2003 SSANGYONG MUSSO Service Manual

M162 ENGINE MECHANICAL 1B1-61
8 . Unscrew the intake side bolts (8, 11, 13, 14) and the exhaustside bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice Number the camshaft bearing cap bolts when removing them, so that they don ’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30 °.
Notice
Turn the crankshaft in the direction of engine rotation.
3. Turn the camshaft using the wrench (special tool) so that the intake camshaft adjustment hole lines up with the cylinder head upper side (3 o ’clock direction at the intake, 9 o ’clock
direction at the exhaust). Notice
Turn the crankshaft and adjust it to OT so that No. 1 cylinder ’ s
piston would be at TDC.
Install the bearing caps according to the numbers on the bearing caps.
Tightening Torque 22.5 - 27.5 Nm
2. Install the exhaust camshaft bearing caps (2, 3, 5) and the
intake camshaft bearing caps (9, 10, 12). Tighten the bolts with specified torque and install the remaining bearing caps. Notice

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

M162 ENGINE MECHANICAL 1B1-63
8. Install the upper guide rail and cylinder head front cover.
9. Install the alternator.

1B1-64 M162 ENGINE MECHANICAL
CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head coverRemoval of cylinder head front cover
1 Chain Tensioner Assembly
2 Exhaust Camshaft Sprocket
3 Upper Guide Rail 4 Cylinder Head Front Cover
5 Wrench (Special Tool)
6 Adjustment Hole Fitting Pin (
4.0 mm)

M162 ENGINE MECHANICAL 1B1-65
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30° .
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with the cylinder head upper surface.
Intake Side : 3 o ’clock direction
Exhaust Side : 9 o ’clock direction
5. Secure the intake and exhaust camshaft.
6. Position the piston of No.1 cylinder at TDC (OT) by turning the crankshaft.
7. Turn the camshaft adjuster of the intake camshaft to the left as much as possible (cam adjuster ‘retarded ’ position).
8. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in gear case
cover.
Tools Required 104 589 01 01 00
Spanner
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning the crankshaft. Notice When the OT mark on vibration damper is aligned with timing
gear case cover, the intake and exhaust cam of cylinderwill make the slope to the center and will face up. In this
way, the adjustment hole of the intake and exhaust camshaft will match in line with the cylinder head upper end, at 3
o’clock, and 9 o ’clock direction each other.
2. Check the timing as below procedure; - Check if the camshaft adjustment hole is positioned to 3 o’clock direction at the intake side and to 9 o ’clock
direction at the exhaust side, respectively and align withthe cylinder head mating surface.
- At this condition, check if the OT mark on vibration damper aligns with the marker on the timing gear case.

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

M162 ENGINE MECHANICAL 1B1-67
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

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