torque SSANGYONG MUSSO 2003 Manual Online

M161 ENGINE MECHANICAL 1B2-41
6. Remove the in take camshaft sprocket (E20 engine).
7. Remove the camshaft adjuster (E23, M161.970 engine).Installation Notice (Flange Bolt)
1 Flange Shaft
2 Flange Bolt
3 Campression Spring
4 Adjust Piston
5 Camshaft Sprocket
6 Seal Cover
7 Nut
Tightening Torque1st step 18 - 22 Nm
2nd step 85
° - 95 °
Notice The flange bolt is designed to be used only once, so always replace with new one.
8. Remove the guide rail pin using the sliding hammer (02) and the threaded pin (03). NoticeApply the sealant on guide rail pin when installation.
9. Unscrew the bolts (A). Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Bolt (A) : (M8 X 35, 4 pieces)

1B2-42 M161 ENGINE MECHANICAL
10. Remove the cylinder head bolts in the reverse order ofthe numerics (No.10 No.1).
Installation Notice
Tighten the bolts as numerical order with specified torque(No.1 No.10).
Holder 104 589 00 40 00
1 Cylinder Head Bolt
2 M8 X 35 Bolt & Washer
3 Bearing Cap
4 Engine Hoist
5 Gasket
6 Hanger Bracket
Tightening Torque 1st step 55 ± 5 Nm
2nd step + 90
°
3rd step + 90 °
11. Remove the No. 1 bearing cap of the exhaust camshaft.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
12. Install the special tool (05) on the bearing cap removed place and hook the engine hoist into them and remove
the cylinder head carefully.
13. Check the cylinder head mating surface and clean the crankcase head bolt mounting hole.
14. Replace the cylind head gasket with new one. Notice Operate during engine cooling.

M161 ENGINE MECHANICAL 1B2-43
15. Check the length of the cylinder head bolt.Tightening Torque When New 100 mm Max. Length 105 mm
Notice Replace the bolt if the measured length exceed the max. length.
16. Installation should follow the removal procedure in the reverse order.

M161 ENGINE MECHANICAL 1B2-45
Tools Required
001 589 72 21 00 Torque Wrench
116 589 2 0 33 00 Sliding Hammer
116 589 01 34 00 Threaded Bolt Removal & Installation Procedure
1. Remove the power steering belt pulley and A/C compressorbracket.
2. Remove the oil line from power steering pump.
3. Rotate the crankshaft so that the piston of number, cylinder is at ATDC20 °
Sliding Hammer 116 589 20 33 00Threaded Pin 116 589 02 34 00
4. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
5. Remove the chain tensioner. Installation Notice
Tightening Torque 78 - 88 Nm
6. Remove the intake and exhaust camshaft sprocket (remove the camshaft adjuster assembly in E23 engine). Installation Notice
Tightening Torque 1st step 18 - 22 Nm
2nd step 85
° - 95 °
Notice The flange bolt is designed to be used only once, so always replace with new one.
7. Remove the guide rail pin using the sliding hammer (02) and the threaded pin (03). NoticeApply the sealant on guide rail pin when installation.

1B2-46 M161 ENGINE MECHANICAL
8. Unscrew the bolts (A).Installation Notice
Tightening Torque 22.5 - 27.5 Nm
9. Remove the belt pulley and vibration damper. Installation Notice (Center Bolt)
Tightening Torque 1st step 180 - 220 Nm 2nd step 80
° - 100 °
10. Unscrew the bolts (1, 2) on timing gear case cover and
remove the timing gear case cover. Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Notice Be careful not to damage the cylinder head gasket.
11. Remove the radial shaft seal
NoticeInstallation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase sealing surface.
13. Replace the O-ring with new one and apply the sealant on the sealing surface.NoticeBe careful not to stain the oil chamber of chain tensioner with the sealant.
14. Installation should follow the removal precedure in the reverse order.
15. Warm up the engine and check for oil leaks.

1B2-48 M161 ENGINE MECHANICAL
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

1B2-50 M161 ENGINE MECHANICAL Components
Service Data Standard
Permissble Deviation of The Vibration DamperRadial Runout Axial Runout0.6 mm 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
001 589 74 21 00 Puller
000 589 88 33 00 Torque Wrench
602 589 00 40 00 Engine Lock Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.
1 Center Bolt (M18 x 50)
2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan 11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

M161 ENGINE MECHANICAL 1B2-51
Engine Lock 602 589 00 40 00
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in thereverse order. Notice If possible, don ’t separate the vibration damper and the
pulley. Tightening Torque
1st step 180 - 220 Nm2nd step + 90
°

1B2-52 M161 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper
1 Center Bolt (M18 x 50)............................... 1st step 200-220 Nm
2nd step 90° +10 °
2 Center Bolt Washer
3 Sleeve (Special Tool)
4 Crankshaft Front Seal
5 Key
Tools Required
601 589 03 14 00 Sleeve Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.
5. Remove the sleeve and install the belt pulley and thevibration damper.
6. Check for leaks while operating the engine.
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk stop in the movement. Installation Notice
Tightening Torque 1st step 200 - 220Nm
2nd step 90
° + 10 °

M161 ENGINE MECHANICAL 1B2-57
Installation Notice
Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the leftside (intake manifold side).
Assemble so that the projected part of the cap and
crankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap. Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice
Remove the bearing cap from front (pulley side) to
rear.
Make sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the bearing cap.
There are five kinds of thrust washers by thickness.
Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the reverse order.
5. After completion of the installation, check for the rotating condition of the crankshaft.
Make sure that the upper and lower bearing shells do
not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
Tightening Torque 40 Nm + 90 °
Tightening Torque 55 Nm + 90°