SSANGYONG MUSSO 2003 Service Manual

M162 ENGINE MECHANICAL 1B1-75
TIMING CHAIN Preceding Work : Removal of cylinder head coverRemoval of spark plug
1 Pin
2 New Timing Chain
3 Timing Chain (Used)
4 Wedge 5 Link
6 Center Plate
7 Outer Plate

1B1-76 M162 ENGINE MECHANICAL
Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
001 589 72 21 00 Torque Wrench Replacement Procedure
1. Position the No.1 cylinder to TDC (OT).
4. Mount the wedges to both sides of the camshaft sprocketas shown in the figure.
2 . Insert the
4mm pin to the intake and exhaust camshaft
flange not to rotate camshaft.
3. Remove the chain tensioner.
5. Cover the chain housing with a clean cloth, and grind off the timing chain pin from the intake camshaft sprocket with
the grinder.

M162 ENGINE MECHANICAL 1B1-77
7. Connect the new timing chain (2) to the used timing chain(3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution by pressing the new timing chain against the exhaustcamshaft sprocket to prevent it to be tangled. Notice Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the link (5) and the center plate (6).
6. Remove the outer plate (7) with the screw driver and
remove the link (5).
11. Install the jaw (a) and the thrust piece (b) to the assembly tool as shown in the figures.

1B1-78 M162 ENGINE MECHANICAL
15. Replace the thrust piece (b) as shown in the figure.
13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool.
12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
16. Install the assembly tool to the link pin and tighten the spindle (c).
Tightening Torque 30 Nm

M162 ENGINE MECHANICAL 1B1-79
17. Rivet the link pin.Check the condition and it again if necessary.
18. Install the chain tensioner. Installation Notice
19. Check the camshaft timing position.
Tightening Torque Screw Plug40 Nm
Tensioner Assembly 72 - 88 Nm

1B1-80 M162 ENGINE MECHANICAL TENSIONING RAIL Preceding Work : Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide
3 Tensioning Rail Pin
4 Guide Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the tensioning rail (1) from the tensioning rail pin (3). Notice
Replace the plastic guide (2) if it is damaged.
For installation, exactly align the plastic guide (2) with the tensioning rail (1).
4. Installation should follow the removal procedure in the reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-81
Tools Required 104 589 01 01 00Spanner
Removal & Installation Procedure
1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating direction using the wrench (4) and loosen the timing chain at upper guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of rotation using the wrench (4, special tool : 104 589 01 01 00).
5. Check for damages at the upper sliding rail and replace it if necessary. Install the upper guide rail pin.
6. Install the chain tensioner.
Installation Notice
CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover
1 Chain Tensioner
2 Upper Guide Rail
3 Upper Guide Rail Pin
4 Wrench (Special Tool)
Tightening Torque
Screw Plug40 Nm
Tensioner Assembly
72 - 88 Nm

1B1-82 M162 ENGINE MECHANICAL
CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover
1 Guide Rail
2 Plastic Guide
3 Guide Rail Pin
4 Tensioning Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
Replace the plastic guide (2) if damaged.
Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when installing.
4. Installation should follow the removal procedure in the reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-83
CRANKSHAFT SPROCKET Preceding Work : Removal of oil panRemoval of tensioning rail Removal of crank case guide rail
6 Bolt (M8 x 20, 1 piece) / Washer ..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain
1 Oil Pump Chain Tensioner
2 Oil Pump Chain Bushing
3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5 Key

1B1-84 M162 ENGINE MECHANICAL
Tools Required
615 589 01 33 00 Puller Removal & Installation Procedure
1. Put the assembly mark at the crankshaft sprocket (4) andthe timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain. Also, align the assembly marks on camshaft sprocketand timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7) from the oil pump. Installation Notice
Puller (04) 615 589 01 33 00
3. Remove the oil pump roller chain (9).
4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the puller (04, special tool). Notice
Make sure not to lose the crankshaft pulley key(5) when removing.
Install the crankshaft sprocket(4) after warming it up.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 29 - 35 Nm