engine SSANGYONG MUSSO 1998 Workshop Repair Manual

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) and
the 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 sprocket
and 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
lMake sure not to lose the crankshaft pulley key(5) when
removing.
lInstall the crankshaft sprocket(4) after warming it up.
6. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 29 - 35 Nm

M162 ENGINE MECHANICAL 1B1-85
PISTON
Preceding Work : Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bolt (M9 x 52, 12 pieces)
....................................................1st step 40 Nm
2nd step 90° + 5°4 Piston
5 Snap Ring
6 Piston Pin

1B1-86 M162 ENGINE MECHANICAL
Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.
Installation Procedure

M162 ENGINE MECHANICAL 1B1-87
1. Check the piston ring gap and apply the engine oil to the
piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in
the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and the piston and coat them
with engine oil.
4. Install the piston ring using the tensioning strap(000 589
04 14 00).
5. Install the piston so that the arrow on the piston head faces
to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark
(// or a number), tighten the bolts.
Installation Notice
Tightening Torque1st step 35 - 45 Nm
2nd step 90° + 5°
Apply the engine oil to the bearing cap upper and lower
bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating
it.

1B1-88 M162 ENGINE MECHANICAL
CONNECTING ROD
Preceding Work : Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 12 m pieces) .. 1st step 40+5 Nm
2nd step 90°+10°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]
Service Data Standard
Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing Bore Center
Width of The Connecting Rod (B) at Bearing Bore
Width of The Connecting Rod (b) at Bushing Bore
Basic Bore at The Bearing Shell (D1)
Basic Bore at The Bushing (d1)
Bushing Inner Diameter (d)
Clearance Between The Piston Pin and The Bushing
Peak-to-valley Height of Connecting Rod Bushing on Inside
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting
Rod Bushing Core
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity
Permissible Difference of Each Connecting Rod in Weight145 ± 0.05 mm
21.940 - 22.000 mm
21.940 - 22.000 mm
51.600 - 51.614 mm
24.500 - 24.571 mm
22.007 - 22.013 mm
0.007 - 0.018 mm
0.005 mm
0.15 mm
0.07 mm
0.01 mm
0.4 g

M162 ENGINE MECHANICAL 1B1-89
Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614mm, replace
the bearing or check the connecting rod.
2. Check connecting rod bolts.
3. Check the assembly mark(indication//or number:arrow) of
the connecting rods and the bearing cap when installing.
Notice
lMake sure it doesn’t exceed over 4g with other
connecting rods when replacing the connecting rods.
lCheck if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing. Notice
If the length exceeds max. length, replace it.
Length When New (L)
Max. Length (L)
Tightening Torque51.7 - 52 mm
52.9 mm
1st step 40 + 5 Nm
2nd step 90°+10°

1B1-90 M162 ENGINE MECHANICAL
PISTON RING
Preceding Work : Removal of piston
1 Piston Compression Ring
2 Piston Compression Ring
3 Piston Oil Ring
4-
5 Coil Spring and Control Ring
6 Hook Spring
Notice
If out of specification, replace the piston ring. Tools Required
000 589 51 37 00 Clamping Strap
Replacement Procedure
1. Measure the piston ring’s gap.
Gap Between
The Piston and
The Piston Ring
Groove 1 0.20 - 0.40 mm
Groove 2 0.20 - 0.40 mm
Groove 3 0.20 - 0.45 mm
Groove 1 0.015 - 0.050 mm
Groove 2 0.020 - 0.040 mm
Groove 3 0.010 - 0.045 mmEnd Gap of The
Piston Ring

M162 ENGINE MECHANICAL 1B1-91
2. Remove the piston ring with a pliers.
3. For installation, position the piston ring to be the ‘TOP’ mark
on the piston ring upward and arrange the piston ring ends
to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away from
the ring end.
Clamping Strap 000 589 51 37 00

1B1-92 M162 ENGINE MECHANICAL
ENGINE OIL SPECIFICATION
1 Drain Plug................................................. 25 Nm
2 Oil Filter3 Engine Oil Filler Cap
4 Dipstick Gauge
Specifications
Application
CapacityDescrition
Min : 6.7L, Max : 8.2L
lAPI SH or above grade
lACEA : A2 or A3
lApproved oil by MB Sheet 229.1
lApproved oil by MB Sheet 224.1
l Initial at 1000-1500km, Replace every 15000km
Quality
Viscosity
Replacemant

M162 ENGINE MECHANICAL 1B1-93
OIL PAN
1 Gasket ................................................... Replace
2 Bolt (M6 x 22, 6 pieces)............................ 10 Nm
3 Drain Plug (M6 x 20)................................. 25 Nm
4 Bolt (M6 x 20, 22 pieces).......................... 10 Nm5 Bolt (M6 x 85)............................................ 10 Nm
6 Bolt (M8 x 40)............................................ 25 Nm
7 Bolt (M10)................................................. 40 Nm
8 Oil Pan
Removal & Installation Procedure
1. Remove the drain plug and drain the oil completely.
2. Disconnect the electric connector from oil level switch.
3. Unscrew the bolts (10) for oil level switch and check the O-
ring (11) for wear or damage. And replace it if necessary.
4. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
5. Clean the inside of oil pan and sealing surface, then apply
the sealant.
6. Replace the gasket with new one.
7. Install the oil pan with gasket, and tighten each bolt in
specified torque.
8. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
M6 X 20, 28 pieces the rest