engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1B2-58 M161 ENGINE MECHANICAL
Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated
on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft
bearing.
Notice
lMeasure at 2 points (1, 2).
lMeasure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft
bearing journal.
Notice
lRecord the mean value when measured at 3 points
(A, B, C).
lMeasure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data,
replace the bearing shell.

M161 ENGINE MECHANICAL 1B2-59
Service Data Standard (Crankshaft Main Bearing Gap)
(Connecting Rod Bearing Gap)
Item
Main Bearing Journal
( NO. 1, 5, 7)Measuring Position
Radial
AxialGap (mm)
Static condition :0.015-0.039
Dynamic condition: 0.031-0.051
(Consider the expansion 0.011-0.016)
0.010 - 0.254
Item
Connecting Rod BearingMeasuring Position
RadialGap (mm)
0.020 - 0.065

1B2-60 M161 ENGINE MECHANICAL
FLYWHEEL/DRIVEN PLATE
Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt
(M10 x 22, 8 pieces) ................ 1st Step 45 Nm
2nd Step 90°+10°
2 Plate3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening TorqueM x 1.5
8.5 - 0.2 mm
8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter
When NewD
d
L
1st step 50 Nm, 2nd step 90°

M161 ENGINE MECHANICAL 1B2-61
Removal & Installation Procedure
1. Unscrew the stretch bolt.
Installation Notice
Sectional View
1 Oil Pan
2 Cover
3 Radial Seal
4 Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (Thickness : 3.5 mm)
8 Washer
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear
lReplace the bolt when the stretch side diameter (d) of
the flywheel mounting bolt is less than 8.0mm.
lFor 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 Torque1st step 45 Nm
2nd step90°+5°

1B2-62 M161 ENGINE MECHANICAL
CAMSHAFT ADJUSTER
1 Bolt (M6 X 16, 3 pieces)......................... 9-11 Nm
2 Cylinder Head Front Cover
3 Bolt........................................................... 35 Nm
4 Armature
5 Roll Pin
6 Nut (M20 X 1.5)....................................60-70 Nm
7 Seal Cover
8 Camshaft Sprocket
9 Adjust Piston
10 Conical Spring11 Flange Bolt
(M7 X 13, 3 pieces).................1st Step 20±2 Nm
2nd Step 90° ± 5° Rotation Added
12 Flange Shaft
13 Compression Spring
14 Control Piston
15 Circlip
16 Oil Gallery
17 Straight Pin
18 Intake Camshaft
Y49 Magnetic Actuator (2-pin connector)

M161 ENGINE MECHANICAL 1B2-63
Removal & Installation Procedure
1. Turn the crankshaft and position the n0.1 cylinder piston at
ATDC 20°.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Remove the cylinder head front cover.
3. Put the alignment marks (arrows) on the camshaft sprocket
and the timing chain.
4. Insert the insert pin into the no.1 and no.6 bearing cap hole
on camshaft to secure intake and exhaust camshaft.
5. Remove the chain tensioner.
6. Unscrew the exhaust sprocket bolt and remove the exhaust
camshaft sprocket.
Installation Notice
Tightening Torque1st step 20 Nm
2nd step 90°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and remove
the roll pin, and remove the armature.
Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7).
Installation Notice
Tightening Torque 60 - 70 Nm
Notice
Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical
spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft.
Installation Notice
Tightening Torque1st step 20 Nm
2nd step + 95°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.
12. Installation should follow the removal procedure in the
reverse order.
13. Check and adjust the camshaft timing.

M161 ENGINE MECHANICAL 1B2-65
CAMSHAFT SPROCKET BOLT
Intake Flange Shaft Bolt
Notice
The sprocket bolts are designed to be used only once, so
always replace with new one.
Exhaust Camshaft Sprocket Bolt
Notice
The sprocket bolts are designed to be used only once, so
always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
E. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
13a.Camshaft Sprocket
22a.Exhaust Camshaft
Tightening Torque1st step 20 Nm
2nd step + 90°
Tightening Torque1st step 20 Nm
2nd step + 90°

1B2-66 M161 ENGINE MECHANICAL
CAMSHAFT
Preceding Work : Removal of cylinder head cover
Removal of camshaft adjust actuator and cylinder head front cover
1 Bolt (M7 X 13, 3 pieces).........1st Step 18-22 Nm
2nd Step 90°+ 5° Rotation Added
2 Exhaust Camshaft Sprocket
3 Timing Chain
4a Intake Camshaft Spocket (E20)4b Camshaft Adjuster and Camshaft Sprocket (E23)
5 Bearing Cap Bolt (20 pieces).........22.5-27.5 Nm
6 Camshaft Bearing Cap
7 Wrench (Special Tool)

M161 ENGINE MECHANICAL 1B2-67
Tools Required
000 589 01 10 00 Box Wrench Insert
104 589 01 01 00Spanner
Removal & Installation Procedure
1. Turn the crankshaft and position the no.1 cylinder piston at
ATDC20°.
2. Put the alignment marks (arrows) on the camshaft sprocket
and the timing chain.
3. Remove the chain tensioner.
Installation Notice
Tightening Torque40 Nm
72 - 88 Nm
Screw Plug
Tensioner Assembly
4. Remove the exhoust camshaft sprocket.
Installation Notice
Tightening Torque1st step 35 - 45 Nm
2nd step 85° - 95°
Notice
The sprocket bolt is designed to be used only once, so
always replace with new one.
5. Take off the timing chain from intake camshaft sprocket,
and secute it not to fall down into the timing gear case.
6. Using the wrench (7), turn the camshaft until there is no
resistence in camshaft bearing area.