engine SSANGYONG MUSSO 2003 Service Manual

1B2-36 M161 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the intake air duct.Installation Notice
2. Remove the ignition coil cover. Installation Notice
3. Remove the spark plug connector and ignition cable. Notice Release 3 screws from the ignition cover and remove the cover for M161 Engine coil.
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 10 Nm

M161 ENGINE MECHANICAL 1B2-37
CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head coverRemoval of thermostat housing assembly
Removal of engine hanger bracket
Removal & Installation Procedure
1. Disconnect the camshaft adjuster connector and removethe 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.

M161 ENGINE MECHANICAL 1B2-39
CYLINDER HEAD Preceding Work : Removal of cylinder head coverRemoval of cylinder head front cover
Removal of intake manifold Removal of cylinder head lower line (intake manifold side)
1 Cylinder Head Bolt (M12 X 100, 10 pieces).................................................... 1st step 55 Nm
2nd step 90 ° rotation added
3rd step 90 ° rotation added
3 Bolt (M8 X 35, 4 pieces) .................22.5-27.5 Nm 4 Camshaft Bearing cap
...................22.5-27.5 Nm
5 Cylinder Head
6 Gasket ................................................... Replace
7 Dowel Sleeve ............................................... Note

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 Torque 1st 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). NoticeApply 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 ofthe 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 Torque 1st 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 Torque When 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.

1B2-44 M161 ENGINE MECHANICAL
TIMING GEAR CASE COVER Preceding Work : Removal of viscous clutchRemoval of cylinder head front cover Removal of tensioning device Removal of water pumpRemoval of oil filter elementRemoval of oil panRemoval of alternator bracker
1 Bolt (M8 X 60, 3 pieces) .................22.5-27.5 Nm
2 Bolt (M8 X 75, 1 piece) ...................22.5-27.5 Nm
3 Seal 4 Timing gear case cover
5 O-ring
6 Sleeve

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 compressorbracket.
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 00Threaded 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 Torque 1st 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). NoticeApply the sealant on guide rail pin when installation.