2003 SSANGYONG MUSSO oil

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

1B2-96 M161 ENGINE MECHANICAL
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

M161 ENGINE MECHANICAL 1B2-97
OIL PAN
1 Bolt
2 Bolt
3 Bolt
4 Bolt
1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket. Notice Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply the sealant.
4. Replace the gasket with new one.
5. Install the oil pan with gasket, and tighten each bolt in specified torque.
6. Check for oil leaks while running the engine.
M8 X 40, 4 pieces M6 X 35, 1 piecesM6 X 100, 2 pieceM6 X 85, 3 piecesM6 X 20, 20 pieces5 Bolt
6 Oil Pan
7 Gasket

1B2-98 M161 ENGINE MECHANICAL Oil Circulation
1 Oil Strainer
2 Oil Pump
3 Oil Pan
4 Oil Non-Return Valve
5 Oil Filter
6 Oil Filter Bypass Valve
7 Main Oil Gallery
8 Closing Ball (
15mm)
9 Crankshaft
10 Connecting Rod Bearing 11 Crankshaft Bearing
12 Connecting Rod
13 Piston
14 Oil Spray (Piston Crown Area)
15 Non-Return Valve (Crankcase) 16 Oil Supply (To Chain Tensioner)
1 7 Camshaft
18 Cam Bearing
19 Valve
20 Oil Gallery (Supply Oil to Intake Tappet)
21 Oil Gallery (Supply Oil to Exhaust Tappet)
22 Ball (
8mm)
23 Camshaft Plug
24 Seal
25 Screw Plug
26 Oil Return Gallery (Cylinder Head and
Crankcase)
27 Oil Return Gallery (Crankcase)
28 End Cover (
20mm)
29 Oil Return Pipe

M161 ENGINE MECHANICAL 1B2-99
ENGINE OIL AND OIL FILTER ELEMENT
1 Oil Filter Cover.......................................... 25 Nm
2 O-ring .................................................... Replace
3 Oil Filter Element4 Oil Drain Plug
5 Oil Filter Bypass Valve
6 Oil Filter Cap