2003 SSANGYONG MUSSO lock

1B2-28 M161 ENGINE MECHANICAL
POLY V-BELT Preceding Work : Removal of cooling fan
1 Poly V-belt (2,155 mm)
2 Belt Tensioning Pulley
Removal & Installation Procedure
1. Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclockwise.
2. Remove the poly v-belt.
Notice Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt after prying the tensioning pulley.3 Belt Tensioner

1B2-30 M161 ENGINE MECHANICAL TENSIONING DEVICE Preceding Work : Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) +Washer .......................................... 22.5-27.5 Nm
2 Bolt (M8 x 25, 1 pieces) + Washer .......................................... 22.5-27.5 Nm
Removal & Installation Procedure
1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in tensioning arm.
3. Unscrew the bolts (1, 2) and remove the tensioning device.
Installation Notice
4. Installation should follow the removal procedure in the reverse order. 3 Tensioning Device
4 Stud bolt
5 Tensioning Arm
Tightening Torque 22.5 - 27.5 Nm

1B2-50 M161 ENGINE MECHANICAL Components
Service Data Standard
Permissble Deviation of The Vibration DamperRadial Runout Axial Runout0.6 mm 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
001 589 74 21 00 Puller
000 589 88 33 00 Torque Wrench
602 589 00 40 00 Engine Lock Removal & Installation Procedure
1. Adjust the piston of number 1 cylinder to the TDC.
1 Center Bolt (M18 x 50)
2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan 11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

M161 ENGINE MECHANICAL 1B2-51
Engine Lock 602 589 00 40 00
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
4. Remove the vibration damper assembly using the puller.
5. Installation should follow the removal procedure in thereverse order. Notice If possible, don ’t separate the vibration damper and the
pulley. Tightening Torque
1st step 180 - 220 Nm2nd step + 90
°

1B2-58 M161 ENGINE MECHANICAL Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaftbearing. Notice
Measure at 2 points (1, 2).
Measure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft bearing journal. Notice
Record the mean value when measured at 3 points
(A, B, C).
Measure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data, replace the bearing shell.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and removethe roll pin, and remove the armature. Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice
Tightening Torque 60 - 70 Nm
Notice Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step + 95
°
Notice The flange bolt is designed to be used only once, so always replace with new one.
12. Installation should follow the removal procedure in the reverse order.
13. Check and adjust the camshaft timing.

M161 ENGINE MECHANICAL 1B2-73
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
OTUTCylinder
1, 4 2, 3

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