work : Removal of valve spring
1 Drift (Special Tool)
2 Valve Stem Seal
3 Protective Sleeve
Drift 119 589 00 43 00
Pliers 104 589 00 37 00
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00
Drift
Replacement Procedure
1. Remove the valve stem seal (2) using the pliers. Notice Check the valve stem seal for damage and replace if
necessary.
2. Coat the valve stem seal with oil and assemble it with the protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.

1B1-72 M162 ENGINE MECHANICAL
CHAIN TENSIONER1 Screw Plug ................................................ 40 Nm
2 Seal
3 Filler Pin
4 Compression Spring 5 Snap Ring
6 Thrust Pin
7 Chain Tensioner Housing
.....................72-88 Nm
8 Seal
Removal Procedure
1. Position the No.1 cylinder to TDC (OT). Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam ’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
NoticeIn case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.If the chain tensioner is tightened again without completely reducing its tension, then the detent spring doesn ’t return
to the original position and the tension gets excedded.

1B1-74 M162 ENGINE MECHANICAL
4. Lightly apply the grease to the seal (2) and install the screwplug (1). Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve) 11 Compression Spring
12 Thrust Piece 13 Chain Tensioner Housing
14 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole
5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

M162 ENGINE MECHANICAL 1B1-83
CRANKSHAFT SPROCKET Preceding Work : Removal of oil panRemoval of tensioning rail Removal of crank case guide rail
6 Bolt (M8 x 20, 1 piece) / Washer ..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain
1 Oil Pump Chain Tensioner
2 Oil Pump Chain Bushing
3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5 Key

1B1-84 M162 ENGINE MECHANICAL
Tools Required
615 589 01 33 00 Puller Removal & Installation Procedure
1. Put the assembly mark at the crankshaft sprocket (4) andthe timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain. Also, align the assembly marks on camshaft sprocketand timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7) from the oil pump. Installation Notice
Puller (04) 615 589 01 33 00
3. Remove the oil pump roller chain (9).
4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the puller (04, special tool). Notice
Make sure not to lose the crankshaft pulley key(5) when removing.
Install the crankshaft sprocket(4) after warming it up.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 29 - 35 Nm