wheel SSANGYONG MUSSO 2003 User Guide

SECTION 1B1
M162 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 otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B1-2Fastener Tightening Specifications . . . . . . . . 1B1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8
Crankcase Ventilation System . . . . . . . . . . 1B1-16
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59
TABLE OF CONTENTS
Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104 Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Cylinder Head Mating Surface . . . . . . . . . 1B1-115

1B1-2 M162 ENGINE MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS N

 m
35 - 40 10 - 15 5 - 10
21 - 25 30
56 - 6650 - 60 10 - 15
41.5 - 49.522.5 - 27.522.5 - 27.5
9 - 11
9 - 11
22.5 - 27.5
9 - 11
22.5 - 27.5
10
+90 °
55
+90 °
+90 °
22.5 - 27.522.5 - 27.5 9 - 109 - 10200
+90 °
40
+90 °
45
+90 °
35
9 - 11 20
+90 °
20
+90 °
20 / + 90 °
20 / + 90 °
22.5 - 27.5
Application
Power Steering Hydraulic Lines A/C High Pressure and Liquid HoseRadiator Support Menber BoltFuel Supply and Return Hose to Fuel DistributorExhaust Manifold and Pipe
Propeller Shaft to Transmission Engine Mounting NutAlternator Carrier BoltBelt Pulley BoltSteering Pump Bolt A/C Bracket Bolt Intake Air Duct BoltIgnition Cable Cover BoltCylinder Head Cover BoltCamshaft Adjuster Bolt Cylinder Head Front Cover Bolt Flange Bolt in Exhaust Camshaft Sprocket Cylinder Head Bolt Cooling Fan Bracket Bolt
Timing Gear Case Cover Bolt M8 M6
Crankshaft Rear Cover BoltVibration Damper Center Bolt Connecting Rod Bearing Cap Bolt Flywheel Stretch Bolt Amarture Bolt in Flywheel Ring and Seal Cover Nut in FlywheelSprocket Bolt to Exhaust Camshaft Camshaft Adjuster Flange Bolt Intake Flange Shaft Bolt Exhaust Camshaft Sprocket Bolt Camshaft Bearing Cap Bolt

1B1-44 M162 ENGINE MECHANICALEngine Lock 602 589 00 40 00
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
Tightening Torque 1st step 200 - 220 Nm
2nd step 90
° +10 °
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in the
reverse order. Notice If possible, don ’t separate the vibration damper and the
pulley.

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).
NoticeDo 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 1B1-53
FLYWHEEL / DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces)............................................... 1st step 45+5 Nm
2nd step +90 ° +10 °
2 Plate 3 Driven Plate (A/T)
4 Dowel Pin
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening Torque
M x 1.5
8.5 - 0.2 mm 8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter When NewDd L
1st step 50 Nm, 2nd step 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

Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm.
For 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 Torque
1st step 45+5 Nm
2nd step 90
° + 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 otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2Fastener 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

1B2-2 M161 ENGINE MECHANICALSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS N

 m
35 - 40 10 - 15 5 - 10
21 - 25 30
56 - 6650 - 60
22.5 - 27.5 41.5 - 49.522.5 - 27.522.5 - 27.5
9 - 11
9 - 11
9 - 11
9 - 11
22.5 - 27.5
10
+90 °
55
+90 °
+90 °
22.5 - 27.522.5 - 27.5 9 - 109 - 10200
+90 °
40
+90 °
45
+90 °
35
9 - 11 20
+90 °
20
+90 °
20 / + 90 °
20 / + 90 °
22.5 - 27.5
Application
Power Steering Hydraulic Lines A/C High Pressure and Liquid HoseRadiator Support Menber BoltFuel Supply and Return Hose to Fuel DistributorExhaust Manifold and Pipe
Propeller Shaft to Transmission Engine Mounting NutAlternator Carrier BoltBelt Pulley BoltSteering Pump Bolt A/C Bracket Bolt Intake Air Duct BoltIgnition Cable Cover BoltCylinder Head Cover BoltCamshaft Adjuster Bolt Cylinder Head Front Cover Bolt Flange Bolt in Exhaust Camshaft Sprocket Cylinder Head Bolt Cooling Fan Bracket Bolt
Timing Gear Case Cover Bolt M8 M6
Crankshaft Rear Cover BoltVibration Damper Center Bolt Connecting Rod Bearing Cap Bolt Flywheel Stretch Bolt Amarture Bolt in Flywheel Ring and Seal Cover Nut in FlywheelSprocket Bolt to Exhaust Camshaft Camshaft Adjuster Flange Bolt Intake Flange Shaft Bolt Exhaust Camshaft Sprocket Bolt Camshaft Bearing Cap Bolt

M161 ENGINE MECHANICAL 1B2-47
CRANKSHAFT SEALING REAR COVER Preceding Work : Removal of the automatic transmission drive plate or flywheel
1 Bolt (M6 x 20, 6 pieces)......................... 9-11 Nm
2 Radial Shaft Seal
3 Rear Cover 4 Sleeve
5 Bolt (M6 x 85, 2 pieces)
......................... 9-11 Nm
6 Washer

M161 ENGINE MECHANICAL 1B2-51
Engine Lock 602 589 00 40 00
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in thereverse order. Notice If possible, don ’t separate the vibration damper and the
pulley. Tightening Torque
1st step 180 - 220 Nm2nd step + 90
°