SSANGYONG MUSSO 1998 Workshop Repair Manual

1B1-68 M162 ENGINE MECHANICAL
Tools Required
111 589 01 59 00 Supporting Bar
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece
116 589 06 63 00 Magnetic Finger
Removal & Installation Procedure
1. Place the supporting bar (12) and the slide (9) at the
camshaft bearing cap (Nos 1 & 7/8&14) and tighten them
with the bearing cap bolt.
Installation Notice
2. Turn the crankshaft to position the each cylinder piston at
TDC.
5. Install the engine lock to the ring gear to prevent the
crankshaft from rotating.
6. Blow up with compressed air.Notice
lRemove the valve spring only at TDC.
lAlways rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for
smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug
hole.
Supporting Bar 111 589 01 59 00
Tightening Torque 22.5 - 27.5 Nm
Mark on The Vibration Damper
OT
120°
240°Cylinder
1, 6
2, 5
3, 4

M162 ENGINE MECHANICAL 1B1-69
8. Install the lever pusher (11) and the thrust piece (8) to the
slide (9).
13. Remove the valve cotter (2) using either the pincette (13)
or magnetic finger.
Lever Pusher 111 589 18 61 00
Magnetic Finger 116 589 06 63 00
9. Mount the thrust piece (8) vertically to the valve spring
retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular
to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
Notice
Check the retainer for damages and replace with a new
one if necessary.
17. Installation should follow the removal procedure in the
reverse order.

1B1-70 M162 ENGINE MECHANICAL
Test (Upper and Lower Valve Tappet and Valve
Cotter)
lUpper Valve Spring Retainer
lLower Valve Spring Retainer
lValve Cotter
12.3 (D)(d) 8.5
Size (mm)
Thickness (mm)
(a) 0.8 - 1.0
9.2 - 9.8 (H)(B) 9.0
Size (mm)

M162 ENGINE MECHANICAL 1B1-71
VALVE STEM SEAL
Preceding Work : Removal of valve spring
1 Drift (Special Tool)
2 Valve Stem Seal
3 Protective Sleeve
Drift 119 589 00 43 00 Pliers 104 589 00 37 00
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00 Drift
Replacement Procedure
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
2. Coat the valve stem seal with oil and assemble it with the
protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.

1B1-72 M162 ENGINE MECHANICAL
CHAIN TENSIONER
1 Screw Plug................................................ 40 Nm
2 Seal
3 Filler Pin
4 Compression Spring5 Snap Ring
6 Thrust Pin
7 Chain Tensioner Housing.....................72-88 Nm
8 Seal
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice
Remove the oil filler cap at adjustment position, and check
whether the intake camshaft cam’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.
If the chain tensioner is tightened again without completely
reducing its tension, then the detent spring doesn’t return
to the original position and the tension gets excedded.

M162 ENGINE MECHANICAL 1B1-73
Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the chain
tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust pin far
enough so that it doesn’t protrude at the chain tensioner
housing. 4. Carefully unscrew the screw plug (1), and remove the seal
(2).
Notice
lFor the removal of screw plug, be careful that it can be
jumped out due to the force of compression spring.
lRemove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring (4),
snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
3. Insert the compression spring (4) with the filler pin (3) into
chain tensioner housing. 2. Install the chain tensioner housing (7), thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
Tightening Torque 35 - 40 Nm

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.