engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1B2-78 M161 ENGINE MECHANICAL
Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the chain
tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust pin far
enough so that it doesn’t protrude at the chain tensioner
housing. 4. Carefully unscrew the screw plug (1), and remove the seal
(2).
Notice
lFor the removal of screw plug, be careful that it can be
jumped out due to the force of compression spring.
lRemove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring (4),
snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
3. Insert the compression spring (4) with the filler pin (3) into
chain tensioner housing. 2. Install the chain tensioner housing (7), Thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
Tightening Torque 72 - 88 Nm

M161 ENGINE MECHANICAL 1B2-79
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece13 Chain Tensioner Housing
1 4 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole 5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

1B2-80 M161 ENGINE MECHANICAL
TIMING CHAIN
Preceding Work : Removal of cylinder head cover
Removal of spark plug
1 Pin
2 New Timing Chain
3 Timing Chain (Used)
4 Wedge5 Link
6 Center Plate
7 Outer Plate

M161 ENGINE MECHANICAL 1B2-81
Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
001 589 72 21 00 Torque Wrench
Replacement Procedure
1. Position the NO.1 cylinder to ATDC 20°.
4. Mount the wedges to both sides of the camshaft sprocket
as shown in the figure. 2. Insert the pin to the intake and exhaust camshaft flange.
3. Remove the chain tensioner.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.

1B2-82 M161 ENGINE MECHANICAL
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the
link (5) and the center plate (6). 6. Remove the outer plate (7) with the screw driver and
remove the link (5).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.

M161 ENGINE MECHANICAL 1B2-83
15. Replace the thrust piece (b) as shown in the figure. 13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool. 12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
16. Install the assembly tool to the link pin and tighten the
spindle (c).
Tightening Torque 30 Nm

1B2-84 M161 ENGINE MECHANICAL
17. Rivet the link pin.
Check the condition and it again if necessary.
18. Install the chain tensioner.
Installation Notice
19. Check the camshaft timing position.Tightening TorqueScrew Plug
40 Nm
Tensioner Assembly
72 - 88 Nm

M161 ENGINE MECHANICAL 1B2-85
TENSIONING RAIL
Preceding Work : Removal of cylinder head
Removal & Installation Procedure
1. Remove the timing gear case cover (3).
Notice
Be careful not to damage the gasket.
2. Remove the sliding rail (1) from the sliding rail pin (2).
Notice
lReplace the plastic guide (2) if it is damaged.
lFor installation, exactly align the plastic guide (2) with
the sliding rail (1).
3. Installation should follow the removal procedure in the
reverse order. 1 Sliding Rail Pin
2 Sliding Rail3 Timing Gear Case Cover

1B2-86 M161 ENGINE MECHANICAL
CYLINDER HEAD GUIDE RAIL
Preceding Work : Removal of cylinder head cover
1 Bolt (M6 X 45, 2 pieces).................. 9-11 Nm
2 Guide Rail
Removal & Installation Procedure
1. Position the number 1 cylinder to ATDC20° guide rail.
2. Install the pin (special tool : 111 589 03 15 00) into the no.1
and no.6 bearing cap hole.
3. Remove the chain tensioner.
Installation Notice
Tightening TorqueScrew Plug40 Nm
Tensioner Assembly
72 - 88 Nm
4. Unscrew the bolt (1) and remove the guide rail.
Installation Notice
Tightening Torque 9 - 11 Nm
5. Installation should follow the removal procedure in the
reverse order.

M161 ENGINE MECHANICAL 1B2-87
CRANKCASE GUIDE RAIL
Preceding Work : Removal of timing gear case cover
Removal & Installation Procedure
1. Remove the timing gear case cover (3).
Notice
Be careful not to damage the gasket when removing/
installing the timing gear case cover.
2. Remove the guide rail (2) from the guide rail pin(1).
Notice
lReplace the plastic guide (2) if damaged.
lConnect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
3. Installation should follow the removal procedure in the
reverse order. 1 Guide Rail Pin
2 Guide Rail3 Timing Gear Case Cover