2003 SSANGYONG MUSSO check engine

M162 ENGINE MECHANICAL 1B1-79
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 Plug40 Nm
Tensioner Assembly 72 - 88 Nm

1B1-80 M162 ENGINE MECHANICAL TENSIONING RAIL Preceding Work : Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide
3 Tensioning Rail Pin
4 Guide Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the tensioning rail (1) from the tensioning rail pin (3). Notice
Replace the plastic guide (2) if it is damaged.
For installation, exactly align the plastic guide (2) with the tensioning rail (1).
4. Installation should follow the removal procedure in the reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-81
Tools Required 104 589 01 01 00Spanner
Removal & Installation Procedure
1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating direction using the wrench (4) and loosen the timing chain at upper guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of rotation using the wrench (4, special tool : 104 589 01 01 00).
5. Check for damages at the upper sliding rail and replace it if necessary. Install the upper guide rail pin.
6. Install the chain tensioner.
Installation Notice
CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover
1 Chain Tensioner
2 Upper Guide Rail
3 Upper Guide Rail Pin
4 Wrench (Special Tool)
Tightening Torque
Screw Plug40 Nm
Tensioner Assembly
72 - 88 Nm

1B1-82 M162 ENGINE MECHANICAL
CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover
1 Guide Rail
2 Plastic Guide
3 Guide Rail Pin
4 Tensioning Rail
Removal & Installation Procedure
1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).
2. Remove the exhaust camshaft sprocket.
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
Replace the plastic guide (2) if damaged.
Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when installing.
4. Installation should follow the removal procedure in the reverse order.
5. Check the camshaft timing position.

M162 ENGINE MECHANICAL 1B1-87
1. Check the piston ring gap and apply the engine oil to thepiston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and the piston and coat them with engine oil.
4. Install the piston ring using the tensioning strap(000 589 04 14 00).
5. Install the piston so that the arrow on the piston head faces to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark (// or a number), tighten the bolts.
Installation Notice
Tightening Torque 1st step 35 - 45 Nm
2nd step 90
° + 5 °
Apply the engine oil to the bearing cap upper and lower bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating it.

M162 ENGINE MECHANICAL 1B1-89
Inspection
1. Measure the basic bore of the connecting rod bearing.Notice If the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod.
2. Check connecting rod bolts.
3. Check the assembly mark(indication//or number:arrow) of the connecting rods and the bearing cap when installing. Notice
Make sure it doesn ’t exceed over 4g with other
connecting rods when replacing the connecting rods.
Check if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the bearing.
Notice If the length exceeds max. length, replace it.
Length When New (L)
Max. Length (L)
Tightening Torque 51.7 - 52 mm
52.9 mm
1st step 40 + 5 Nm 2nd step 90 °+10 °

M162 ENGINE MECHANICAL 1B1-93
OIL PAN
1 Gasket ................................................... Replace
2 Bolt (M6 x 22, 6 pieces)............................ 10 Nm
3 Drain Plug (M6 x 20) ................................. 25 Nm
4 Bolt (M6 x 20, 22 pieces) .......................... 10 Nm 5 Bolt (M6 x 85)
............................................ 10 Nm
6 Bolt (M8 x 40) ............................................ 25 Nm
7 Bolt (M10) ................................................. 40 Nm
8 Oil Pan
Removal & Installation Procedure
1. Remove the drain plug and drain the oil completely.
2. Disconnect the electric connector from oil level switch.
3. Unscrew the bolts (10) for oil level switch and check the O- ring (11) for wear or damage. And replace it if necessary.
4. Unscrew the bolts and remove the oil pan and gasket.
NoticeArrange the bolts according to each size.
5. Clean the inside of oil pan and sealing surface, then apply the sealant.
6. Replace the gasket with new one.
7. Install the oil pan with gasket, and tighten each bolt in specified torque.
8. Check for oil leaks while running the engine.
M8 X 40, 4 pieces M6 X 85, 3 piecesM6 X 35, 3 piecesM6 X 20, 28 pieces
the rest

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.