engine SSANGYONG MUSSO 2003 Repair Manual

1B1-32 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the intake air duct.Installation Notice
2. Remove the ignition cable cover. Installation Notice
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and the gasket. Installation Notice
Notice Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover. Notice
Replace the gasket with a new one if necessary.
5. Installation should follow the removal procedure in the reverse order.
6. Check for oil leaks by operating the engine.
Tightening Torque 8 - 9 Nm
Tightening Torque 9 - 10 Nm
Tightening Torque 9 - 10 Nm

M162 ENGINE MECHANICAL 1B1-33
CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head coverRemoval of coolant connection fitting
1 Camshaft Position Sensor
2 Magnet Assembly
3 Upper Guide Rail
4 Bolt (M6 x 60, 3 pieces) .................22.5-27.5 Nm 5 Bolt (M8 x 80, 3 pieces)
.................22.5-27.5 Nm
6 Front Cover
7 Rubber Gasket ...................................... Replace
8 Bolt (M6 x 16, 3 pieces) ......................... 9-11 Nm
Removal & Installation Procedure
1. Remove the magnet assembly. Installation Notice
Tightening Torque 9 - 11 Nm

1B1-34 M162 ENGINE MECHANICAL
2. Remove the cylinder head front cover (6).Installation Notice
4. Remove the gasket (arrow). Installation Notice Replace the gasket with new one and apply the sealant.
5. Installation should follow the removal procedure in the reverse order.
Apply the sealant at the mating surface of the cylinder head
and the front cover.
3. Remove the upper guide rail pin and the guide rail (3).
Installation Notice Install it while the chain tensioner is loose.
Tightening Torque 22.5 - 27.5 Nm

M162 ENGINE MECHANICAL 1B1-35
CYLINDER HEAD Preceding Work : Removal of cylinder head coverRemoval of cylinder head front cover
Removal of upper intake manifold
1 Cylinder Head Bolt (14 pieces).................................................... 1st step 55 Nm
2nd step 90 °
3rd step 90 °
2 Washers (14 pieces)
3 Flange Bolts (3 pieces) ................1st step 20 Nm
2nd step 90 °4 Exhaust Camshaft Sprocket
5 Cylinder Head
6 Gasket ................................................... Replace
7 Dowel Sleeve

1B1-36 M162 ENGINE MECHANICAL
4. Remove the three flange bolts in the exhaust camshaftsprocket. Installation Notice
5. Separate the chain from the camshaft sprockrt. Notice Be careful not to drop the chain into the timing case.
Do not reuse the removed bolts.
Tools Required
000 589 01 10 00 Box Wrench Insert
116 589 02 34 00 Screw-fixed Pin
116 589 20 33 00 Sliding Hammer Removal & Installation Procedure
1. Rotate the crankshaft so that the piston of number 1 cylinder
is at TDC. Notice Rotate the crankshaft in the normal engine direction.
2. Put the alignment marks (arrows) on the timing chain and camshaft sprocket.
3. Drain the coolant from the crankcase.
Tightening Torque 1st step 18 - 22 Nm
2nd step 90
° ± 5 °

M162 ENGINE MECHANICAL 1B1-37
7. Remove the cylinder head bolts in numerical order.Installation Notice
8. Check the length of the cylinder head bolt. Installation Notice Box Wrench Insert 000 589 01 10 00
Replace the bolt if the measured length exceed the max. length.
Apply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating surface.
10. Installation should follow the removal procedure in the reverse order.
6. Remove the guide rail fixing pin from the cylinder head using
the sliding hammer (01) and the threaded pin (02).
Sliding Hammer 116 589 20 33 00Threaded Pin 116 589 02 34 00
Tightening Torque 1st step 55 Nm
2nd step 9 0
°
3rd step 9 0 °
Length (L)New 160 ± 0.8 mm
Max. 162 ± 0.7 mm

1B1-38 M162 ENGINE MECHANICAL
TIMING GEAR CASE COVER Preceding Work : Removal of cylinder head front coverRemoval of alternator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper
1 Bolt (M8 x 60, 3 pieces) .................22.5-27.5 Nm
2 A/C Bracket
3 Bolt (M8 x 65, 3 pieces) .................22.5-27.5 Nm
4 Bolt (M8 x 40, 1 piece) ...................22.5-27.5 Nm
5 Bolt (M8 x 60, 1 piece) ...................22.5-27.5 Nm 6 Seal
7 Timing Gear Case Cover
8 Roll Pin
9 Bolt (M6 x 22, 6 pieces)
......................... 9-11 Nm
Removal & Installation Procedure
1. Put the alignment marks (arrows) on the timing chain and camshaft sprocket.
2. Unscrew the A/C bracket bolts (1) and remove the bracket.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm

M162 ENGINE MECHANICAL 1B1-39
3. Remove the cooling fan and the viscous clutch. Unscrewthe three bolts from the cooling fan bracket and remove the bracket (arrows). Installation Notice
4. Remove the timing gear case cover after unscrewing the bolts (3) and (4) from the timing gear case cover and the bolt (9) from the oil pan. Notice Be careful not to damage the oil pan gasket.Installation Notice
Apply the sealant after cleaning the timing gear case
cover surface.
Be careful not to stain the oil chamber of chain tensioner
with the sealant.
5. Installation should follow the removal procedure in the reverse order.
6. Warm up the engine and check for oil leaks.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque Bolt (3,4) 22.5 - 27.5 Nm
Bolt (9) 9 - 11 Nm

1B1-40 M162 ENGINE MECHANICAL
CRANKSHAFT SEALING REAR COVER Preceding Work : Removal of the automatic transmission drive plate
1 Bolt (M6 x 20, 6 pieces)......................... 9-11 Nm
2 Radial Shaft Seal
3 Rear Cover 4 Sleeve
5 Bolt (M6 x 85, 2 pieces)
......................... 9-11 Nm
6 Washer

M162 ENGINE MECHANICAL 1B1-41
Tools Required
601 589 03 43 00 Sleeve Removal & Installation Procedure
1. Unscrew the bolts (1) and (5) and remove the closing coverby pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
NoticeDo not use the grease.
6. Using the special tool, press the radial shaft seal and the rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan bolt (5) as specified and remove the special tool. Installation Notice
Seal Assembler 601 589 03 43 00
Tightening Torque(Bolt 1,5) 9 - 11 Nm