2003 SSANGYONG MUSSO engine oil

M161 ENGINE MECHANICAL 1B2-77
CHAIN TENSIONER1 Screw Plug ................................................ 40 Nm
2 Seal
3 Filler Pin
4 Compression Spring 5 Snap Ring
6 Thrust Pin
7 Chain Tensioner Housing
.....................72-88 Nm
8 Seal
Removal Procedure
1. Position the number 1 cylinder to A TDC 20°.
Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam ’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
NoticeIn case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.If the chain tensioner is tightened again without completely reducing its tension, then the snap ring doesn ’t return to
the original position and the tension gets excedded.

M161 ENGINE MECHANICAL 1B2-79
4. Lightly apply the grease to the seal (2) and install the screwplug (1). Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece 13 Chain Tensioner Housing
14 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole
5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

1B2-88 M161 ENGINE MECHANICAL
CRANKSHAFT SPROCKET Preceding Work : Removal of oil panRemoval of tensioning rail Removal of crank case guide rail Removal of cylinder head
6 Bolt (M8 x 20, 1 piece) / Washer ..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain
1 Oil Pump Chain Tensioner
2 Oil Pump Chain Spring
3 Oil Pump Chain Bushing (Pin)
4 Crankshaft Sprocket
5 Key

M161 ENGINE MECHANICAL 1B2-89
Tools Required
615 589 01 33 00 Caulking Bolt Removal & Installation Procedure
1. Put the assembly mark at the crankshaft sprocket (4) andthe timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain. Also, align the assembly marks on camshaft sprocketand timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7) from the oil pump. Installation Notice
Caulking (04) 615 589 01 33 00
3. Remove the oil pump roller chain (9).
4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (3), and the oil pump chain spring (2).
5. Remove the crankshaft sprocket (4) using the puller (04, special tool). Notice
Make sure not to lose the crankshaft pulley key (5) when
removing.
Install the crankshaft sprocket (4) after warming it up.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 29 - 35 Nm

1B2-90 M161 ENGINE MECHANICAL PISTON Preceding Work : Removal of engineRemoval of cylinder head Removal of oil pan Removal of oil pumpRemoval of baffle plate
1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bolt(M9 x 52, 8 pieces) ......................1st step 40 Nm
2nd step 90 ° +5 ° 4 Piston
5 Snap Ring
6 Piston Pin

1B2-92 M161 ENGINE MECHANICAL
1. Check the piston ring gap and apply the engine oil to thepiston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and the piston and coat them with engine oil.
4. Install the piston ring using the tensioning strap(000 589 04 14 00).
5. Install the piston so that the arrow on the piston head faces to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark (// or a number), tighten the bolts.
Installation Notice
Tightening Torque 1st step 35 - 45 Nm
2nd step 90
°+5 °
Apply the engine oil to the bearing cap upper and lower bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating it.

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 1B2-95
PISTON RING Preceding Work : Removal of piston
1 Piston Compression Ring (Top Ring)
2 Piston Compression Ring (2nd Ring)
3 Piston Oil Ring 4-
5 Spacer
6 Side Rail
Notice If out of specification, replace the piston ring.
Tools Required
000 589 51 37 00 Clamping Strap
Replacement Procedure
1. Measure the piston ring ’s gap.
Gap Between The Piston and The Piston Ring
Groove 1 0.20 - 0.40 mm Groove 2 0.20 - 0.40 mm Groove 3 0.20 - 0.45 mm
Groove 1 0.028 - 0.060 mm Groove 2 0.010 - 0.045 mmGroove 3 0.010 - 0.045 mmEnd Gap of The Piston Ring