ignition SSANGYONG MUSSO 1998 Workshop User Guide

GENERAL ENGINE INFORMATION 1A3-15
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths
of an inch. When any internal engine parts are
serviced, care and cleanliness are important. A liberal
coating of enigne oil should be applied to friction areas
during assembly, to protect and lubricate the surfaces
on initial operation. Proper cleaning and protection
of machined surfaces and friction areas is part fo the
repair procedure. This is considered standard shop
practice even if not specifically stated.
Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same
mating surfaces, as when they were removed.Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable
before removing or installing any electrical unit,
or when a tool or equipment could easily come in
contact with exposed electrical terminals.
Disconnecting this cable will help prevent
personal injury and damage to the vehicle. The
ignition must also be in LOCK unless otherwise
noted.
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against
accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.

SECTION 1B1
M162 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B1-2
Fastener Tightening Specifications . . . . . . . . 1B1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8
Crankcase Ventilation System . . . . . . . . . . 1B1-16
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59
TABLE OF CONTENTS
Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Cylinder Head Mating Surface . . . . . . . . . 1B1-115

1B1-2 M162 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N
· ·· ·
·m
35 - 40
10 - 15
5 - 10
21 - 25
30
56 - 66
50 - 60
10 - 15
41.5 - 49.5
22.5 - 27.5
22.5 - 27.5
9 - 11
9 - 11
22.5 - 27.5
9 - 11
22.5 - 27.5
10
+90°
55
+90°
+90°
22.5 - 27.5
22.5 - 27.5
9 - 10
9 - 10
200
+90°
40
+90°
45
+90°
35
9 - 11
20
+90°
20
+90°
20 / + 90°
20 / + 90°
22.5 - 27.5Application
Power Steering Hydraulic Lines
A/C High Pressure and Liquid Hose
Radiator Support Menber Bolt
Fuel Supply and Return Hose to Fuel Distributor
Exhaust Manifold and Pipe
Propeller Shaft to Transmission
Engine Mounting Nut
Alternator Carrier Bolt
Belt Pulley Bolt
Steering Pump Bolt
A/C Bracket Bolt
Intake Air Duct Bolt
Ignition Cable Cover Bolt
Cylinder Head Cover Bolt
Camshaft Adjuster Bolt
Cylinder Head Front Cover Bolt
Flange Bolt in Exhaust Camshaft Sprocket
Cylinder Head Bolt
Cooling Fan Bracket Bolt
Timing Gear Case Cover Bolt M8
M6
Crankshaft Rear Cover Bolt
Vibration Damper Center Bolt
Connecting Rod Bearing Cap Bolt
Flywheel Stretch Bolt
Amarture Bolt in Flywheel
Ring and Seal Cover Nut in Flywheel
Sprocket Bolt to Exhaust Camshaft
Camshaft Adjuster Flange Bolt
Intake Flange Shaft Bolt
Exhaust Camshaft Sprocket Bolt
Camshaft Bearing Cap Bolt

M162 ENGINE MECHANICAL 1B1-13
20. Disconnect following sensors connector.
lHFM sensor.
lCoolant temperature sensor.
l2 knock sensors.
lCamshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness
23. Separate the hose toward engine from canister purge
solenoid valve.
24. Remove the automatic transmission oil cooler line.

M162 ENGINE MECHANICAL 1B1-31
CYLINDER HEAD COVER
1 Ignition Cable Dust Cover
2 Bolt (M6 x 65, 8 pieces)......................... 9-11 Nm
3 Bolt (M6 x 50, 4 pieces)......................... 9-11 Nm
4 Spacer Sleeve
5 Thrust Piece
Composition of The Cylinder Head Cover Bolts
A. M6 x 50, 4 Pieces - Bolts + Washers
B. M6 x 65, 8 Pieces - Bolts + Washers
6 Cylinder Head Cover
7 Gasket ................................................... Replace
8 Spart Plug Hole Seal.............................. Replace
9 Camshaft Seal....................................... Replace

1B1-32 M162 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the intake air duct.
Installation Notice
2. Remove the ignition cable cover.
Installation Notice
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and
the gasket.
Installation Notice Notice
Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover.
Notice
Replace the gasket with a new one if necessary.
5. Installation should follow the removal procedure in the
reverse order.
6. Check for oil leaks by operating the engine.
Tightening Torque 8 - 9 Nm
Tightening Torque 9 - 10 Nm
Tightening Torque 9 - 10 Nm

