SSANGYONG MUSSO 2003 Service Manual

M161 ENGINE MECHANICAL 1B2-9
MAINTENANCE AND REPAIRON-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

1B2-10 M161 ENGINE MECHANICAL
4. Disconnect the coupling of HFM sensor and remove the aircleaner cross pipe.
6. Loosen the radiator drain cock and drain the coolant. Notice Open the coolant reservoir cap.
5. Remove the air cleaner cover. Remove the mounting bolts
and air cleaner housing and element assembly.
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice
Tightening Torque 28 - 47 Nm

M161 ENGINE MECHANICAL 1B2-11
10. Remove the upper mounting bolts of radiator and thenremove the radiator.
7. Loosen the cylinder block drain plug and then drain thecoolant completely. Installation Notice
Tightening Torque 30 Nm
Notice Replace the seal before installation of the drain plug.
8. Remove the cooling fan shroud.
9. Disconnect the each hose from radiator.

1B2-12 M161 ENGINE MECHANICAL
12. Discharge the refrigerant from A/C system, and disconnectthe 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.
NoticeCompletely drain the oil.
Tightening Torque 21 - 25 Nm

M161 ENGINE MECHANICAL 1B2-13
19. Disconnect the engine ground wire.
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.

1B2-14 M161 ENGINE MECHANICAL
20. Disconnect following sensors connector.HFM sensor.
Coolant temperature sensor.
2 knock sensors.
Camshaft 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 1B2-15
Tightening Torque 30 Nm
29. Remove the exhaust manifold and exhaust pipe.
Installation Notice
25. Separate the vacuum hose for brake booster.
26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.Installation Notice
28. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate.
Tightening Torque 81 - 89 Nm

1B2-16 M161 ENGINE MECHANICAL
30. Remove the transmission mounting bolts and separatethe transmission from the engine. Installation Notice
Tightening Torque 65 Nm
31. Remove the bolts for engine mounting bracket. Installation Notice
Tightening Torque 50 - 75 Nm
32. Hook the chain to the bracket of engine and by using a hoist or crane, carefully separate the engine assembly from the vehicle.
33. Installation should follow the removal procedure in the reverse order.

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 OverMid-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 Bracket 11 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

1B2-18 M161 ENGINE MECHANICAL Operation at Idling and Mid-Load
The throttle valve(6) is closed or very partially opened, and the vacuum pressure in intake manifold is high. The blow-by gas and the fresh air that is additionally supplied through the vent connection(D) in the crankcase in partialload gets supplied to the combustion chamber from the crank
chamber(12) through the oil separation chamber(11), air- conditioner bracket(10), vent line(9), and restrictor(7)mounted to the cylinder head. The circulated engine oil returns to the oil pan through the oil return pipe(13) at the bottom of oil separation
chamber(11). The fresh air gets supplied to the crank chamber(12) through the HFM sensor(1), intake air duct(4), vent line(5), oil separation chamber(3), chain housing(17), and the timing gear case cover(15). The additional supply of the fresh air is needed to prevent from forming the residues of the engine oil.