2003 SSANGYONG MUSSO check engine

M162 ENGINE MECHANICAL 1B1-29
3. Pointed rib.
4. Belt cord visible in the base of rib.
POLY V - BELT INSPECTION

Make marks on the belt with chalk.
Rotate the engine and check the belt for damage. Notice If one of the following types of damages is found, replace the belt.
1. Rubber lumps in the base of rib.
2. Dirt or grit ingrained.
5. Cord torn out at the side.
6. Outer cords frayed.

1B1-32 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the intake air duct.Installation Notice
2. Remove the ignition cable cover. Installation Notice
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and the gasket. Installation Notice
Notice Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover. Notice
Replace the gasket with a new one if necessary.
5. Installation should follow the removal procedure in the reverse order.
6. Check for oil leaks by operating the engine.
Tightening Torque 8 - 9 Nm
Tightening Torque 9 - 10 Nm
Tightening Torque 9 - 10 Nm

M162 ENGINE MECHANICAL 1B1-37
7. Remove the cylinder head bolts in numerical order.Installation Notice
8. Check the length of the cylinder head bolt. Installation Notice Box Wrench Insert 000 589 01 10 00
Replace the bolt if the measured length exceed the max. length.
Apply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating surface.
10. Installation should follow the removal procedure in the reverse order.
6. Remove the guide rail fixing pin from the cylinder head using
the sliding hammer (01) and the threaded pin (02).
Sliding Hammer 116 589 20 33 00Threaded Pin 116 589 02 34 00
Tightening Torque 1st step 55 Nm
2nd step 9 0
°
3rd step 9 0 °
Length (L)New 160 ± 0.8 mm
Max. 162 ± 0.7 mm

M162 ENGINE MECHANICAL 1B1-39
3. Remove the cooling fan and the viscous clutch. Unscrewthe three bolts from the cooling fan bracket and remove the bracket (arrows). Installation Notice
4. Remove the timing gear case cover after unscrewing the bolts (3) and (4) from the timing gear case cover and the bolt (9) from the oil pan. Notice Be careful not to damage the oil pan gasket.Installation Notice
Apply the sealant after cleaning the timing gear case
cover surface.
Be careful not to stain the oil chamber of chain tensioner
with the sealant.
5. Installation should follow the removal procedure in the reverse order.
6. Warm up the engine and check for oil leaks.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque Bolt (3,4) 22.5 - 27.5 Nm
Bolt (9) 9 - 11 Nm

M162 ENGINE MECHANICAL 1B1-41
Tools Required
601 589 03 43 00 Sleeve Removal & Installation Procedure
1. Unscrew the bolts (1) and (5) and remove the closing coverby pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
NoticeDo not use the grease.
6. Using the special tool, press the radial shaft seal and the rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan bolt (5) as specified and remove the special tool. Installation Notice
Seal Assembler 601 589 03 43 00
Tightening Torque(Bolt 1,5) 9 - 11 Nm

M162 ENGINE MECHANICAL 1B1-45
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 °

1B1-46 M162 ENGINE MECHANICAL CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate
1 Special Tool
2 Special Tool3 Crankshaft Rear Seal
Tools Required
601 589 03 43 00 Sleeve Replacement Proceudre
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.
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
NoticeDo not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.

1B1-50 M162 ENGINE MECHANICALInstallation 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 left side (intakemanifold side).
Assemble so that the projected part of the cap andcrankcase 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 faceoutward and insert the thrust bearing into the bearingcap.
There are five kinds of thrust washers by thickness. Selectthe 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°