engine oil SSANGYONG MUSSO 1998 Workshop Manual Online

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).

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°

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

M161 ENGINE MECHANICAL 1B2-3
N
· ·· ·
·m
20 / + 90°
40
72 - 88
20 / + 90°
25 - 35
22.5 - 27.5
22.5 - 27.5
22.5 - 27.5
22.5 - 27.5
30
26 - 34
30
8 - 10
25
25
22.5 - 27.5
29 - 35
22.5 - 27.5
9 - 11
50
9 - 11
15Application
Exhaust Camshaft Sproket Bolt
Chain Tensioner Screw Plug
Chain Tensioner Assembly
Exhaust Camshaft Sprocket to Camshaft
Oil Pump Sprocket Bolt
Tensioning Device Bolt
Water Pump Pulley
Upper Intake Manifold Bolt
Lower Intake Mainfold Bolt
Flange Bolt to Exhaust Mainfold
Exhaust Mainfold Nut to Stud Bolt
Rivet Nut in Exhuast Mainfold Hole
Pre-Silencer Bolt
Oil Drain Plug
Oil Filter Cover
Oil Filter Bolt
Oil Pump Drive Sprocket Bolt
Oil Pump Mounting Bolt
Oil Strainer Bracket Bolt
Oil Pressure Relief Valve Screw Plug
Oil Dipstick Guide tube Bolt
Oil Gallery Screw Plug
FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

1B2-4 M161 ENGINE MECHANICAL
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01
Torque Wrench
112 589 00 72 00
Oil Extractor000 589 72 21 00
Torque Wrench
001 589 66 21 00
Torque Wrench
000 589 01 10 00
Box Wrench Insert124 589 15 21 00
Radiator Cap
Testing Unit
116 589 02 34 00
Screw-Fixed Pin000 589 40 37 00
Hose Clamp

M161 ENGINE MECHANICAL 1B2-7
SPECIAL TOOLS TABLE (Cont’d)
103 589 01 63 00
Rivet Set
103 589 02 09 00
Oil Filter
Socket Wrench102 589 12 15 00
Drift
615 589 01 33 00
Caulking Bolt
102 589 00 15 00
Drift
000 589 51 37 00
Clamping Strap001 589 72 21 00
Torque Wrench 601 589 03 14 00
Sleeve

M161 ENGINE MECHANICAL 1B2-9
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 10 99 01 Torque Wrench
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor

1B2-12 M161 ENGINE MECHANICAL
12. Discharge the refrigerant from A/C system, and disconnect
the discharge pipe and suction pipe from the compressor.
14. Remove the fuel feed and return line.
Notice
Before removing the fuel lines, release the pressure in the
fuel system.
Installation Notice 13. Remove the acceleration control cable and automatic
transmission pressure cable. 11. Remove the hydraulic pipe of power steering.
Notice
Completely drain the oil.
Tightening Torque 21 - 25 Nm

1B2-14 M161 ENGINE MECHANICAL
20. Disconnect following sensors connector.
lHFM sensor.
lCoolant temperature sensor.
l2 knock sensors.
lCamshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness.
23. Separate the hose toward engine from canister purge
solenoid valve.
24. Remove the automatic transmission oil cooler line.

M161 ENGINE MECHANICAL 1B2-17
CRANKCASE VENTILATION SYSTEM
Operation at Idling and Mid-Load
1 HFM Sensor
2 Cylinder Head Cover
3 Oil Spearation Chamber (Full-Load or Over
Mid-Load)
4 Intake Air Duct (Cross Pipe)
5 Vent Line (Full-Load or Over Mid-Load)
6 Throttle Valve
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold
9 Vent Line (Mid-Load at Idling)
10 Air Conditioner Bracket11 Oil Separation Chamber (Mid-Load at Idling)
12 Crank Chamber
13 Oil Return Pipe
14 Oil Pan
15 Timing Gear Case Cover
16 Crankcase
17 Chain Housing
A Fresh Air
C Blow-by Gas
D Vent Connection