SSANGYONG MUSSO 1998 Workshop Repair Manual

1B1-108 M162 ENGINE MECHANICAL
11. Tighten the screw plug with the seal (arrow).
Screw Plug (Part No. 000 908 01 00 02)
Seal (Part No. 007 603 01 01 03)
8. Make a screw hole at the oil gallery using M10 x 1 thread.
9. All the oil gallery should be cleaned with the compressed
air.
10. Apply the Loctite 270 to new plug and press in using a
suitable drift (arrow).

M162 ENGINE MECHANICAL 1B1-109
CORE PLUGS IN CRANKCASE
Preceding Work : Draining of the coolant
1 Core Plug............................................... Replace

1B1-110 M162 ENGINE MECHANICAL
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 out
using 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 240 hardens.
6. Warm up the engine and check the coolant for leaks. 4. Clean the sealing surface and apply Loctite 241.

M162 ENGINE MECHANICAL 1B1-111
Group Code Letter and Cylinder Bore Size
Repair Size
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
CYLINDER BORE
Group Code Letter of Cylinder
A
X
B
X + 5
X + 10Piston Type to be Used
A or X
A, X or B
X or B
X + 5
X + 10Cylinder Bore Size (mm)
f 89.900 - f 90.906
f 89.906 - f 89.912
f 89.912 - f 89.918
f 89.950 - f 89.968
f 90.000 - f 90.018
Type
Standard Size
f 89.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5)Group Code Letter
1)
A
X
B
A
X
B
A
X
BCylinder Bore Size (mm)f 89.900 - f 90.906
f 89.906 - f 89.912
f 89.912 - f 89.918
f 90.150 - f 90.156
f 89.156 - f 90.162
f 90.162 - f 90.168
f 90.400 - f 90.406
f 90.406 - f 90.412
f 90.412 - f 90.418

1B1-112 M162 ENGINE MECHANICAL
Service Data Standard
Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3. Measuring Points
A . Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
Wear Limit in Longitudinal and Transverse Direction
Permissible Deviation of Cylinder Out-of-round
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)
Basic Peak-to-valley Height After Final Honing and Brushing
Chamfer Angle
Honing AngleWhen new
Wear limit0.1 mm
0.007 mm
0.05 mm
0.05 mm
0.003 - 0.006 mm
60°
50° ± 10°

M162 ENGINE MECHANICAL 1B1-113
CRANKCASE MATING SURFACE
Service Data Standard
Height of The Crankcase “H” (When new)
Minimum Height After Milling
Flatness
Permissible Deviation of Parallelism of The
Upper to Lower Mating Surface
Peak-to-valley HeightCrankcase Upper Mating Surface
Crankcase Lower Mating Surface
Axial Direction
Transverse Direction
Crankcase Upper Mating Surface
Crankcase Lower Mating Surface282.25 - 282.35mm
281.95mm
0.03mm
0.04mm
0.1mm
0.05mm
0.005 - 0.020mm
0.025mm

1B1-114 M162 ENGINE MECHANICAL
Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder after
finishing the chamfering with a suitable tool (e.g., hand milling
cutter).

M162 ENGINE MECHANICAL 1B1-115
CYLINDER HEAD MATING SURFACE
Preceding Work : Removal of valves
Service Data Standard
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.Overall Height of Cylinder Head
Minimum Height After Machining
Flatness
Distance ‘T’
(Between Camshaft Bearing
and Valve Stem)Axial Direction
Transverse Direction
Standard Size
Repair Size135.9 - 136.0 mm
135.5 mm
0.08 mm
0.0 mm
24.21 - 24.75 mm
22.21 - 22.75 mm
23.96 - 24.51 mm
21.96 - 22.51 mm
Intake
Exhaust
Intake
Exhaust

1B1-116 M162 ENGINE MECHANICAL
Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard
).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to
Service data standard).
7. Mill the cylinder head valve seat (refer to
Service data
standard
).
Universal Tool
Surface Grinding Machine
Sceledum, Type RTY
Roaro
Schio/Italy

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 otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2
Fastener 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