2003 SSANGYONG MUSSO engine

1B1-84 M162 ENGINE MECHANICAL
Tools Required
615 589 01 33 00 Puller 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
Puller (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 (2), and the oil pump chain spring (3).
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

M162 ENGINE MECHANICAL 1B1-85
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, 12 pieces).................................................... 1st step 40 Nm
2nd step 90 ° + 5 ° 4 Piston
5 Snap Ring
6 Piston Pin

1B1-86 M162 ENGINE MECHANICAL
Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.Notice Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice Remove the snap ring using a clean cloth as shown in the right picture so that the piston, piston ring, and the snapring don ’t get damaged.
Installation Procedure

M162 ENGINE MECHANICAL 1B1-87
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.

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

M162 ENGINE MECHANICAL 1B1-89
Inspection
1. Measure the basic bore of the connecting rod bearing.Notice If the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod.
2. Check connecting rod bolts.
3. Check the assembly mark(indication//or number:arrow) of the connecting rods and the bearing cap when installing. Notice
Make sure it doesn ’t exceed over 4g with other
connecting rods when replacing the connecting rods.
Check if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the bearing.
Notice If the length exceeds max. length, replace it.
Length When New (L)
Max. Length (L)
Tightening Torque 51.7 - 52 mm
52.9 mm
1st step 40 + 5 Nm 2nd step 90 °+10 °

1B1-90 M162 ENGINE MECHANICAL PISTON RING Preceding Work : Removal of piston
1 Piston Compression Ring
2 Piston Compression Ring
3 Piston Oil Ring 4-
5 Coil Spring and Control Ring
6 Hook Spring
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 0.015 - 0.050 mmGroove 2 0.020 - 0.040 mmGroove 3 0.010 - 0.045 mmEnd Gap of The Piston Ring

M162 ENGINE MECHANICAL 1B1-91
2. Remove the piston ring with a pliers.
3. For installation, position the piston ring to be the ‘TOP ’ mark
on the piston ring upward and arrange the piston ring ends to be 120 ° apart.
4. Adjust the hook spring joint in the oil ring 180 ° away from
the ring end.
Clamping Strap 000 589 51 37 00