161 SSANGYONG MUSSO 2003 Service Manual

SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)
GENERAL ENGINE INFORMATION TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A2-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A2-1
Component Locator . . . . . . . . . . . . . . . . . . 1A2-3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-3
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-4
Performance Curve . . . . . . . . . . . . . . . . . . 1A2-5
E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-5
E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A2-7
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-7Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
1A2-8
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8
Engine Cranking At The Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9
Compression Pressure Test . . . . . . . . . . . . 1A2-10
Cylinder Pressure Leakage Test . . . . . . . . . 1A2-12
General Information . . . . . . . . . . . . . . . . . 1A2-14
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
E20 Engine
M161.940 1998
89.9 x 78.7

9.6:1

135 / 5500
19.3 / 4000
ATDC 13.15° / ABDC 13.57°
BBDC 16.58° / BTDC 17.05°
Application
Engine Model Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition SystemCompression RatioNumber of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type Max. Output (ps/rpm)
Max. Torque (kg m/rpm)Firing Order
Ignition Type
Ignition Timing
Valve Timing Intake Open/Close ExhaustOpen/Close
Valve Clearance Adjustment SPECIFICATIONS
ENGINE SPECIFICATIONS E23 EngineM161.970 2295
90.9 x 88.4
MSE 3.53S 10.4:1
4
DOHC
Chain-Driven 149 / 5500
22.4 / 4000 1-3-4-2
Distributorless
BTDC 6° ± 2 °
ATDC 19.25° / ABDC 28.76°
BBDC 20.62° / BTDC 15.08° Automatic Control

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 1B2-3
N

 m
20 / + 90 °
40
72 - 88
20 / + 90 °
25 - 35
22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 30
26 - 34
30
8 - 10 2525
22.5 - 27.5 29 - 35
22.5 - 27.5 9 - 11
50
9 - 11
15Application
Exhaust Camshaft Sproket Bolt
Chain Tensioner Screw Plug
Chain Tensioner AssemblyExhaust Camshaft Sprocket to CamshaftOil Pump Sprocket Bolt
Tensioning Device Bolt
Water Pump PulleyUpper Intake Manifold BoltLower Intake Mainfold BoltFlange Bolt to Exhaust Mainfold Exhaust Mainfold Nut to Stud Bolt Rivet Nut in Exhuast Mainfold HolePre-Silencer BoltOil Drain PlugOil Filter Cover Oil Filter Bolt Oil Pump Drive Sprocket BoltOil Pump Mounting BoltOil Strainer Bracket Bolt
Oil Pressure Relief Valve Screw Plug Oil Dipstick Guide tube Bolt Oil Gallery Screw Plug
FASTENER TIGHTENING SPECIFICATIONS (Co n t ’d)

1B2-4 M161 ENGINE MECHANICALSPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 Torque Wrench
112 589 00 72 00 Oil Extractor 000 589 72 21 00
Torque Wrench
001 589 66 21 00 Torque Wrench
000 589 01 10 00
Box Wrench Insert 124 589 15 21 00
Radiator CapTesting Unit
116 589 02 34 00
Screw-Fixed Pin 000 589 40 37 00
Hose Clamp

M161 ENGINE MECHANICAL 1B2-5
SPECIAL TOOLS TABLE (Co n t’d)
104 589 01 01 00 Spanner
111 589 18 61 00Lever Pusher 111 589 25 63 00
Thrust Piece
111 589 01 59 00Supporting Bar
116 589 06 63 00
Magnetic Finger
119 589 00 43 00 Drift 000 589 58 43 00 Chain Assembly
104 589 00 37 00
Pliers

1B2-6 M161 ENGINE MECHANICALSPECIAL TOOLS TABLE (Co n t ’d)
116 589 20 33 00
Sliding Hammer
602 589 00 40 00 Engine Lock 103 589 00 33 00
Puller
601 589 03 43 00Sleeve
001 589 65 09 00
Socket Wrench Insert
001 589 74 21 00 Torque Wrench 000 589 04 14 00
Clamping Strap
000 589 88 33 00
Puller

M161 ENGINE MECHANICAL 1B2-7
SPECIAL TOOLS TABLE (Co n t’d)
103 589 01 63 00 Rivet Set
103 589 02 09 00 Oil Filter
Socket Wrench 102 589 12 15 00
Drift
615 589 01 33 00Caulking Bolt
102 589 00 15 00 Drift
000 589 51 37 00 Clamping Strap 001 589 72 21 00
Torque Wrench
601 589 03 14 00
Sleeve

1B2-8 M161 ENGINE MECHANICALSPECIAL TOOLS TABLE (Co n t ’d)
617 589 00 10 00 Wrench Socket
104 589 00 40 00 Holder 111 589 03 15 00
Insert Pin
116 589 01 34 00Threaded Bolt

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