height SSANGYONG MUSSO 2003 Service Manual

GENERAL INFORMATION 0B-5
Application
Overall Length (mm) Overall Width (mm)Overall Height (mm)Wheel Base (mm)
Tread : Front (mm)Rear (mm)
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application
Manual : Curb Weight (kg)
Gross Vehicle Weight (kg)
Automatic : Curb Weight (kg)
Gross Vehicle Weight (kg)
Passenger Capacity
Vehicle Weights
Application
4656 18641735263015101520
661LA1860 2520 1916 2520 5 662NA
19682520 1989 2520 5 662LA
18902520 2005 2520 5 2.0L DOHC
19372520
--
5 2.3L DOHC
18502520 1942 25205 3.2L DOHC
19302520 2025 25205

1B1-88 M162 ENGINE MECHANICAL
CONNECTING ROD Preceding Work : Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt(M9 x 52, 12 m pieces) .. 1st step 40+5 Nm 2nd step 90°+10 °
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]
Service Data Standard
Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing Bore Center Width of The Connecting Rod (B) at Bearing BoreWidth of The Connecting Rod (b) at Bushing BoreBasic Bore at The Bearing Shell (D1)Basic Bore at The Bushing (d1) Bushing Inner Diameter (d) Clearance Between The Piston Pin and The BushingPeak-to-valley Height of Connecting Rod Bushing on Inside
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing BorePermissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting Rod Bushing Core
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity
Permissible Difference of Each Connecting Rod in Weight 145 ± 0.05 mm
21.940 - 22.000 mm
21.940 - 22.000 mm
51.600 - 51.614 mm
24.500 - 24.571 mm
22.007 - 22.013 mm 0.007 - 0.018 mm 0.005 mm0.15 mm
0.07 mm
0.01 mm
0.4 g

1B1-112 M162 ENGINE MECHANICAL Service Data Standard Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size inaxial and transverse direction at three points (1,2,3).
1,2,3. Measuring PointsA . Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c . Location of the Oil Ring at BDC
Chamfer Angle
Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out-of-round Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) Basic Peak-to-valley Height After Final Honing and Brushing Chamfer AngleHoning Angle When new
Wear limit 0.1 mm
0.007 mm 0.05 mm0.05 mm
0.003 - 0.006 mm 60°
50 ° ± 10 °

M162 ENGINE MECHANICAL 1B1-113
CRANKCASE MATING SURFACE
Service Data StandardHeight of The Crankcase “H” (When new)
Minimum Height After Milling Flatness Permissible Deviation of Parallelism of The Upper to Lower Mating SurfacePeak-to-valley Height Crankcase Upper Mating SurfaceCrankcase Lower Mating SurfaceAxial Direction
Transverse Direction Crankcase Upper Mating SurfaceCrankcase Lower Mating Surface282.25 - 282.35mm
281.95mm0.03mm0.04mm0.1mm
0.05mm
0.005 - 0.020mm
0.025mm

M162 ENGINE MECHANICAL 1B1-115
CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves
Service Data Standard Notice Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.Overall Height of Cylinder HeadMinimum Height After MachiningFlatness Distance
‘T’
(Between Camshaft Bearing
and Valve Stem) Axial Direction
Transverse DirectionStandard Size Repair Size 135.9 - 136.0 mm
135.5 mm0.08 mm 0.0 mm
24.21 - 24.75 mm 22.21 - 22.75 mm 23.96 - 24.51 mm21.96 - 22.51 mm
Intake
Exhaust Intake
Exhaust

1B1-116 M162 ENGINE MECHANICAL Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard ).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard ).
Universal Tool
Surface Grinding Machine
Sceledum, Type RTYRoaro
Schio/Italy

M161 ENGINE MECHANICAL 1B2-93
CONNECTING ROD Preceding Work : Removal of piston
1 Connecting Rod Bushing
2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt(M9 x 52, 8 pieces) ............1st step 40 Nm
2nd step 90 °
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]
Service Data Standard
Distance (L) from The Connecting Rod Bearing to Bushing Bore Center Width of The Connecting Rod (B) at Bearing Bore Width of The Connecting Rod (b) at Bushing BoreBasic Bore at The Bearing Shell (D1)Basic Bore at The Bushing (d1) Bushing Inner Diameter (d) Clearance Between The Piston Pin and The BushingPeak-to-valley Height of Connecting Rod Bushing on InsidePermissible Wwist of Connecting Rod Bearing Bore toConnecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore fromConcentricity
Permissible Difference of Each Connecting Rod in Weight E20 : 154 mm
E23 : 149 ± 0.05 mm 21.940 - 22.000 mm 21.940 - 22.000 mm 51.600 - 51.614 mm24.500 - 24.571 mm22.007 - 22.013 mm 0.007 - 0.018 mm
0.005 mm
0.1/100 mm
0.045/100 mm
0.01 mm0.4 g

M161 ENGINE MECHANICAL 1B2-109
Service Data Standard Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size inaxial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points
A . Axial Direction B. Transverse Directiona. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c . Location of the Oil Ring at BDC
Chamfer Angle
Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out-of-round Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) Basic Peak-to-valley Height After Final Honing and Brushing Chamfer AngleHoning Angle When new
Wear limit
0.1 mm
0.007 mm 0.05 mm0.05 mm
0.003 - 0.006 mm
75°
50 ° ± 10 °
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase. Type
Standard Size E20 :
89.9
E23 :
90.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5) Group Code Letter
1)
A XB A XBAX B Cylinder Bore Size (mm)
89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
90.150 - 90.156
89.156 -
90.162
90.162 - 90.168
90.400 - 90.406
90.406 - 90.412
90.412 - 90.418

1B2-110 M161 ENGINE MECHANICAL
CRANKCASE MATING SURFACE
Service Data StandardHeight of the Crankcase “H” (When New)
Minimum Height After Milling Flatness Permissible Deviation of Parallelism of the Upper to Lower Mating SurfacePeak-to-valley Height Crankcase Upper Mating SurfaceCrankcase Lower Mating SurfaceAxial Direction
Transverse Direction Crankcase Upper Mating SurfaceCrankcase Lower Mating Surface289.35 - 289.45mm
289.05mm0.03mm0.04mm0.1mm
0.05mm
0.012 - 0.009mm0.025 - 0.020mm

1B2-112 M161 ENGINE MECHANICAL
CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves
Service Data Standard Notice Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.Overall Height of Cylinder HeadMinimum Height After MachiningFlatness Distance
‘T’
(Between Camshaft Bearing
and Valve Stem) Axial Direction
Transverse DirectionStandard Size Repair Size 135.9 - 136.0 mm
135.5 mm0.08 mm 0.0 mm
24.21 - 24.75 mm 22.21 - 22.75 mm 23.96 - 24.51 mm21.96 - 22.51 mm
Intake ExhaustIntakeExhaust