engine SSANGYONG MUSSO 2003 Service Manual

1B1-102 M162 ENGINE MECHANICAL
OIL NON-RETURN VALVE Preceding Work : Removal of timing gear case cover
1 Oil Non-return Valve
Functions The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As aresult, the chain tensioner can be activated with oil in itself.
Replacement Procedure
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

M162 ENGINE MECHANICAL 1B1-103
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge
2 Oil Dipstick Guide Tube
Removal & Installation Procedure
1. Pull out the oil dipstick level gauge (1).
2. Remove the bolt (4) in the upper intake manifold and remove the oil dipstick guide tube. Installation Notice
3. Install new O-ring to the dipstick guide tube.
4. Installation should follow the removal procedure in the reverse order.
5. Check for leaks by starting the engine. 3 O-ring
4 Bolt (M6 x 12, 1 piece)
........................... 9-11 Nm
Tightening Torque 9 - 11 Nm

1B1-104 M162 ENGINE MECHANICALUNIT REPAIR
OIL GALLERY IN CRANKCASE Preceding Work : Removal of crankshaft, removal of oil spray nozzle
1 Plug
2 Steel Ball
Cleaning Procedure
1. Remove the plug (1) with a screwdriver.
2. Using a round bar (3) and hammer, remove the steel ball (2).
3. Using the compressed air, blow into the oil galleries and clean it off. 3 Round Bar
...................................11 x 750 mm

M162 ENGINE MECHANICAL 1B1-105
1 Plug....................................................... Replace
2 Main Oil Gallery
Tools Required
102 589 12 15 00 Drift Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of 16mm, depth of 15mm.
2. Using an M16 x 1.5 thread (tap), make the thread at the end of main oil gallery (4).
3. Throughly clean the oil gallery with compressed air and tighten the screw plug (M16 x 1.5) after applying sealing bond on it.
4. Apply Loctite 270 on new plug and tighten to the hole until the drift is stopped after inserting new plug into the drift. 3 Screw Plug

1B1-106 M162 ENGINE MECHANICAL
OIL GALLERY IN CYLINDER HEAD Preceding Work : Removal of cylinder headRemoval of camshaft
Removal of tappet
1 Screw Plug................................................ 15 Nm
2 Seal
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2). Installation Notice Replace the seal with new one.
2. Clean the oil gallery using the compressed air.3 Steel Ball (8mm)
Tightening Torque 15 Nm

M162 ENGINE MECHANICAL 1B1-107
Sealing Procedure
1. Remove the screw plug (1) and the seal.Installation Notice
2. Remove the steel ball from the oil gallery (4), (5), (6) and (7) using the round bar (12,
6 x 700 mm).
4. Enlarge the oil gallery at the rear of the cylinder head to be diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery using the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth 8mm.
Tightening Torque 15 Nm
3. Remove the plug (8) using the screw driver.

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 outusing 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
AX
B
X + 5
X + 10 Piston Type to be Used
A or X
A, X or B
X or B
X + 5
X + 10 Cylinder Bore Size (mm)

89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
89.950 - 89.968
90.000 - 90.018
Type
Standard Size
89.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5) Group Code Letter
1)
A XBA X BAXB Cylinder Bore Size (mm) 89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
90.150 - 90.156
89.156 -
90.162
90.162 - 90.168
90.400 - 90.406
90.406 - 90.412
90.412 - 90.418