engine SSANGYONG MUSSO 1998 Workshop Owners Manual

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 cover
Removal 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 camshaft
sprocket.
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 Torque1st 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
lReplace the bolt if the measured length exceed the
max. length.
lApply 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 00
Threaded Pin 116 589 02 34 00
Tightening Torque1st 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 cover
Removal 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 Nm6 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. Unscrew
the 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
lApply the sealant after cleaning the timing gear case
cover surface.
lBe 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 TorqueBolt (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 Cover4 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 cover
by 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.
Notice
Do 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

1B1-42 M162 ENGINE MECHANICAL
1 Center Bolt (M18 x 50)......1st step 200- 220 Nm
2nd step 90°+10°
2 Vibration Damper Disk
3 Bolt (M6 x 20, 6 pieces).....................7.7-9.5 Nm
BELT PULLEY AND VIBRATION DAMPER
Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
4 Vibration Damper Assembly
5 Woodruff Key
6 Bolt (M6 x 12, 4 pieces)......................... 9-11 Nm
7 Cooling Fan Pulley

M162 ENGINE MECHANICAL 1B1-43
Components
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)
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
602 589 00 40 00 Engine Lock
Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.