SSANGYONG MUSSO 2003 Service Manual

M161 ENGINE MECHANICAL 1-1B-69
CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head coverRemoval of cylinder head front cover
1 Insert Pin ( 6.5mm, Special Tool)
2 Intake Camshaft Sprocket
3 Camshaft Bearing Cap
4 Timing Chain 5 Exhaust Camshaft Sprocket
6 Bolt (M7 X 13, 3 pieces)
.........1st step 20 ± 2 Nm
2nd step 90 ° ± 5 ° rotation added
7 Strate Pin

1B2-70 M161 ENGINE MECHANICAL
Tools Required 104 589 01 01 00 Spanner
111 589 03 15 00 Insert Pin Inspection Procedure
1. Position the NO.1 cylinder piston to ATDC 20° by turning
the crankshaft Notice
When the ATDC 20 ° mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up.
In this way, the insert hole in NO.1 and NO.4 camshaftbearing cap will match in line with the flange hole forcamshaft sprocket.
2. Check the timing as below procedure;
- Check if the insert pin (111 589 03 15 00) can be inserted into the NO.1 and NO.4 bearing cap hole.
- At this condition, check if the ATDC 20 ° mark on vibration
damper aligns with the marker on the timing gear case.

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.

1B2-72 M161 ENGINE MECHANICAL
VALVE SPRING Preceding Work : Removal of camshaftRemoval of spark plug
1 Valve Tappet Assembly
2 Valve Cotter
3 Upper Retainer
4 Valve Spring..........Check, Replace if necessary
5 Valve Stem Seal
6 Lower Retainer 7 Connecting Hose
8 Thrust Piece
9 Slide
10 Adjust Bolt 11 Lever Pusher
12 Supporting Bar

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

1B2-74 M161 ENGINE MECHANICAL8. Install the lever pusher (11) and the thrust piece (8) to the slide (9).
13. Remove the valve cotter (2) using either the pincette (13) or magnetic finger. Lever Pusher 111 589 18 61 00
Magnetic Finger 116 589 06 63 00
9. Mount the thrust piece (8) vertically to the valve spring
retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
NoticeCheck the retainer for damages and replace with a new
one if necessary.
17. Installation should follow the removal procedure in the reverse order.

M161 ENGINE MECHANICAL 1B2-75
Test (Upper and Lower Valve Tappet and Valve Cotter)
Upper Valve Spring Retainer
Lower Valve Spring Retainer
Valve Cotter
12.3
(D) (d)
8.5
Size (mm)
Thickness (mm) (a) 0.8 - 1.0
9.2 - 9.8
(H) (B) 9.0
Size (mm)

1B2-76 M161 ENGINE MECHANICAL
VALVE STEM SEAL Preceding Work : Removal of valve spring
1 Drift (Special Tool)
2 Valve Stem Seal
3 Protective Sleeve
Drift 119 589 00 43 00
Pliers 104 589 00 37 00
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00
Drift
Replacement Procedure
1. Remove the valve stem seal (2) using the pliers. Notice Check the valve stem seal for damage and replace if
necessary.
2. Coat the valve stem seal with oil and assemble it with the protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.

M161 ENGINE MECHANICAL 1B2-77
CHAIN TENSIONER1 Screw Plug ................................................ 40 Nm
2 Seal
3 Filler Pin
4 Compression Spring 5 Snap Ring
6 Thrust Pin
7 Chain Tensioner Housing
.....................72-88 Nm
8 Seal
Removal Procedure
1. Position the number 1 cylinder to A TDC 20°.
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.
NoticeIn 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 snap ring doesn ’t return to
the original position and the tension gets excedded.

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