oil SSANGYONG MUSSO 1998 Workshop Workshop Manual

M162 ENGINE MECHANICAL 1B1-45
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°

1B1-46 M162 ENGINE MECHANICAL
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.

M162 ENGINE MECHANICAL 1B1-47
CRANKSHAFT
Preceding Work : Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of oil pump
Removal of oil shield
1 12-sided Stretch Bolt........ 55 Nm x 90°, Iubricate
2 Crank Shaft Bearing Cap
3 Crank Shaft Low Main Bearing
4 Lower Thrust Bearing
5 Crank Shaft

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
lColor 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 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

1B1-50 M162 ENGINE MECHANICAL
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°

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
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+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 Cover13 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 TENSIONER
1 Screw Plug................................................ 40 Nm
2 Seal
3 Filler Pin
4 Compression Spring5 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.
Notice
In 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.