torque SSANGYONG MUSSO 1998 Workshop Manual Online

M161 ENGINE MECHANICAL 1B2-37
CYLINDER HEAD FRONT COVER
Preceding Work : Removal of cylinder head cover
Removal of thermostat housing assembly
Removal of engine hanger bracket
Removal & Installation Procedure
1. Disconnect the camshaft adjuster connector and remove
the camshaft adjuster (E23 engine only).
Installation Notice
Tightening Torque 9 - 11 Nm
1 Bolt (M6 X 16, 3 pieces)......................... 9-11 Nm
2 Camshaft Adjuster
3 Bolt (M8 X 35, 2 pieces).................22.5-27.5 Nm
4 Bolt (M6 X 22, 6 pieces)......................... 9-11 Nm
5 Front Cover (E23 : M161.973)6 Front Cover (E20 : M161.943)
7 Sleeve
8 O-ring .................................................... Replace
9 Thermostat Housing

1B2-38 M161 ENGINE MECHANICAL
2. Remove the cylinder head front cover.
Installation Notice
Tightening Torque (3) 22.5 - 27.5 Nm
Tightening Torque (4) 9 - 11 Nm
Apply the sealant at the mating surface of the cylinder head
and the front cover.
3. Remove the O-ring.
Installation Notice
Replace the O-ring with new one and apply the sealant.
4. Installation should follow the removal procedure in the
reverse order.

1B2-40 M161 ENGINE MECHANICAL
Tools Required
617 589 00 10 00 Wrench Socket
116 589 2 0 33 00 Sliding Hammer
116 589 01 34 00 Threaded Bolt
001 589 66 21 00 Torque Wrence
104 589 00 40 00 Holder
Removal & Installation Procedure
1. Rotate the crankshaft so that the piston of number 1 cylinder
is at ATDC 20.
2. Put the pin into the camshaft bearing cap (number 1, 6).
Pin 111 589 03 15 00
3. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
4. Remove the chain tensioner.
Installation Notice
Tightening Torque 72 - 88 Nm
Tightening Torque1st step 18 - 22 Nm
2nd step 85° - 95°
5. Remove the exhaust camshaft sprocket.
Installation Notice
Notice
The flange bolt is designed to be used only once, so always
replace with new one.

M161 ENGINE MECHANICAL 1B2-41
6. Remove the in take camshaft sprocket (E20 engine).
7. Remove the camshaft adjuster (E23, M161.970 engine).
Installation Notice (Flange Bolt)
1 Flange Shaft
2 Flange Bolt
3 Campression Spring
4 Adjust Piston
5 Camshaft Sprocket
6 Seal Cover
7 Nut
Tightening Torque1st step 18 - 22 Nm
2nd step 85° - 95°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.
8. Remove the guide rail pin using the sliding hammer (02)
and the threaded pin (03).
Notice
Apply the sealant on guide rail pin when installation.
9. Unscrew the bolts (A).
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Bolt (A) : (M8 X 35, 4 pieces)

1B2-42 M161 ENGINE MECHANICAL
10. Remove the cylinder head bolts in the reverse order of
the numerics (No.10 ® No.1).
Installation Notice
Tighten the bolts as numerical order with specified torque
(No.1 ® No.10).
Holder 104 589 00 40 00
1 Cylinder Head Bolt
2 M8 X 35 Bolt & Washer
3 Bearing Cap
4 Engine Hoist
5 Gasket
6 Hanger Bracket
Tightening Torque1st step 55 ± 5 Nm
2nd step + 90°
3rd step + 90°
11. Remove the No. 1 bearing cap of the exhaust camshaft.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
12. Install the special tool (05) on the bearing cap removed
place and hook the engine hoist into them and remove
the cylinder head carefully.
13. Check the cylinder head mating surface and clean the
crankcase head bolt mounting hole.
14. Replace the cylind head gasket with new one.Notice
Operate during engine cooling.

M161 ENGINE MECHANICAL 1B2-43
15. Check the length of the cylinder head bolt.
Tightening TorqueWhen New 100 mm
Max. Length 105 mm
Notice
Replace the bolt if the measured length exceed the max.
length.
16. Installation should follow the removal procedure in the
reverse order.

M161 ENGINE MECHANICAL 1B2-45
Tools Required
001 589 72 21 00 Torque Wrench
116 589 2 0 33 00 Sliding Hammer
116 589 01 34 00 Threaded Bolt
Removal & Installation Procedure
1. Remove the power steering belt pulley and A/C compressor
bracket.
2. Remove the oil line from power steering pump.
3. Rotate the crankshaft so that the piston of number, cylinder
is at ATDC20°
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00
4. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
5. Remove the chain tensioner.
Installation Notice
Tightening Torque 78 - 88 Nm
6. Remove the intake and exhaust camshaft sprocket
(remove the camshaft adjuster assembly in E23 engine).
Installation Notice
Tightening Torque1st step 18 - 22 Nm
2nd step 85° - 95°
Notice
The flange bolt is designed to be used only once, so always
replace with new one.
7. Remove the guide rail pin using the sliding hammer (02)
and the threaded pin (03).
Notice
Apply the sealant on guide rail pin when installation.

1B2-46 M161 ENGINE MECHANICAL
8. Unscrew the bolts (A).
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
9. Remove the belt pulley and vibration damper.
Installation Notice (Center Bolt)
Tightening Torque1st step 180 - 220 Nm
2nd step 80° - 100°
10. Unscrew the bolts (1, 2) on timing gear case cover and
remove the timing gear case cover.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
Notice
Be careful not to damage the cylinder head gasket.
11. Remove the radial shaft seal
Notice
Installation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase sealing
surface.
13. Replace the O-ring with new one and apply the sealant on
the sealing surface.
Notice
Be careful not to stain the oil chamber of chain tensioner
with the sealant.
14. Installation should follow the removal precedure in the
reverse order.
15. Warm up the engine and check for oil leaks.

1B2-48 M161 ENGINE MECHANICAL
Tools Required
601 589 03 43 00 Sleeve
Removal & Installation Procedure
1. Unscrew the bolts (1) and (5) and remove the closing cover
by pulling the rear cover lug (arrows).
Notice
Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear
sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
Notice
Do not use the grease.
6. Using the special tool, press the radial shaft seal and the
rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan
bolt (5) as specified and remove the special tool.
Installation Notice
Seal Assembler 601 589 03 43 00
Tightening Torque(Bolt 1,5) 9 - 11 Nm

1B2-50 M161 ENGINE MECHANICAL
Components
Service Data Standard
Permissble Deviation of The Vibration DamperRadial Runout
Axial Runout0.6 mm
0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
001 589 74 21 00 Puller
000 589 88 33 00 Torque Wrench
602 589 00 40 00 Engine Lock
Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.
1 Center Bolt (M18 x 50)
2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)