torque SSANGYONG MUSSO 2003 Workshop Manual

1B1-62 M162 ENGINE MECHANICAL
4. Turn the intake camshaft adjuster to the direction of camshaftrotation by hard until it stops and then install the chain. Notice
Make sure that the camshaft sprocket and timing chain are aligned with marks.
Intake camshaft adjuster should be in retarded position.
5. Install the chain on the exhaust sprocket and tighten the sprocket bolts. Notice
7. Rotate the crankshaft 2 revolutions and check followings: - TDC of no. 1 cylinder : OT
- Alignment between camshaft adjustment hole andcylinder head surface.
- Alignments between timing chain and sprocket marks. Notice
Turn the crankshaft in the direction of engine rotation.
Read just if not aligned.
6. Install the chain tensioner and tighten it as specified.
Notice

Make sure that the camshaft sprocket and timing chain are aligned with marks.
Replace the sprocket bolt with new one.
Tightening Torque 1st step 18 - 22 Nm
2nd step 90
° ± 5 °
Tightening Torque (1) 40 Nm
(2) 72 - 88 Nm

1B1-66 M162 ENGINE MECHANICAL
11. Check the camshaft timing.The sprocket bolt is designed to be used only once, so replace with new one.
10. Install the chain tensioner.
Installation Notice Tightening Torque
1st step 18 - 22 Nm
2nd step 90
° ± 5 °
9. Install the chain to the exhaust camshaft sprocket and
install it to the camshaft. Installation Notice (Sprocket Bolt)
TighteningTorque Screw Plug
40 Nm
Tensioner Assembly
72 - 88 Nm

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

M162 ENGINE MECHANICAL 1B1-73
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 and
compression 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 35 - 40 Nm

1B1-74 M162 ENGINE MECHANICAL
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

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.

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

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

1B1-84 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