SECTION 1B2
M161 ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2
Fastener Tightening Specifications . . . . . . . . 1B2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B2-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B2-4
Maintenance and Repair . . . . . . . . . . . . . . 1B2-9
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B2-9
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B2-9
Crankcase Ventilation System . . . . . . . . . . 1B2-17
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-21
Power Steering Pump and A/C Bracket . . . 1B2-22
Hydraulic Engine Mounting Insulator . . . . . . 1B2-25
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-28
Tensioning Deivce . . . . . . . . . . . . . . . . . . . . 1B2-30
Tensioning Device Shock Absorber . . . . . . 1B2-31
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B2-32
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B2-35
Cylinder Head Front Cover . . . . . . . . . . . . . 1B2-37
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B2-39
Timing Gear Case Cover . . . . . . . . . . . . . . 1B2-44
Crankshaft Sealing Rear Cover . . . . . . . . . 1B2-47
Belt Pulley and Vibration Damper . . . . . . . . 1B2-49
Crankshaft Front Radial Seal . . . . . . . . . . . 1B2-52
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B2-53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-54
Flywheel/Driven Plate . . . . . . . . . . . . . . . . . 1B2-60
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B2-62
TABLE OF CONTENTS
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B2-65
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-66
Camshaft Timing Position . . . . . . . . . . . . . . 1B2-69
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B2-72
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B2-76
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B2-77
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B2-80
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B2-85
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B2-86
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B2-87
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B2-88
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-90
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B2-93
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-95
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-97
Engine Oil and Oil Filter Element . . . . . . . . 1B2-99
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-101
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B2-103
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B2-104
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B2-105
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B2-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B2-106
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B2-108
Crankcase Mating Surface . . . . . . . . . . . . 1B2-110
Cylinder Head Mating Surface . . . . . . . . . 1B2-112

1B2-2 M161 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N
· ·· ·
·m
35 - 40
10 - 15
5 - 10
21 - 25
30
56 - 66
50 - 60
22.5 - 27.5
41.5 - 49.5
22.5 - 27.5
22.5 - 27.5
9 - 11
9 - 11
9 - 11
9 - 11
22.5 - 27.5
10
+90°
55
+90°
+90°
22.5 - 27.5
22.5 - 27.5
9 - 10
9 - 10
200
+90°
40
+90°
45
+90°
35
9 - 11
20
+90°
20
+90°
20 / + 90°
20 / + 90°
22.5 - 27.5Application
Power Steering Hydraulic Lines
A/C High Pressure and Liquid Hose
Radiator Support Menber Bolt
Fuel Supply and Return Hose to Fuel Distributor
Exhaust Manifold and Pipe
Propeller Shaft to Transmission
Engine Mounting Nut
Alternator Carrier Bolt
Belt Pulley Bolt
Steering Pump Bolt
A/C Bracket Bolt
Intake Air Duct Bolt
Ignition Cable Cover Bolt
Cylinder Head Cover Bolt
Camshaft Adjuster Bolt
Cylinder Head Front Cover Bolt
Flange Bolt in Exhaust Camshaft Sprocket
Cylinder Head Bolt
Cooling Fan Bracket Bolt
Timing Gear Case Cover Bolt M8
M6
Crankshaft Rear Cover Bolt
Vibration Damper Center Bolt
Connecting Rod Bearing Cap Bolt
Flywheel Stretch Bolt
Amarture Bolt in Flywheel
Ring and Seal Cover Nut in Flywheel
Sprocket Bolt to Exhaust Camshaft
Camshaft Adjuster Flange Bolt
Intake Flange Shaft Bolt
Exhaust Camshaft Sprocket Bolt
Camshaft Bearing Cap Bolt

1B2-14 M161 ENGINE MECHANICAL
20. Disconnect following sensors connector.
lHFM sensor.
lCoolant temperature sensor.
l2 knock sensors.
lCamshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness.
23. Separate the hose toward engine from canister purge
solenoid valve.
24. Remove the automatic transmission oil cooler line.

M161 ENGINE MECHANICAL 1B2-35
CYLINDER HEAD COVER
1 Ignition Coil Cover
2 Spark Plug Connector
3 Bolt (M6 X 45 : 4 pieces, M6 X 60 :
6 pieces)............................................. 10 ± 1 Nm4 Cylinder Head Cover
5 Gasket ................................................... Replace