2003 SSANGYONG MUSSO oil change

M162 ENGINE MECHANICAL 1B1-17
Operation at Idling and Mid-Load
It show that the throttle valve (19) is closed or very partially opened and the vacuum pressure in intake manifold is high. The blowby gas in the crankcase in partial load flows into the intake manifold through the vent line (20) after passingthe air conditioner bracket (6) and the filter (4). The air reentered into the intake manifold will be dilluted on the flow
through the restriction hole (11) in the vent line (10). The circulated engine oil is separated at the air conditioner bracket (6) and then returns into the oil pan through thedrain pipe (7). The vacuum pressure generated at the crankcase sucks fresh air from intake air line(13) through the air admissionand vent connection (17,18). The fresh air prevents engine oil from being contami-nated and the air admission and vent connection (17,18) is designed to control the rapid pressure changes in intakeair line (13).
Operation at Full-Load
The throttle valve (19) is fully opened. All the blowby gases flow into the intake air duct (13) after passing through the oil separator (15,16) of the cylinder head cover (14) when fully loaded. This dilluted air will be supplied to the combustion chamber through the intakemanifold (12).

1B1-50 M162 ENGINE MECHANICALInstallation Notice
Make sure the crankshaft bearing cap properly seated in place in the crankcase side. When perfectly installed,the projected part (arrow) locates in the left side (intakemanifold side).
Assemble so that the projected part of the cap andcrankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap. Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice
Remove the bearing cap from front (pulley side) to rear.
Make sure that the upper and lower bearing shells do not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must faceoutward and insert the thrust bearing into the bearingcap.
There are five kinds of thrust washers by thickness. Selectthe proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the reverse order.
5. After completion of the installation, check for the rotating condition of the crankshaft.
Make sure that the upper and lower bearing shells do
not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
Tightening Torque 40 Nm + 90 °
Tightening Torque 55 Nm + 90°

M161 ENGINE MECHANICAL 1B2-57
Installation Notice
Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the leftside (intake manifold side).
Assemble so that the projected part of the cap and
crankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap. Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice
Remove the bearing cap from front (pulley side) to
rear.
Make sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the bearing cap.
There are five kinds of thrust washers by thickness.
Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the reverse order.
5. After completion of the installation, check for the rotating condition of the crankshaft.
Make sure that the upper and lower bearing shells do
not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
Tightening Torque 40 Nm + 90 °
Tightening Torque 55 Nm + 90°

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °

OM600 ENGINE MECHANICAL 1B3-167
6. Coat the cylinder bore, connecting rod bearing journal,connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap (7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a wooden stick (18). Notice The arrow on the piston crown must point toward the front of vehicle.
9. Insert the connecting rod bearing shells (9, 10). Notice Be careful of the difference in upper and lower bearing shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice Position so that the retaining lugs are on the same side of the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connecting rod bolts.
Limit ‘ C ’ 7.1mm

M162 ENGINE CONTROLS 1F1-23
Failurecode ItemChecking method
Te s t stepRequirementSpecified
value Possible cause
106 11 The value will
be changed in 1.2 - 1.7 V
- Voltage
(alternating)
0.9 - 1.6
71 11
71 72

Engine:in cranking
7.1 
Ignition:ON
- Remove the connector from the Camshaft positionsensor betweenNo.1 terminal andNo.3 terminal.
13
11 -14 V



Camshaft
positionsensor(E23 only)- Power supply
 Cable
 OVPR



Ignition
coil(T1/1) - primary coil voltage(No.2 and 5 cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 %(using engine tester)
 Ignition:OFF 200 - 350 VCamshaft position
sensor
64, 8.0
8.1
8.1 


Connecting
resistance of ignition coilbetween T1/1 and T1/2 
Cable
 Ignition coil T1/1
 Ignition coil T1/2
72 11



Ignition
coil(T1/2) - primary coil voltage(No.3 and 4cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 %(using engine tester) 200 - 350 V
65, 9.0
9.1
0.9 - 1.6
72 71
 Ignition:OFF 9.1 


Connecting
resistance of ignition coilbetween T1/2 and T1/1 
Cable
 Ignition coil T1/1
 Ignition coil T1/2
The
resistance of
ignition coil at 20°C is
approached 0.6
The
resistance of
ignition coil at 20°C is
approached 0.6

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drainplug.
2. Remove the axle housing cover. Notice Clean the cover and housing contact surface.
3. Remove the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly. Notice Place alignment marks on the bearing cap not to change the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
4. Disassemble the parts of the differential carrier assembly.
Tightening Torque 28 - 42Nm

FRONT DISC BRAKES 4D-5
4. Measure rotor disc thickness.
UNIT REPAIR FRONT DISC BRAKE Inspection Procedure
1. Clean all components and visually check the followings. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDO Wear Limit

61.4 mm
61.0 mm
Standard
10 mm Wear Limit
2.0 mm
Standard
60.4 mm
60.0 mm
3. Measure pad thickness. Notice Always change the all pads on one wheel at a time.
5. Check the rotor disc for score or runout.
Standard 24 mm Wear Limit
22 mm