filler SSANGYONG MUSSO 1998 Workshop Repair Manual

GENERAL INFORMATION 0B-13
Weather-Strip Lubrication
Apply a thin film silicone grease using a clean cloth.
EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are
removed for rotation. Inspect the lines and the hoses
for proper hookup, binding, leaks, cracks, chafing, etc.
Inspect the disc brake pads for wear. Inspect the rotors
for surface condition. Inspect other brake parts, the
parking brake, etc., at the same time. Inspect the brakes
more often if habit or conditions result in frequent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle
boot and seals for damage, tears or leakage. Replace
the seals if necessary.
Exhaust System Inspection
Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the exhaust
system. Look for broken, damaged, missing, or out-of-
position parts as well as open seams, holes, loose
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep
into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints
and throttle cable joints, the intermediate throttle shaft
bearing, the return spring at throttle valve assembly, and
the accelerator pedal sliding face with suitable grease.
Check the throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper
tension. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the
secondary latch. It should keep the hood from opening
all the way when the primary latch is released. The hood
must close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
and the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare
tire, all the jacking equipment, and the tools must be
securely stowed at all times. Oil the jack ratchet or the
screw mechanism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the
latches, the glove box and the console doors, and any
folding seat hardware.
Underbody Flushing
Flushing the underbody will remove any corrosive
materials used for ice and snow removal and dust control.
At least every spring clean the underbody. First, loosen
the sediment packed in closed areas of the vehicle. Then
flush the underbody with plain water.
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the fluid
is dirty or rusty, drain, flush and refill the engine cooling
system with new coolant. Keep the coolant at the proper
mixture in order to ensure proper freeze protection,
corrosion protection and engine operating temperature.
Inspect the hoses. Replace the cracked, swollen, or
deteriorated hoses. Tighten the clamps. Clean the
outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure
test the cooling system and the cap in order to help
ensure proper operation.

GENERAL ENGINE INFORMATION 1A1-11
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap
4 Vibration Damper
Permissible Pressure Leakage
6 Cylinder Pressure Leakage Tester with
Connecting Hose
Universal Tool
At Whole Engine
At Valve and Cylinder Head Gasket
At Piston and Piston RingMax. 25 %
Max. 10 %
Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC Mark
Cylinder Numberb (240°)
3, 4a (120°)
2, 5 OT (TDC)
1, 6
Cylinder Pressure Leakage Tester
Bosch, EFAW 210A
Sun, CLT 228

1A1-12 GENERAL ENGINE INFORMATION
Leakage Test
1. Warm the engine up to normal operating temperature.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
9. Connect the connecting hose to tester and measure the
leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 5 - 3 - 6 - 2 - 4
11. Compare the leakage pressure with the specifications.8. Position the piston of No.1 cylinder at TDC by rotating the
crankshaft.

1A2-4 GENERAL ENGINE INFORMATION
23 Camshaft Adjuster
24 Oil Filler Cap
25 Engine Hanger Bracket
26 Cooling Fan and Viscous Clutch
27 Oil Filter
28 Timing Chain29 Oil Pump Drive Chain
30 Oil Strainer
31 Oil Pump
32 Ring Gear and Flywheel of Drive Plate
33 Piston
SIDE VIEW

1A2-12 GENERAL ENGINE INFORMATION
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap
5 Vibration Damper
Permissible Pressure Leakage
6 Cylinder Pressure Leakage Tester with
Connecting Hose
Universal Tool
At Whole Engine
At Valve and Cylinder Head Gasket
At Piston and Piston RingMax. 25 %
Max. 10 %
Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC Mark
Cylinder NumberUT (BDC : 180°)
2, 3OT (TDC)
1, 4
Cylinder Pressure Leakage Tester Bosch EF AW 210A
Sun, CLT 228

GENERAL ENGINE INFORMATION 1A2-13
Leakage Test
1. Warm the engine up to normal operating temperature.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
9. Connect the connecting hose to tester and measure the
leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 3 - 4 - 2
11. Compare the leakage pressure with the specifications.8. Position the piston of No.1 cylinder at TDC by rotating the
crankshaft.

1A3-14 GENERAL ENGINE INFORMATION
Leakage Test
1. Run the engine to be the coolant temperature 80°C.
2. Remove the fuel injection nozzle.
3. Open the coolant subtank cap.
4. Check the coolant level and replenish if necessary.
5. Open the oil filler cap.
6. Remove the air cleaner cover and element.
7. Position the piston at TDC.
8. Install the connector (1) and connection piece (2).
9. Calibrate the tester and connect the connection hose
(3)
10. Pressurize with compressed air and compare the
pressure changes with permissible pressure leakage.
11. If permissible pressure leakage is out of standard, check
followings :
- Intake and exhaust lines.
- Sounds in oil filler area.
- Air bubbles in radiator coolant.
12. Do pressure leakage test for the remaining cylinders
according to the firing order.
lOM 662LA Engine : 1-2-4-5-3
lOM 661LA Engine : 1-3-4-2
13. Remove the tester.
14. Close the coolant pressure cap and oil filler cap.
15. Install the air cleaner element and cover.
16. Install the fuel injection nozzle.

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