engine SSANGYONG MUSSO 2003 Service Manual

1B2-66 M161 ENGINE MECHANICAL CAMSHAFT Preceding Work : Removal of cylinder head coverRemoval of camshaft adjust actuator and cylinder head front cover
1 Bolt (M7 X 13, 3 pieces) .........1st Step 18-22 Nm
2nd Step 90 °+ 5 ° Rotation Added
2 Exhaust Camshaft Sprocket
3 Timing Chain
4a Intake Camshaft Spocket (E20) 4b Camshaft Adjuster and Camshaft Sprocket (E23)
5 Bearing Cap Bolt (20 pieces) .........22.5-27.5 Nm
6 Camshaft Bearing Cap
7 Wrench (Special Tool)

M161 ENGINE MECHANICAL 1B2-67
Tools Required
000 589 01 10 00 Box Wrench Insert104 589 01 01 00Spanner
Removal & Installation Procedure
1. Turn the crankshaft and position the no.1 cylinder piston at ATDC20 °.
2. Put the alignment marks (arrows) on the camshaft sprocket
and the timing chain.
3. Remove the chain tensioner. Installation Notice
Tightening Torque 40 Nm
72 - 88 Nm
Screw Plug
Tensioner Assembly
4. Remove the exhoust camshaft sprocket. Installation Notice
Tightening Torque 1st step 35 - 45 Nm
2nd step 85
° - 95 °
Notice The sprocket bolt is designed to be used only once, so always replace with new one.
5. Take off the timing chain from intake camshaft sprocket, and secute it not to fall down into the timing gear case.
6. Using the wrench (7), turn the camshaft until there is no resistence in camshaft bearing area.

1B2-68 M161 ENGINE MECHANICAL
7. Remove the bearing cap, and remove the intake and theexhaust camshaft. Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Notice Check the numbers on the bearing cap not to be miked up.
8. Apply the engine oil on the valve tappet and camshaft bearing.
9. Installation should follow the removal procedure in the reverse order. Notice
Base circle of cam should cantact with the valve tappet.
Install the camshaft bearing caps according to the
numbers on the cylinder head cast and bearing cap.
10. Check the camshaft timing position.

M161 ENGINE MECHANICAL 1-1B-69
CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head coverRemoval of cylinder head front cover
1 Insert Pin ( 6.5mm, Special Tool)
2 Intake Camshaft Sprocket
3 Camshaft Bearing Cap
4 Timing Chain 5 Exhaust Camshaft Sprocket
6 Bolt (M7 X 13, 3 pieces)
.........1st step 20 ± 2 Nm
2nd step 90 ° ± 5 ° rotation added
7 Strate Pin

1B2-70 M161 ENGINE MECHANICAL
Tools Required 104 589 01 01 00 Spanner
111 589 03 15 00 Insert Pin Inspection Procedure
1. Position the NO.1 cylinder piston to ATDC 20° by turning
the crankshaft Notice
When the ATDC 20 ° mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up.
In this way, the insert hole in NO.1 and NO.4 camshaftbearing cap will match in line with the flange hole forcamshaft sprocket.
2. Check the timing as below procedure;
- Check if the insert pin (111 589 03 15 00) can be inserted into the NO.1 and NO.4 bearing cap hole.
- At this condition, check if the ATDC 20 ° mark on vibration
damper aligns with the marker on the timing gear case.

M161 ENGINE MECHANICAL 1B2-71
Adjustment Procedure
1. Position the NO.1 cylinder to ATDC 20° .
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Adjust the timing position with inserting the insert pin (f6.5mm, 111 589 03 15 00) into the NO.1 and NO.4
camshaft bearing cap hole and flange hole while rotating the camshaft by using wrench (104 589 01 01 00).
5. Install the chain to the intake camshaft sprocket.
6. Install the chain to the exhaust camshaft sprocket and tighten the bolt.Installation Notice
Tightening Torque 1st step 20 Nm
2nd step + 90
°
The sprocket bolt is designed to be used only once, so replace with new one.
7. Install the chain tensioner. Installation Notice
Screw plug
Tensioner assembly 40 Nm
80 ± 8 Nm
Tightening
Torque
8. Check the camshaft timing.

1B2-72 M161 ENGINE MECHANICAL
VALVE SPRING Preceding Work : Removal of camshaftRemoval of spark plug
1 Valve Tappet Assembly
2 Valve Cotter
3 Upper Retainer
4 Valve Spring..........Check, Replace if necessary
5 Valve Stem Seal
6 Lower Retainer 7 Connecting Hose
8 Thrust Piece
9 Slide
10 Adjust Bolt 11 Lever Pusher
12 Supporting Bar

M161 ENGINE MECHANICAL 1B2-73
Tools Required
111 589 01 59 00 Supporting Bar
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece
116 589 06 63 00 Magnetic Finger Removal & Installation Procedure
1. Place the supporting bar (12) and the slide (9) at thecamshaft bearing cap (Nos 1 & 7/8&14) and tighten them with the bearing cap bolt. Installation Notice
2. Turn the crankshaft to position the each cylinder piston at TDC.
5. Install the engine lock to the ring gear to prevent the crankshaft from rotating.
6. Blow up with compressed air. Notice

Remove the valve spring only at TDC.
Always rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug hole. Supporting Bar 111 589 01 59 00
Tightening Torque 22.5 - 27.5 Nm
Mark on The Vibration Damper
OTUTCylinder
1, 4 2, 3

1B2-74 M161 ENGINE MECHANICAL8. Install the lever pusher (11) and the thrust piece (8) to the slide (9).
13. Remove the valve cotter (2) using either the pincette (13) or magnetic finger. Lever Pusher 111 589 18 61 00
Magnetic Finger 116 589 06 63 00
9. Mount the thrust piece (8) vertically to the valve spring
retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
NoticeCheck the retainer for damages and replace with a new
one if necessary.
17. Installation should follow the removal procedure in the reverse order.

M161 ENGINE MECHANICAL 1B2-75
Test (Upper and Lower Valve Tappet and Valve Cotter)
Upper Valve Spring Retainer
Lower Valve Spring Retainer
Valve Cotter
12.3
(D) (d)
8.5
Size (mm)
Thickness (mm) (a) 0.8 - 1.0
9.2 - 9.8
(H) (B) 9.0
Size (mm)