2003 SSANGYONG MUSSO filler

1B1-96 M162 ENGINE MECHANICAL3 Oil Filler Cap 4 Dipstick Gauge
9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after starting the engine.
11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary.

M161 ENGINE MECHANICAL 1B2-77
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 number 1 cylinder to A TDC 20°.
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 snap ring doesn ’t return to
the original position and the tension gets excedded.

1B2-78 M161 ENGINE MECHANICAL 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 andcompression 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 72 - 88 Nm

M161 ENGINE MECHANICAL 1B2-79
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

1B2-100 M161 ENGINE MECHANICAL9. Fill up engine oil through the engine oil filler opening.
10. Check for oil leaks at normal engine temperature after starting the engine.
11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary.
4. Remove the drain plug (1) and drain the engine oil.
Notice Leave the oil filler cap (3) open to ease the engine oil discharge.
5. Tighten the engine oil drain plug after cleaning it. Installation Notice
Tools Required
103 589 02 09 00 Oil Filter Socket Wrench Replacement Procedure
1. Install the socket wrench ”7” (special tool : 103 589 02 09
00) on the oil filter cover (2). NoticeMake the screw cover removable by tightening the bolt at the side of the socket wrench (special tool).
2. Install the wrench to the upper bolt in the socket wrench and remove the oil cover by turning it.
3. Remove the oil filter element.
Notice Work with a cloth under the vehicle when removing the oil filter element to not drain the oil. Replace the seal washer with new one.
6. Replace the O-ring(5) in the oil filter cover with new one.
Notice Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
Tightening Torque 25 Nm
8. Temporarily tighten the oil filter cover (2). Install the socket wrench “7” (special tool : 103 589 02 09 00), and then
completely tighten it. Installation Notice
2 Oil Filter Cover
5 O-ring
6 Oil Filter Element
7 Special Tool (Socket Wrench)
Tightening Torque 25 Nm

1B3-146 OM600 ENGINE MECHANICAL
Notice Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill
Faulty chain tensioners should be replaced completely.
3 Screw Plug
4 Aluminum Gasket
5 Ball
6 Ball Guide
7 Compression Spring
8 Compression Spring
9 Housing
10 Thrust Pin 11 Valve Disc
12 O-Ring
13 Snap Ring
14 Compression Spring
15 Filler
A Feed Bore from Cylinder Head
B To Oil Pan

1D1-4 M162 ENGINE COOLINGDIAGNOSIS
3. Connect the special tool to the reservoir filler cap and apply 1.4 bar of pressure.
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester Test Procedure
1. Loosen the cap a little and release pressure and removethe cap. NoticeFor the risk of scalding, cap must not be opened unless the coolant temperature is below 90 °C.
2. Fill coolant up to upper edge (arrow) of reservoir.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at the all coolant hoses and pipes and each connections. Replace or retighten if necessary.

1D2-4 M161 ENGINE COOLINGDIAGNOSIS
3. Connect the special tool to the reservoir filler cap and apply 1.4 bar of pressure.
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test Procedure
1. Loosen the cap a little and release pressure and remove
the cap. Notice For the risk of scalding, cap must not be opened unless the coolant temperature is below 90 °C.
2. Fill coolant up to upper edge (arrow) of reservoir.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at the all coolant hoses and pipes and each connections. Replace
or retighten if necessary.