1998 SSANGYONG MUSSO Workshop Repair Manual

1B1-80 M162 ENGINE MECHANICAL
TENSIONING RAIL
Preceding Work : Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide
3 Tensioning Rail Pin
4 Guide Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the tensioning rail (1) from the tensioning rail pin
(3).
Notice
lReplace the plastic guide (2) if it is damaged.
lFor installation, exactly align the plastic guide (2) with
the tensioning rail (1).
4. Installation should follow the removal procedure in the
reverse order.
5. Check the camshaft timing position.

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 TorqueScrew Plug40 Nm
Tensioner Assembly
72 - 88 Nm

1B1-82 M162 ENGINE MECHANICAL
CRANKCASE GUIDE RAIL
Preceding Work : Removal of timing gear case cover
1 Guide Rail
2 Plastic Guide
3 Guide Rail Pin
4 Tensioning Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
lReplace the plastic guide (2) if damaged.
lConnect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
4. Installation should follow the removal procedure in the
reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-83
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
6 Bolt (M8 x 20, 1 piece) / Washer..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain 1 Oil Pump Chain Tensioner
2 Oil Pump Chain Bushing
3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5 Key

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) and
the 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 sprocket
and 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
lMake sure not to lose the crankshaft pulley key(5) when
removing.
lInstall the crankshaft sprocket(4) after warming it up.
6. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 29 - 35 Nm

M162 ENGINE MECHANICAL 1B1-85
PISTON
Preceding Work : Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap
2 Connecting Rod
3 Connecting Rod Bolt (M9 x 52, 12 pieces)
....................................................1st step 40 Nm
2nd step 90° + 5°4 Piston
5 Snap Ring
6 Piston Pin

1B1-86 M162 ENGINE MECHANICAL
Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.
Installation Procedure

M162 ENGINE MECHANICAL 1B1-87
1. Check the piston ring gap and apply the engine oil to the
piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in
the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and the piston and coat them
with engine oil.
4. Install the piston ring using the tensioning strap(000 589
04 14 00).
5. Install the piston so that the arrow on the piston head faces
to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark
(// or a number), tighten the bolts.
Installation Notice
Tightening Torque1st step 35 - 45 Nm
2nd step 90° + 5°
Apply the engine oil to the bearing cap upper and lower
bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating
it.