2003 SSANGYONG MUSSO Service Manual

M161 ENGINE MECHANICAL 1B2-81
Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
001 589 72 21 00 Torque Wrench Replacement Procedure
1. Position the NO.1 cylinder to ATDC 20°.
4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure.
2. Insert the pin to the intake and exhaust camshaft flange.
3. Remove the chain tensioner.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.

1B2-82 M161 ENGINE MECHANICAL7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution by pressing the new timing chain against the exhaustcamshaft sprocket to prevent it to be tangled. Notice Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the link (5) and the center plate (6).
6. Remove the outer plate (7) with the screw driver and
remove the link (5).
11. Install the jaw (a) and the thrust piece (b) to the assembly tool as shown in the figures.

M161 ENGINE MECHANICAL 1B2-83
15. Replace the thrust piece (b) as shown in the figure.
13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool.
12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
16. Install the assembly tool to the link pin and tighten the spindle (c).
Tightening Torque 30 Nm

1B2-84 M161 ENGINE MECHANICAL
17. Rivet the link pin.Check the condition and it again if necessary.
18. Install the chain tensioner. Installation Notice
19. Check the camshaft timing position. Tightening Torque
Screw Plug
40 Nm
Tensioner Assembly 72 - 88 Nm

M161 ENGINE MECHANICAL 1B2-85
TENSIONING RAIL Preceding Work : Removal of cylinder head
Removal & Installation Procedure
1. Remove the timing gear case cover (3).Notice Be careful not to damage the gasket.
2. Remove the sliding rail (1) from the sliding rail pin (2). Notice
Replace the plastic guide (2) if it is damaged.
For installation, exactly align the plastic guide (2) with
the sliding rail (1).
3. Installation should follow the removal procedure in the reverse order.
1 Sliding Rail Pin
2 Sliding Rail
3 Timing Gear Case Cover

1B2-86 M161 ENGINE MECHANICAL
CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover
1 Bolt (M6 X 45, 2 pieces).................. 9-11 Nm
2 Guide Rail
Removal & Installation Procedure
1. Position the number 1 cylinder to ATDC20 ° guide rail.
2. Install the pin (special tool : 111 589 03 15 00) into the no.1 and no.6 bearing cap hole.
3. Remove the chain tensioner. Installation Notice
Tightening Torque Screw Plug40 Nm
Tensioner Assembly
72 - 88 Nm
4. Unscrew the bolt (1) and remove the guide rail. Installation Notice
Tightening Torque 9 - 11 Nm
5. Installation should follow the removal procedure in the reverse order.

M161 ENGINE MECHANICAL 1B2-87
CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover
Removal & Installation Procedure
1. Remove the timing gear case cover (3).Notice Be careful not to damage the gasket when removing/
installing the timing gear case cover.
2. Remove the guide rail (2) from the guide rail pin(1).
Notice
Replace the plastic guide (2) if damaged.
Connect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
3. Installation should follow the removal procedure in the reverse order.
1 Guide Rail Pin
2 Guide Rail
3 Timing Gear Case Cover

1B2-88 M161 ENGINE MECHANICAL
CRANKSHAFT SPROCKET Preceding Work : Removal of oil panRemoval of tensioning rail Removal of crank case guide rail Removal of cylinder head
6 Bolt (M8 x 20, 1 piece) / Washer ..........29-35 Nm
7 Oil Pump Sprocket
8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain
1 Oil Pump Chain Tensioner
2 Oil Pump Chain Spring
3 Oil Pump Chain Bushing (Pin)
4 Crankshaft Sprocket
5 Key