SSANGYONG MUSSO 1998 Workshop Repair Manual

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

1B2-88 M161 ENGINE MECHANICAL
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
Removal of cylinder head
6 Bolt (M8 x 20, 1 piece) / Washer..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain 1 Oil Pump Chain Tensioner
2 Oil Pump Chain Spring
3 Oil Pump Chain Bushing (Pin)
4 Crankshaft Sprocket
5 Key

M161 ENGINE MECHANICAL 1B2-89
Tools Required
615 589 01 33 00 Caulking Bolt
Removal & Installation Procedure
1. Put the assembly mark at the crankshaft sprocket (4) and
the timing chain (10) with the paint (arrow).
Installation Notice
Align the assembly marks on cranshaft sprocket and timing
chain. Also, align the assembly marks on camshaft sprocket
and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7)
from the oil pump.
Installation Notice
Caulking (04) 615 589 01 33 00
3. Remove the oil pump roller chain (9).
4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (3), and the oil pump chain spring (2).
5. Remove the crankshaft sprocket (4) using the puller (04,
special tool).
Notice
lMake sure not to lose the crankshaft pulley key (5) when
removing.
lInstall the crankshaft sprocket (4) after warming it up.
6. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 29 - 35 Nm

1B2-90 M161 ENGINE MECHANICAL
PISTON
Preceding Work : Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal 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

M161 ENGINE MECHANICAL 1B2-91
Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.
Installation Procedure