torque SSANGYONG MUSSO 2003 Owners Manual

1B2-60 M161 ENGINE MECHANICAL
FLYWHEEL/DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt(M10 x 22, 8 pieces) ................ 1st Step 45 Nm 2nd Step 90°+10 °
2 Plate 3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening Torque
M x 1.5
8.5 - 0.2 mm 8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter When NewDd L
1st step 50 Nm, 2nd step 90 °

M161 ENGINE MECHANICAL 1B2-61
Removal & Installation Procedure
1. Unscrew the stretch bolt.Installation Notice
Sectional View
1 Oil Pan
2 Cover
3 Radial Seal
4 Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (Thickness : 3.5 mm)
8 Washer
9 Bolt
10 Front Drive Plate 11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

Replace the bolt when the stretch side diameter (d) of
the flywheel mounting bolt is less than 8.0mm.
For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90 ° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for Auto. transmission vehicle.
3. Installation should follow the removal procedure in the reverse order. Tightening Torque
1st step 45 Nm
2nd step 90
°+5 °

M161 ENGINE MECHANICAL 1B2-63
Removal & Installation Procedure
1. Turn the crankshaft and position the n0.1 cylinder piston atATDC 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 Torque 1st 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 removethe 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 Torque 1st 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-T30e. 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 Torque
1st step 20 Nm
2nd step + 90
°
Tightening Torque 1st step 20 Nm
2nd step + 90
°

M161 ENGINE MECHANICAL 1B2-67
Tools Required
000 589 01 10 00 Box Wrench Insert104 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 Torque 40 Nm
72 - 88 Nm
Screw Plug
Tensioner Assembly
4. Remove the exhoust camshaft sprocket. Installation Notice
Tightening Torque 1st 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 theexhaust 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
Base circle of cam should cantact with the valve tappet.
Install 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 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 Torque 1st 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 assembly 40 Nm
80 ± 8 Nm
Tightening
Torque
8. Check the camshaft timing.

M161 ENGINE MECHANICAL 1B2-73
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 thecamshaft 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

Remove the valve spring only at TDC.
Always 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
OTUTCylinder
1, 4 2, 3

1B2-78 M161 ENGINE MECHANICAL Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the chaintensioner 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
For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring.
Remove the screw plug only when the seal andcompression 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 72 - 88 Nm