2003 SSANGYONG MUSSO Service Manual

M162 ENGINE MECHANICAL 1B1-109
CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant
1 Core Plug............................................... Replace

1B1-110 M162 ENGINE MECHANICAL
Tools Required
102 589 00 15 00 Drift Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes outusing the screw driver.
3. Pull out the plug carefully using a pliers.
5. Press in new plug using a drift. Notice
Wait for about 45minutes before filling the coolant so that the Loctite 240 hardens.
6. Warm up the engine and check the coolant for leaks.
4. Clean the sealing surface and apply Loctite 241.

M162 ENGINE MECHANICAL 1B1-111
Group Code Letter and Cylinder Bore Size Repair Size 1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
CYLINDER BORE
Group Code Letter of Cylinder
AX
B
X + 5
X + 10 Piston Type to be Used
A or X
A, X or B
X or B
X + 5
X + 10 Cylinder Bore Size (mm)

89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
89.950 - 89.968
90.000 - 90.018
Type
Standard Size
89.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5) Group Code Letter
1)
A XBA X BAXB 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

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

1B1-114 M162 ENGINE MECHANICAL Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

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