1998 SSANGYONG MUSSO service

M162 ENGINE MECHANICAL 1B1-49
Selection of Crankshaft Main Bearing
1. Crankcase Side
There 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 the marking
letter on the crankshaft main journal when repaired.
Color Dot Marking
Blue
Yellow
Red
White
VioletCrankshaft Journal Diameter (mm)
57.960 - 57.965
57.955 - 57.960
57.950 - 57.955
57.945 - 57.950
57.940 - 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 DataUnit : mm
Crankshaft
Bearing Jour-
nal DiameterCrankshaft
Bearing
DiameterCrankshaft
Journal Width
at fit bearingConnecting Rod
Bearing Journal
DiameterConnecting
Rod Bearing
Jourmal Width
Standard size
1st repair size
2nd repair size
3rd repair size
4th repair size57.950-57.965
57.700-57.715
57.450-57.465
57.200-57.215
56.950-56.96558 24.50-24.533
-47.94-47.96
47.75
47.50
47.25
47.0027.958-28.042
- Crankshaft Standard
and Repair Size

1B1-52 M162 ENGINE MECHANICAL
Service Data Standard (Crankshaft Main Bearing Gap)
(Connecting Rod Bearing Gap)
Item
Main Bearing Journal
( NO. 1, 5, 7)
Main Bearing Journal
( NO. 3, 4, 6)Measuring Position
Radial
Axial
Radial
AxialGap (mm)
Static condition :0.015 - 0.039
Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.011 - 0.016)
0.010 - 0.254
Static condition :0.011 - 0.039
Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.015 - 0.022)
0.010 - 0.254
Item
Connecting Rod BearingMeasuring Position
RadialGap (mm)
0.030 - 0.050

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 Plate3 Driven Plate (A/T)
4 Dowel Pin
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening TorqueM x 1.5
8.5 - 0.2 mm
8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter
When NewD
d
L
1st step 50 Nm, 2nd step 90°

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 Bore
Width of The Connecting Rod (b) at Bushing Bore
Basic Bore at The Bearing Shell (D1)
Basic Bore at The Bushing (d1)
Bushing Inner Diameter (d)
Clearance Between The Piston Pin and The Bushing
Peak-to-valley Height of Connecting Rod Bushing on Inside
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore
Permissible 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 Weight145 ± 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 mm
0.15 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 in
axial and transverse direction at three points (1,2,3).
1,2,3. Measuring Points
A . 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 Angle
Honing AngleWhen new
Wear limit0.1 mm
0.007 mm
0.05 mm
0.05 mm
0.003 - 0.006 mm
60°
50° ± 10°

M162 ENGINE MECHANICAL 1B1-113
CRANKCASE MATING SURFACE
Service Data Standard
Height of The Crankcase “H” (When new)
Minimum Height After Milling
Flatness
Permissible Deviation of Parallelism of The
Upper to Lower Mating Surface
Peak-to-valley HeightCrankcase Upper Mating Surface
Crankcase Lower Mating Surface
Axial Direction
Transverse Direction
Crankcase Upper Mating Surface
Crankcase Lower Mating Surface282.25 - 282.35mm
281.95mm
0.03mm
0.04mm
0.1mm
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 Head
Minimum Height After Machining
Flatness
Distance ‘T’
(Between Camshaft Bearing
and Valve Stem)Axial Direction
Transverse Direction
Standard Size
Repair Size135.9 - 136.0 mm
135.5 mm
0.08 mm
0.0 mm
24.21 - 24.75 mm
22.21 - 22.75 mm
23.96 - 24.51 mm
21.96 - 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 RTY
Roaro
Schio/Italy