2003 SSANGYONG MUSSO torque

1B2-52 M161 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper
1 Center Bolt (M18 x 50)............................... 1st step 200-220 Nm
2nd step 90° +10 °
2 Center Bolt Washer
3 Sleeve (Special Tool)
4 Crankshaft Front Seal
5 Key
Tools Required
601 589 03 14 00 Sleeve Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.
5. Remove the sleeve and install the belt pulley and thevibration damper.
6. Check for leaks while operating the engine.
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk stop in the movement. Installation Notice
Tightening Torque 1st step 200 - 220Nm
2nd step 90
° + 10 °

M161 ENGINE MECHANICAL 1B2-57
Installation Notice
Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the leftside (intake manifold side).
Assemble so that the projected part of the cap and
crankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap. Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the upper and lower bearing shells and thrust washers. Installation Notice
Remove the bearing cap from front (pulley side) to
rear.
Make sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the bearing cap.
There are five kinds of thrust washers by thickness.
Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the reverse order.
5. After completion of the installation, check for the rotating condition of the crankshaft.
Make sure that the upper and lower bearing shells do
not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
Tightening Torque 40 Nm + 90 °
Tightening Torque 55 Nm + 90°

1B2-60 M161 ENGINE MECHANICAL
FLYWHEEL/DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt(M10 x 22, 8 pieces) ................ 1st Step 45 Nm 2nd Step 90°+10 °
2 Plate 3 Driven Plate (A/T)
4 Dowel Pin
5 Flywheel (M/T)
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening Torque
M x 1.5
8.5 - 0.2 mm 8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter When NewDd L
1st step 50 Nm, 2nd step 90 °

M161 ENGINE MECHANICAL 1B2-61
Removal & Installation Procedure
1. Unscrew the stretch bolt.Installation Notice
Sectional View
1 Oil Pan
2 Cover
3 Radial Seal
4 Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (Thickness : 3.5 mm)
8 Washer
9 Bolt
10 Front Drive Plate 11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

Replace the bolt when the stretch side diameter (d) of
the flywheel mounting bolt is less than 8.0mm.
For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90 ° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for Auto. transmission vehicle.
3. Installation should follow the removal procedure in the reverse order. Tightening Torque
1st step 45 Nm
2nd step 90
°+5 °

M161 ENGINE MECHANICAL 1B2-63
Removal & Installation Procedure
1. Turn the crankshaft and position the n0.1 cylinder piston atATDC 20 °.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Remove the cylinder head front cover.
3. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
4. Insert the insert pin into the no.1 and no.6 bearing cap hole on camshaft to secure intake and exhaust camshaft.
5. Remove the chain tensioner.
6. Unscrew the exhaust sprocket bolt and remove the exhaust camshaft sprocket. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step 90
°
Notice The flange bolt is designed to be used only once, so always replace with new one.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and removethe roll pin, and remove the armature. Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice
Tightening Torque 60 - 70 Nm
Notice Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step + 95
°
Notice The flange bolt is designed to be used only once, so always replace with new one.
12. Installation should follow the removal procedure in the reverse order.
13. Check and adjust the camshaft timing.

M161 ENGINE MECHANICAL 1B2-65
CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt Notice The sprocket bolts are designed to be used only once, so always replace with new one. Exhaust Camshaft Sprocket Bolt Notice The sprocket bolts are designed to be used only once, so always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
E. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
Tightening Torque
1st step 20 Nm
2nd step + 90
°
Tightening Torque 1st step 20 Nm
2nd step + 90
°

M161 ENGINE MECHANICAL 1B2-67
Tools Required
000 589 01 10 00 Box Wrench Insert104 589 01 01 00Spanner
Removal & Installation Procedure
1. Turn the crankshaft and position the no.1 cylinder piston at ATDC20 °.
2. Put the alignment marks (arrows) on the camshaft sprocket
and the timing chain.
3. Remove the chain tensioner. Installation Notice
Tightening Torque 40 Nm
72 - 88 Nm
Screw Plug
Tensioner Assembly
4. Remove the exhoust camshaft sprocket. Installation Notice
Tightening Torque 1st step 35 - 45 Nm
2nd step 85
° - 95 °
Notice The sprocket bolt is designed to be used only once, so always replace with new one.
5. Take off the timing chain from intake camshaft sprocket, and secute it not to fall down into the timing gear case.
6. Using the wrench (7), turn the camshaft until there is no resistence in camshaft bearing area.