SSANGYONG MUSSO 1998 Workshop Repair Manual

1B2-62 M161 ENGINE MECHANICAL
CAMSHAFT ADJUSTER
1 Bolt (M6 X 16, 3 pieces)......................... 9-11 Nm
2 Cylinder Head Front Cover
3 Bolt........................................................... 35 Nm
4 Armature
5 Roll Pin
6 Nut (M20 X 1.5)....................................60-70 Nm
7 Seal Cover
8 Camshaft Sprocket
9 Adjust Piston
10 Conical Spring11 Flange Bolt
(M7 X 13, 3 pieces).................1st Step 20±2 Nm
2nd Step 90° ± 5° Rotation Added
12 Flange Shaft
13 Compression Spring
14 Control Piston
15 Circlip
16 Oil Gallery
17 Straight Pin
18 Intake Camshaft
Y49 Magnetic Actuator (2-pin connector)

M161 ENGINE MECHANICAL 1B2-63
Removal & Installation Procedure
1. Turn the crankshaft and position the n0.1 cylinder piston at
ATDC 20°.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Remove the cylinder head front cover.
3. Put the alignment marks (arrows) on the camshaft sprocket
and the timing chain.
4. Insert the insert pin into the no.1 and no.6 bearing cap hole
on camshaft to secure intake and exhaust camshaft.
5. Remove the chain tensioner.
6. Unscrew the exhaust sprocket bolt and remove the exhaust
camshaft sprocket.
Installation Notice
Tightening Torque1st step 20 Nm
2nd step 90°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and remove
the roll pin, and remove the armature.
Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7).
Installation Notice
Tightening Torque 60 - 70 Nm
Notice
Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical
spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft.
Installation Notice
Tightening Torque1st step 20 Nm
2nd step + 95°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.
12. Installation should follow the removal procedure in the
reverse order.
13. Check and adjust the camshaft timing.

M161 ENGINE MECHANICAL 1B2-65
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 20 Nm
2nd step + 90°
Tightening Torque1st step 20 Nm
2nd step + 90°

1B2-66 M161 ENGINE MECHANICAL
CAMSHAFT
Preceding Work : Removal of cylinder head cover
Removal of camshaft adjust actuator and cylinder head front cover
1 Bolt (M7 X 13, 3 pieces).........1st Step 18-22 Nm
2nd Step 90°+ 5° Rotation Added
2 Exhaust Camshaft Sprocket
3 Timing Chain
4a Intake Camshaft Spocket (E20)4b Camshaft Adjuster and Camshaft Sprocket (E23)
5 Bearing Cap Bolt (20 pieces).........22.5-27.5 Nm
6 Camshaft Bearing Cap
7 Wrench (Special Tool)

M161 ENGINE MECHANICAL 1B2-67
Tools Required
000 589 01 10 00 Box Wrench Insert
104 589 01 01 00Spanner
Removal & Installation Procedure
1. Turn the crankshaft and position the no.1 cylinder piston at
ATDC20°.
2. Put the alignment marks (arrows) on the camshaft sprocket
and the timing chain.
3. Remove the chain tensioner.
Installation Notice
Tightening Torque40 Nm
72 - 88 Nm
Screw Plug
Tensioner Assembly
4. Remove the exhoust camshaft sprocket.
Installation Notice
Tightening Torque1st step 35 - 45 Nm
2nd step 85° - 95°
Notice
The sprocket bolt is designed to be used only once, so
always replace with new one.
5. Take off the timing chain from intake camshaft sprocket,
and secute it not to fall down into the timing gear case.
6. Using the wrench (7), turn the camshaft until there is no
resistence in camshaft bearing area.

1B2-68 M161 ENGINE MECHANICAL
7. Remove the bearing cap, and remove the intake and the
exhaust camshaft.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Notice
Check the numbers on the bearing cap not to be miked
up.
8. Apply the engine oil on the valve tappet and camshaft
bearing.
9. Installation should follow the removal procedure in the
reverse order.
Notice
lBase circle of cam should cantact with the valve tappet.
lInstall the camshaft bearing caps according to the
numbers on the cylinder head cast and bearing cap.
10. Check the camshaft timing position.

M161 ENGINE MECHANICAL 1-1B-69
CAMSHAFT TIMING POSITION
Preceding Work : Removal of cylinder head cover
Removal of cylinder head front cover
1 Insert Pin (f 6.5mm, Special Tool)
2 Intake Camshaft Sprocket
3 Camshaft Bearing Cap
4 Timing Chain5 Exhaust Camshaft Sprocket
6 Bolt (M7 X 13, 3 pieces).........1st step 20 ± 2 Nm
2nd step 90° ± 5° rotation added
7 Strate Pin

1B2-70 M161 ENGINE MECHANICAL
Tools Required
104 589 01 01 00 Spanner
111 589 03 15 00 Insert Pin
Inspection Procedure
1. Position the NO.1 cylinder piston to ATDC 20° by turning
the crankshaft
Notice
When the ATDC 20° 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 insert hole in NO.1 and NO.4 camshaft
bearing cap will match in line with the flange hole for
camshaft sprocket.
2. Check the timing as below procedure;
- Check if the insert pin (111 589 03 15 00) can be inserted
into the NO.1 and NO.4 bearing cap hole.
- At this condition, check if the ATDC 20° mark on vibration
damper aligns with the marker on the timing gear case.

M161 ENGINE MECHANICAL 1B2-71
Adjustment Procedure
1. Position the NO.1 cylinder to ATDC 20° .
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Adjust the timing position with inserting the insert pin
(
f6.5mm, 111 589 03 15 00) into the NO.1 and NO.4
camshaft bearing cap hole and flange hole while rotating
the camshaft by using wrench (104 589 01 01 00).
5. Install the chain to the intake camshaft sprocket.
6. Install the chain to the exhaust camshaft sprocket and
tighten the bolt.
Installation Notice
Tightening Torque1st step 20 Nm
2nd step + 90°
The sprocket bolt is designed to be used only once, so
replace with new one.
7. Install the chain tensioner.
Installation Notice
Screw plug
Tensioner assembly40 Nm
80 ± 8 Nm Tightening
Torque
8. Check the camshaft timing.