engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1B1-74 M162 ENGINE MECHANICAL
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece13 Chain Tensioner Housing
1 4 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole 5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

M162 ENGINE MECHANICAL 1B1-75
TIMING CHAIN
Preceding Work : Removal of cylinder head cover
Removal of spark plug
1 Pin
2 New Timing Chain
3 Timing Chain (Used)
4 Wedge5 Link
6 Center Plate
7 Outer Plate

1B1-76 M162 ENGINE MECHANICAL
Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
001 589 72 21 00 Torque Wrench
Replacement Procedure
1. Position the No.1 cylinder to TDC (OT).
4. Mount the wedges to both sides of the camshaft sprocket
as shown in the figure. 2. Insert the
f4mm pin to the intake and exhaust camshaft
flange not to rotate camshaft.
3. Remove the chain tensioner.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.

M162 ENGINE MECHANICAL 1B1-77
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the
link (5) and the center plate (6). 6. Remove the outer plate (7) with the screw driver and
remove the link (5).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.

1B1-78 M162 ENGINE MECHANICAL
15. Replace the thrust piece (b) as shown in the figure. 13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool. 12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
16. Install the assembly tool to the link pin and tighten the
spindle (c).
Tightening Torque 30 Nm

M162 ENGINE MECHANICAL 1B1-79
17. Rivet the link pin.
Check the condition and it again if necessary.
18. Install the chain tensioner.
Installation Notice
19. Check the camshaft timing position.
Tightening
TorqueScrew Plug40 Nm
Tensioner Assembly
72 - 88 Nm

1B1-80 M162 ENGINE MECHANICAL
TENSIONING RAIL
Preceding Work : Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide
3 Tensioning Rail Pin
4 Guide Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the tensioning rail (1) from the tensioning rail pin
(3).
Notice
lReplace the plastic guide (2) if it is damaged.
lFor installation, exactly align the plastic guide (2) with
the tensioning rail (1).
4. Installation should follow the removal procedure in the
reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-81
Tools Required
104 589 01 01 00Spanner
Removal & Installation Procedure
1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating direction
using the wrench (4) and loosen the timing chain at upper
guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of
rotation using the wrench (4, special tool : 104 589 01 01
00).
5. Check for damages at the upper sliding rail and replace it if
necessary. Install the upper guide rail pin.
6. Install the chain tensioner.
Installation Notice
CYLINDER HEAD GUIDE RAIL
Preceding Work : Removal of cylinder head cover
1 Chain Tensioner
2 Upper Guide Rail
3 Upper Guide Rail Pin
4 Wrench (Special Tool)
Tightening TorqueScrew Plug40 Nm
Tensioner Assembly
72 - 88 Nm

1B1-82 M162 ENGINE MECHANICAL
CRANKCASE GUIDE RAIL
Preceding Work : Removal of timing gear case cover
1 Guide Rail
2 Plastic Guide
3 Guide Rail Pin
4 Tensioning Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
lReplace the plastic guide (2) if damaged.
lConnect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
4. Installation should follow the removal procedure in the
reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-83
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
6 Bolt (M8 x 20, 1 piece) / Washer..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain 1 Oil Pump Chain Tensioner
2 Oil Pump Chain Bushing
3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5 Key