SSANGYONG MUSSO 1998 Workshop Repair Manual

1B1-58 M162 ENGINE MECHANICAL
CAMSHAFT SPROCKET BOLT
Intake Flange Shaft Bolt
Notice
The sprocket bolts are designed to be used only once, so
always replace with new one.
Exhaust Camshaft Sprocket Bolt
Notice
The sprocket bolts are designed to be used only once, so
always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
E. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
Tightening Torque1st step 18 - 22 Nm
2nd step 90° ± 5°
Tightening Torque1st step 18 - 22 Nm
2nd step 90° ± 5°

M162 ENGINE MECHANICAL 1B1-59
CAMSHAFT
Preceding Work : Removal of cylinder head cover, removal of coolant connection fitting
1 Chain Tensioner Assembly..................72-88 Nm
2 Exhaust Camshaft Sprocket
3 Upper Guide Rail
4 Cylinder Head Front Cover5 Intake Camshaft Sprocket
6 Chain
7 Wrench (Special Tool)

1B1-60 M162 ENGINE MECHANICAL
Tools Required
000 589 01 10 00 Box Wrench Insert
104 589 01 01 00Spanner
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
2. Remove the alternator.
3. Remove the chain tensioner.
4. Remove the cylinder head front cover and the upper guide
rail.
6. Unscrew the exhaust camshaft sprocket bolt and remove
the sprocket.
7. Separate the chain from the intake camshaft sprocket and
put the chain not to be dropped into timing case. 5. Put the alignment marks (arrows) on the camshaft sprocket
(2, 5) and the timing chain (6).

M162 ENGINE MECHANICAL 1B1-61
8 . Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust
side bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and
exhaust side camshaft bearing cap bolts.
Notice
Number the camshaft bearing cap bolts when removing
them, so that they don’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
Notice
Turn the crankshaft in the direction of engine rotation.
3. Turn the camshaft using the wrench (special tool) so that
the intake camshaft adjustment hole lines up with the cylinder
head upper side (3 o’clock direction at the intake, 9 o’clock
direction at the exhaust).
Notice
Turn the crankshaft and adjust it to OT so that No. 1 cylinder’s
piston would be at TDC. Install the bearing caps according to the numbers on the
bearing caps.
Tightening Torque 22.5 - 27.5 Nm 2. Install the exhaust camshaft bearing caps (2, 3, 5) and the
intake camshaft bearing caps (9, 10, 12). Tighten the bolts
with specified torque and install the remaining bearing caps.
Notice

1B1-62 M162 ENGINE MECHANICAL
4. Turn the intake camshaft adjuster to the direction of camshaft
rotation by hard until it stops and then install the chain.
Notice
lMake sure that the camshaft sprocket and timing chain
are aligned with marks.
lIntake camshaft adjuster should be in retarded position.
5. Install the chain on the exhaust sprocket and tighten the
sprocket bolts.
Notice
7. Rotate the crankshaft 2 revolutions and check followings:
- TDC of no. 1 cylinder : OT
- Alignment between camshaft adjustment hole and
cylinder head surface.
- Alignments between timing chain and sprocket marks.
Notice
lTurn the crankshaft in the direction of engine rotation.
lRead just if not aligned. 6. Install the chain tensioner and tighten it as specified.
Notice lMake sure that the camshaft sprocket and timing chain
are aligned with marks.
lReplace the sprocket bolt with new one.
Tightening Torque1st step 18 - 22 Nm
2nd step 90° ± 5°
Tightening Torque( 1 ) 40 Nm
(2) 72 - 88 Nm

M162 ENGINE MECHANICAL 1B1-63
8. Install the upper guide rail and cylinder head front cover.
9. Install the alternator.

1B1-64 M162 ENGINE MECHANICAL
CAMSHAFT TIMING POSITION
Preceding Work : Removal of cylinder head cover
Removal of cylinder head front cover
1 Chain Tensioner Assembly
2 Exhaust Camshaft Sprocket
3 Upper Guide Rail4 Cylinder Head Front Cover
5 Wrench (Special Tool)
6 Adjustment Hole Fitting Pin (
f4.0 mm)

M162 ENGINE MECHANICAL 1B1-65
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30° .
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with the
cylinder head upper surface.
lIntake Side : 3 o’clock direction
lExhaust Side : 9 o’clock direction
5. Secure the intake and exhaust camshaft.
6. Position the piston of No.1 cylinder at TDC (OT) by turning
the crankshaft.
7. Turn the camshaft adjuster of the intake camshaft to the
left as much as possible (cam adjuster ‘retarded’ position).
8. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in gear case
cover. Tools Required
104 589 01 01 00Spanner
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning
the crankshaft.
Notice
When the OT 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 adjustment hole of the intake and exhaust camshaft
will match in line with the cylinder head upper end, at 3
o’clock, and 9 o’clock direction each other.
2. Check the timing as below procedure;
- Check if the camshaft adjustment hole is positioned to 3
o’clock direction at the intake side and to 9 o’clock
direction at the exhaust side, respectively and align with
the cylinder head mating surface.
- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear case.

1B1-66 M162 ENGINE MECHANICAL
11. Check the camshaft timing.The sprocket bolt is designed to be used only once, so
replace with new one.
10. Install the chain tensioner.
Installation NoticeTightening Torque1st step 18 - 22 Nm
2nd step 90° ± 5°
9. Install the chain to the exhaust camshaft sprocket and
install it to the camshaft.
Installation Notice (Sprocket Bolt)
Tightening
TorqueScrew Plug
40 Nm
Tensioner Assembly
72 - 88 Nm

M162 ENGINE MECHANICAL 1B1-67
VALVE SPRING
Preceding Work : Removal of camshaft
Removal 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 Retainer7 Connecting Hose
8 Thrust Piece
9 Slide
10 Adjust Bolt
11 Lever Pusher
12 Supporting Bar