2003 SSANGYONG MUSSO engine

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 1B1-69
8. Install the lever pusher (11) and the thrust piece (8) to theslide (9).
13. Remove the valve cotter (2) using either the pincette (13) or magnetic finger. Lever Pusher 111 589 18 61 00
Magnetic Finger 116 589 06 63 00
9. Mount the thrust piece (8) vertically to the valve spring
retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
NoticeCheck the retainer for damages and replace with a new
one if necessary.
17. Installation should follow the removal procedure in the reverse order.

1B1-70 M162 ENGINE MECHANICAL
Test (Upper and Lower Valve Tappet and Valve Cotter)
Upper Valve Spring Retainer
Lower Valve Spring Retainer
Valve Cotter
12.3
(D) (d)
8.5
Size (mm)
Thickness (mm) (a) 0.8 - 1.0
9.2 - 9.8
(H) (B) 9.0
Size (mm)

M162 ENGINE MECHANICAL 1B1-71
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.

1B1-72 M162 ENGINE MECHANICAL
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 No.1 cylinder to TDC (OT). 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 detent spring doesn ’t return
to the original position and the tension gets excedded.

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

M162 ENGINE MECHANICAL 1B1-75
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