2003 SSANGYONG MUSSO Service Manual

M161 ENGINE MECHANICAL 1B2-105
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge
2 Oil Dipstick Guide Tube
3 O-ring
Removal & Installation Procedure
1. Pull out the oil dipstick level gauge (1).
2. Unscrew the bolt (4) and remove the oil dipstick guide tube (2).Installation Notice 4 Bolt (M6 X 16, 1 piece)
........................... 9-11 Nm
5 Clamp
Tightening Torque 9 - 11 Nm
It is very hard to remove the oil dipstick guide tube without
special tool. If it is not necessary, do not remove the guide tube.
3. Installation should follow the removal procedure in the reverse order.
4. Check for leaks by starting the engine.

1B2-106 M161 ENGINE MECHANICALUNIT REPAIR
CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant
1 Core Plug ............................................... Replace

M161 ENGINE MECHANICAL 1B2-107
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 241 hardens.
6. Warm up the engine and check the coolant for leaks.
4. Clean the sealing surface and apply Loctite 241.

1B2-108 M161 ENGINE MECHANICAL Group Code Letter and Cylinder Bore Size
CYLINDER BORE
Group Code Letter of Cylinder
AX
B
X + 5
X + 10 AX
B
X + 5
X + 10 Piston Type to be Used
A or X
A, X or B
X or BX + 5
X + 10 A or X
A, X or B
X or BX + 5
X + 10 Cylinder Bore Size (mm)

90.906 - 90.912
90.906 - 90.912
90.912 - 90.918
90.950 - 90.968
91.000 - 91.018
89.900 - 90.906
89.906 - 89.912
89.912 - 89.918
89.950 - 89.968
90.000 - 90.018
Engine
E23 E20

M161 ENGINE MECHANICAL 1B2-109
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 Points
A . Axial Direction B. Transverse Directiona. 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
75°
50 ° ± 10 °
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase. Type
Standard Size E20 :
89.9
E23 :
90.9
1st Repair Size
(Standard Size + 0.25)
2nd Repair Size
(Standard Size + 0.5) Group Code Letter
1)
A XB A XBAX B 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

1B2-110 M161 ENGINE MECHANICAL
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 Surface289.35 - 289.45mm
289.05mm0.03mm0.04mm0.1mm
0.05mm
0.012 - 0.009mm0.025 - 0.020mm

M161 ENGINE MECHANICAL 1B2-111
Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

1B2-112 M161 ENGINE MECHANICAL
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 ExhaustIntakeExhaust