SSANGYONG MUSSO 1998 Workshop Repair Manual

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.

1B1-44 M162 ENGINE MECHANICAL
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
Tightening Torque1st step 200 - 220 Nm
2nd step 90° +10°
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in the
reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.

M162 ENGINE MECHANICAL 1B1-45
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 the
vibration 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 Torque1st step 200 - 220Nm
2nd step 90° + 10°

1B1-46 M162 ENGINE MECHANICAL
CRANKSHAFT REAR RADIAL SEAL
Preceding Work : Removal of flywheel or drive plate
1 Special Tool
2 Special Tool3 Crankshaft Rear Seal
Tools Required
601 589 03 43 00 Sleeve
Replacement Proceudre
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.
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice
Do not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.

M162 ENGINE MECHANICAL 1B1-47
CRANKSHAFT
Preceding Work : Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of oil pump
Removal of oil shield
1 12-sided Stretch Bolt........ 55 Nm x 90°, Iubricate
2 Crank Shaft Bearing Cap
3 Crank Shaft Low Main Bearing
4 Lower Thrust Bearing
5 Crank Shaft