engine SSANGYONG MUSSO 2003 Service Manual

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

M161 ENGINE MECHANICAL 1B2-79
4. Lightly apply the grease to the seal (2) and install the screwplug (1). Installation Notice
Sectional View
1 Screw Plug
2 Ball (Nonreturn Valve)
3 Compression Spring
4 Ball Guide
5 Seal (Aluminum)
6 Filler Pin
7 Compression Spring
8 Snap Ring
9 Thrust Pin
10 Ball (Nonreturn Valve)
11 Compression Spring
12 Thrust Piece 13 Chain Tensioner Housing
14 Seal
15 Timing Gear Case Cover
16 Cylinder Head
17 Bolt / Washer
18 Tensioning Rail
19 Cylinder Head Gasket
20 Timing Chain
21 Tensioning Rail Base (Sliding Surface)
A Oil Supply Hole
B Chain Tensioner Oil Storage Hole
5. Check for leaks by operating the engine.
Tightening Torque 40 Nm

1B2-80 M161 ENGINE MECHANICAL 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

M161 ENGINE MECHANICAL 1B2-81
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 ATDC 20°.
4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure.
2. Insert the pin to the intake and exhaust camshaft flange.
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.

1B2-82 M161 ENGINE MECHANICAL7. 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.

M161 ENGINE MECHANICAL 1B2-83
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

1B2-84 M161 ENGINE MECHANICAL
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 Plug
40 Nm
Tensioner Assembly 72 - 88 Nm

M161 ENGINE MECHANICAL 1B2-85
TENSIONING RAIL Preceding Work : Removal of cylinder head
Removal & Installation Procedure
1. Remove the timing gear case cover (3).Notice Be careful not to damage the gasket.
2. Remove the sliding rail (1) from the sliding rail pin (2). Notice
Replace the plastic guide (2) if it is damaged.
For installation, exactly align the plastic guide (2) with
the sliding rail (1).
3. Installation should follow the removal procedure in the reverse order.
1 Sliding Rail Pin
2 Sliding Rail
3 Timing Gear Case Cover