engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1B2-48 M161 ENGINE MECHANICAL
Tools Required
601 589 03 43 00 Sleeve
Removal & Installation Procedure
1. Unscrew the bolts (1) and (5) and remove the closing cover
by pulling the rear cover lug (arrows).
Notice
Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear
sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
Notice
Do not use the grease.
6. Using the special tool, press the radial shaft seal and the
rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan
bolt (5) as specified and remove the special tool.
Installation Notice
Seal Assembler 601 589 03 43 00
Tightening Torque(Bolt 1,5) 9 - 11 Nm

M161 ENGINE MECHANICAL 1B2-49
BELT PULLEY AND VIBRATION DAMPER
Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
1 Center Bolt
(M18 X 55) ....................... 1st step 200-220 Nm
2nd step 90° + 10° rotation added
2 Vibration Damper Disk5 Vibration Damper Assembly
6 Key

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 the
reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.Tightening Torque1st step 180 - 220 Nm
2nd step + 90°

1B2-52 M161 ENGINE MECHANICAL
CRANKSHAFT FRONT RADIAL SEAL
Preceding Work : Removal of belt pulley and vibration damper
1 Center Bolt (M18 x 50)
............................... 1st step 200-220 Nm
2nd step 90° +10°
2 Center Bolt Washer
3 Sleeve (Special Tool)
4 Crankshaft Front Seal
5 Key
Tools Required
601 589 03 14 00 Sleeve
Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal mounting
hole and the crankshaft.
5. Remove the sleeve and install the belt pulley and the
vibration damper.
6. Check for leaks while operating the engine.2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
Tightening Torque1st step 200 - 220Nm
2nd step 90° + 10°

M161 ENGINE MECHANICAL 1B2-53
CRANKSHAFT REAR RADIAL SEAL
Preceding Work : Removal of flywheel or drive plate
1 Special Tool
2 Special Tool3 Crankshaft Rear Seal
Tools Required
601 589 03 43 00 Sleeve
Replacement Proceudre
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal mounting
hole and the crankshaft.
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice
Do not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.

1B2-54 M161 ENGINE MECHANICAL
CRANKSHAFT
Preceding Work : Removal of engine
Removal of cylinder head
Removal of timing gear case cover
Removal of crankcase sealing rear cover
Removal of oil pan
Removal of baffle plate
Removal of oil pump
1 Bearing Cap Bolt
(M8 X 55-10 pieces) ............ 1st step 50-60 Nm
2nd step 90°+5° rotation added
2 Bearing Cap
3 Upper Main Bearing
4 Lower Main Bearing
5 Upper Thrust Bearing
6 Lower Thrust Bearing
8 Crank Shaft

M161 ENGINE MECHANICAL 1B2-55
Arrangement of the Thrust Bearing and the Main Bearing
1 - 8 Weight Balance/Color Marking Point
j1 - j5 Journal Main Bearing #1 - #5
lColor Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6
, 8 , and it indicates the diameter of crankshaft journal
by color as below.A Crankcase Side
B Bearing Cap Side (Oil Pan Side)
1 Upper Main Bearing
2 Upper Thrust Bearing
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

1B2-56 M161 ENGINE MECHANICAL
Selection of Crankshaft Main Bearing
1. Crankcase Side
There 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
marking letter 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 - 57.955
57.945 - 57.950
57.940 - 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 DataUnit : mm
Crankshaft
Bearing Jour-
nal DiameterCrankshaft
Bearing
DiameterCrankshaft
Journal Width
at fit bearingConnecting Rod
Bearing Journal
DiameterConnecting
Rod Bearing
Jourmal Width
Standard size
1st repair size
2nd repair size
3rd repair size
4th repair size57.950-57.965
57.700-57.715
57.450-57.465
57.200-57.215
56.950-56.96558 24.50-24.533 47.94-47.96
47.75
47.50
47.25
47.0027.958-28.042 Crankshaft Standard
and Repair Size
- --

M161 ENGINE MECHANICAL 1B2-57
Installation Notice
lMake 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 (intake manifold side).
lAssemble so that the projected part of the cap and
crankcase 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
lRemove the bearing cap from front (pulley side) to
rear.
lMake sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
lThe oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the
bearing cap.
lThere are five kinds of thrust washers by thickness.
Select the 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.
lMake sure that the upper and lower bearing shells do
not change each other.
lCoat the bearing shell with engine oil.
lInstall the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 622.20 mm
Part No. : 601 030 02 622.25 mm
Part No. : 601 030 03 622.30 mm
Part No. : 601 030 04 622.40 mm
Tightening Torque 40 Nm + 90°
Tightening Torque 55 Nm + 90°