lock SSANGYONG MUSSO 2003 User Guide

1B1-20 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the belt pulley.Installation Notice
2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump. Installation Notice
Notice Pull the tensioning pulley clockwise as shown in the figure.
4. Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A/C compressor. Notice Discharge all the refrigerant before removing the pipes.
Tightening Torque 40.5 - 49.5 Nm
Tightening Torque 22.5 - 27.5 Nm

M162 ENGINE MECHANICAL 1B1-25
POLY V - BELT Preceding Work : Removal of cooling fan
1 Poly V-belt
Removal & Installation Procedure
1. Release the belt tension by turning the belt tensioning pulley nut clockwise.
2. Remove the poly v-belt.
Notice Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley clockwise.2 Belt Tensioning Pulley

M162 ENGINE MECHANICAL 1B1-27
TENSIONING DEVICE Preceding Work : Removal of poly v-belt
1 Belt (L = 2245)
2 Bolt Combi(M8 x 14, 3 pieces) + Washer....................................................... 22.5-27.5Nm
Removal & Installation Procedure
1. Remove the poly v-belt.
2. Remove the tensioning pulley by turning its mounting nut counter clockwise as shown in figure. Installation Notice 3 Water Pump Pulley
4 Nut
5 Tensioning Pulley
Tightening Torque 40.5 - 49.5 Nm

M162 ENGINE MECHANICAL 1B1-43
Components
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)
Service Data Standard
Permissble Deviation of The Vibration Damper Radial Runout
Axial Runout0.6 mm 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
602 589 00 40 00 Engine Lock Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.

1B1-44 M162 ENGINE MECHANICALEngine Lock 602 589 00 40 00
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
Tightening Torque 1st step 200 - 220 Nm
2nd step 90
° +10 °
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in the
reverse order. Notice If possible, don ’t separate the vibration damper and the
pulley.

M162 ENGINE MECHANICAL 1B1-51
Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaftbearing. Notice
Measure at 2 points (1, 2).
Measure ‘A’,‘B’and ‘C’ as shown. If average value of ‘B’
and ‘C’is less than value ‘A’, then the average value of
‘B’ and ‘C’ is actual average value. If average value of
‘B’ and ‘C’ is more than value ‘A’is actual average value.
4. Measure and record the diameter of the crankshaft bearing journal. Notice
Record the mean value when measured at 3 points (A,
B, C).
Measure the inner diameter of bearing and the diameter
of journal and if it is out of the standard data, replace the bearing shell.

M162 ENGINE MECHANICAL 1B1-61
8 . Unscrew the intake side bolts (8, 11, 13, 14) and the exhaustside bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice Number the camshaft bearing cap bolts when removing them, so that they don ’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30 °.
Notice
Turn the crankshaft in the direction of engine rotation.
3. Turn the camshaft using the wrench (special tool) so that the intake camshaft adjustment hole lines up with the cylinder head upper side (3 o ’clock direction at the intake, 9 o ’clock
direction at the exhaust). Notice
Turn the crankshaft and adjust it to OT so that No. 1 cylinder ’ s
piston would be at TDC.
Install the bearing caps according to the numbers on the bearing caps.
Tightening Torque 22.5 - 27.5 Nm
2. Install the exhaust camshaft bearing caps (2, 3, 5) and the
intake camshaft bearing caps (9, 10, 12). Tighten the bolts with specified torque and install the remaining bearing caps. Notice

M162 ENGINE MECHANICAL 1B1-65
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30° .
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with the cylinder head upper surface.
Intake Side : 3 o ’clock direction
Exhaust Side : 9 o ’clock direction
5. Secure the intake and exhaust camshaft.
6. Position the piston of No.1 cylinder at TDC (OT) by turning the crankshaft.
7. Turn the camshaft adjuster of the intake camshaft to the left as much as possible (cam adjuster ‘retarded ’ position).
8. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in gear case
cover.
Tools Required 104 589 01 01 00
Spanner
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning the crankshaft. Notice When the OT mark on vibration damper is aligned with timing
gear case cover, the intake and exhaust cam of cylinderwill make the slope to the center and will face up. In this
way, the adjustment hole of the intake and exhaust camshaft will match in line with the cylinder head upper end, at 3
o’clock, and 9 o ’clock direction each other.
2. Check the timing as below procedure; - Check if the camshaft adjustment hole is positioned to 3 o’clock direction at the intake side and to 9 o ’clock
direction at the exhaust side, respectively and align withthe cylinder head mating surface.
- At this condition, check if the OT mark on vibration damper aligns with the marker on the timing gear case.

1B1-68 M162 ENGINE MECHANICAL
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
OT
120 °
240 °Cylinder
1, 6 2, 5 3, 4

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