engine SSANGYONG MUSSO 2003 Service Manual

1B2-56 M161 ENGINE MECHANICAL Selection of Crankshaft Main Bearing
1. Crankcase SideThere are seven punching marks on the mating surface to oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing according to the punching mark when repaired.
2. Crankshaft Bearing Cap Side Select the crankshaft main bearing according to themarking letter on the crankshaft main journal whenrepaired.
Color Dot Marking
Blue
Yellow
Red
White VioletCrankshaft Journal Diameter (mm)
57.960 - 57.965 57.955 - 57.960 57.950 - 57.95557.945 - 57.95057.940 - 57.945
Punching Mark


Bearing Color Selected
Blue
Yellow
Red
Marking Letter
B Y
R
W VBearing Color Selected
Blue
Yellow Red
White Violet
Service Data Unit : mm
Crankshaft
Bearing Jour- nal Diameter Crankshaft
Bearing
Diameter Crankshaft
Journal Width at fit bearing Connecting Rod
Bearing Journal Diameter Connecting
Rod Bearing
Jourmal Width
Standard size
1st repair size
2nd repair size 3rd repair size4th repair size 57.950-57.965 57.700-57.71557.450-57.46557.200-57.215
56.950-56.965 58 24.50-24.533 47.94-47.96
47.75 47.5047.25 47.0027.958-28.042
Crankshaft Standard
and Repair Size
-
--

M161 ENGINE MECHANICAL 1B2-57
Installation Notice
Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the leftside (intake manifold side).
Assemble so that the projected part of the cap and
crankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap. Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice
Remove the bearing cap from front (pulley side) to
rear.
Make sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the bearing cap.
There are five kinds of thrust washers by thickness.
Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the reverse order.
5. After completion of the installation, check for the rotating condition of the crankshaft.
Make sure that the upper and lower bearing shells do
not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
Tightening Torque 40 Nm + 90 °
Tightening Torque 55 Nm + 90°

1B2-58 M161 ENGINE MECHANICAL Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaftbearing. Notice
Measure at 2 points (1, 2).
Measure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft bearing journal. Notice
Record the mean value when measured at 3 points
(A, B, C).
Measure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data, replace the bearing shell.

M161 ENGINE MECHANICAL 1B2-59
Service Data Standard (Crankshaft Main Bearing Gap) (Connecting Rod Bearing Gap)
Item
Main Bearing Journal ( NO. 1, 5, 7) Measuring Position
RadialAxial Gap (mm)
Static condition :0.015-0.039
Dynamic condition: 0.031-0.051
(Consider the expansion 0.011-0.016)
0.010 - 0.254
Item
Connecting Rod Bearing Measuring Position
Radial Gap (mm)
0.020 - 0.065

1B2-60 M161 ENGINE MECHANICAL
FLYWHEEL/DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt(M10 x 22, 8 pieces) ................ 1st Step 45 Nm 2nd Step 90°+10 °
2 Plate 3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)
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 °

M161 ENGINE MECHANICAL 1B2-61
Removal & Installation Procedure
1. Unscrew the stretch bolt.Installation Notice
Sectional View
1 Oil Pan
2 Cover
3 Radial Seal
4 Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (Thickness : 3.5 mm)
8 Washer
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 Nm
2nd step 90
°+5 °

1B2-62 M161 ENGINE MECHANICAL CAMSHAFT ADJUSTER
1 Bolt (M6 X 16, 3 pieces)......................... 9-11 Nm
2 Cylinder Head Front Cover
3 Bolt ........................................................... 35 Nm
4 Armature
5 Roll Pin
6 Nut (M20 X 1.5) .................................... 60-70 Nm
7 Seal Cover
8 Camshaft Sprocket
9 Adjust Piston
10 Conical Spring 11 Flange Bolt
(M7 X 13, 3 pieces) .................1st Step 20±2 Nm
2nd Step 90 ° ± 5 ° Rotation Added
12 Flange Shaft
13 Compression Spring
14 Control Piston
15 Circlip
16 Oil Gallery
17 Straight Pin
18 Intake Camshaft
Y49 Magnetic Actuator (2-pin connector)

M161 ENGINE MECHANICAL 1B2-63
Removal & Installation Procedure
1. Turn the crankshaft and position the n0.1 cylinder piston atATDC 20 °.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Remove the cylinder head front cover.
3. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
4. Insert the insert pin into the no.1 and no.6 bearing cap hole on camshaft to secure intake and exhaust camshaft.
5. Remove the chain tensioner.
6. Unscrew the exhaust sprocket bolt and remove the exhaust camshaft sprocket. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step 90
°
Notice The flange bolt is designed to be used only once, so always replace with new one.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and removethe roll pin, and remove the armature. Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice
Tightening Torque 60 - 70 Nm
Notice Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step + 95
°
Notice The flange bolt is designed to be used only once, so always replace with new one.
12. Installation should follow the removal procedure in the reverse order.
13. Check and adjust the camshaft timing.

M161 ENGINE MECHANICAL 1B2-65
CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt Notice The sprocket bolts are designed to be used only once, so always replace with new one. Exhaust Camshaft Sprocket Bolt Notice The sprocket bolts are designed to be used only once, so always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
E. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
Tightening Torque
1st step 20 Nm
2nd step + 90
°
Tightening Torque 1st step 20 Nm
2nd step + 90
°