engine SSANGYONG MUSSO 2003 Service Manual

1B2-46 M161 ENGINE MECHANICAL
8. Unscrew the bolts (A).Installation Notice
Tightening Torque 22.5 - 27.5 Nm
9. Remove the belt pulley and vibration damper. Installation Notice (Center Bolt)
Tightening Torque 1st step 180 - 220 Nm 2nd step 80
° - 100 °
10. Unscrew the bolts (1, 2) on timing gear case cover and
remove the timing gear case cover. Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Notice Be careful not to damage the cylinder head gasket.
11. Remove the radial shaft seal
NoticeInstallation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase sealing surface.
13. Replace the O-ring with new one and apply the sealant on the sealing surface.NoticeBe careful not to stain the oil chamber of chain tensioner with the sealant.
14. Installation should follow the removal precedure in the reverse order.
15. Warm up the engine and check for oil leaks.

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

1B2-48 M161 ENGINE MECHANICAL
Tools Required
601 589 03 43 00 Sleeve Removal & Installation Procedure
1. Unscrew the bolts (1) and (5) and remove the closing coverby pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
NoticeDo not use the grease.
6. Using the special tool, press the radial shaft seal and the rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan bolt (5) as specified and remove the special tool. Installation Notice
Seal Assembler 601 589 03 43 00
Tightening Torque(Bolt 1,5) 9 - 11 Nm

M161 ENGINE MECHANICAL 1B2-49
BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutchRemoval of fan shroud Removal of drive belt
1 Center Bolt(M18 X 55) ....................... 1st step 200-220 Nm
2nd step 90° + 10 ° rotation added
2 Vibration Damper Disk 5 Vibration Damper Assembly
6 Key

1B2-50 M161 ENGINE MECHANICAL Components
Service Data Standard
Permissble Deviation of The Vibration DamperRadial Runout Axial Runout0.6 mm 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
001 589 74 21 00 Puller
000 589 88 33 00 Torque Wrench
602 589 00 40 00 Engine Lock Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.
1 Center Bolt (M18 x 50)
2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan 11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

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
°

1B2-52 M161 ENGINE MECHANICAL 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 thevibration 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 Torque 1st step 200 - 220Nm
2nd step 90
° + 10 °

M161 ENGINE MECHANICAL 1B2-53
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.

1B2-54 M161 ENGINE MECHANICAL CRANKSHAFT Preceding Work : Removal of engineRemoval of cylinder head Removal of timing gear case cover Removal of crankcase sealing rear coverRemoval of oil panRemoval of baffle plateRemoval of oil pump
1 Bearing Cap Bolt(M8 X 55-10 pieces) ............ 1st step 50-60 Nm 2nd step 90°+5 ° rotation added
2 Bearing Cap
3 Upper Main Bearing
4 Lower Main Bearing
5 Upper Thrust Bearing
6 Lower Thrust Bearing
8 Crank Shaft

M161 ENGINE MECHANICAL 1B2-55
Arrangement of the Thrust Bearing and the Main Bearing1 - 8 Weight Balance/Color Marking Point
j1 - j5 Journal Main Bearing #1 - #5 Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6
, 8 , and it indicates the diameter of crankshaft journal
by color as below. A Crankcase Side
B Bearing Cap Side (Oil Pan Side)
1 Upper Main Bearing
2 Upper Thrust Bearing
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing