2003 SSANGYONG MUSSO torque

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 °

1B1-50 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°

M162 ENGINE MECHANICAL 1B1-53
FLYWHEEL / DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces)............................................... 1st step 45+5 Nm
2nd step +90 ° +10 °
2 Plate 3 Driven Plate (A/T)
4 Dowel Pin
Service Data Standard (Stretch Bolt)
Nominal Size
Stretch Side Diameter
Bolt Length
Tightening Torque
M x 1.5
8.5 - 0.2 mm 8.0 mm
21.8 - 22.2 mm-
When New
Min. Diameter When NewDd L
1st step 50 Nm, 2nd step 90 °

1B1-54 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Unscrew the stretch bolt.Installation Notice
Sectional View
1 Oil Pan
2 Cover
3 Crankshaft Front Seal
4 Flywheel MTG Bolt
5 Crankshaft
6 Dowel Pin
7 Plate
8 TGCC
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm.
For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90 ° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for Auto. transmission vehicle.
3. Installation should follow the removal procedure in the reverse order. Tightening Torque
1st step 45+5 Nm
2nd step 90
° + 10 °

1B1-56 M162 ENGINE MECHANICAL Removal & Installation Procedure
1. Turn the crankshaft to the direction of engine rotation andposition the no.1 cylinder piston at TDC which the camshaft
is positioned at OT.
2. Remove the cylinder head front cover.
3. Paint the alignment marks (arrows) on the intake and exhaust camshaft sprocket and the timing chain.
4. Unscrew the bolt (3) from the armature (4) and remove the armature. Installation Notice
3 Bolt
4 Amarture
6 Nut (M20 x 1.5)
11 Seal Cover
5. Unscrew the nut (6) and remove the ring and seal cover
(11). Installation Notice
Tightening Torque 35 Nm
Tightening Torque 60 - 70 Nm
12 Camshaft Sprocket
17 Control Piston
21 Intake Camshaft
6. Unscrew the sprocket bolt from the exhaust camshaft and remove the sprocket. Installation Notice The sprocket bolt is designed to be used only once, so always replace with new one. Tightening Torque
1st step 18 - 22 Nm
2nd step 90
° ± 5 °

M162 ENGINE MECHANICAL 1B1-57
7. Remove the camshaft sprocket (13) and adjust piston (14),and remove the flange shaft (16) from the intake camshaft (22) after removing the bolt (15). Installation Notice The sprocket bolt is designed to be used only once, so always replace with new one.
8. Installation should follow the removal procedure in the reverse order.
9. Adjust the camshaft timing.
Tightening Torque 1st step 18 - 22 Nm
2nd step 90
° ± 5 °

1B1-58 M162 ENGINE MECHANICAL
CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt Notice The sprocket bolts are designed to be used only once, so always replace with new one. Exhaust Camshaft Sprocket Bolt Notice The sprocket bolts are designed to be used only once, so always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30e . 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
E. M7 x 13 Collar Bolt Torx-T30
e . 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
Tightening Torque
1st step 18 - 22 Nm
2nd step 90
° ± 5 °
Tightening Torque 1st step 18 - 22 Nm
2nd step 90
° ± 5 °

M162 ENGINE MECHANICAL 1B1-61
8 . Unscrew the intake side bolts (8, 11, 13, 14) and the exhaustside bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice Number the camshaft bearing cap bolts when removing them, so that they don ’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30 °.
Notice
Turn the crankshaft in the direction of engine rotation.
3. Turn the camshaft using the wrench (special tool) so that the intake camshaft adjustment hole lines up with the cylinder head upper side (3 o ’clock direction at the intake, 9 o ’clock
direction at the exhaust). Notice
Turn the crankshaft and adjust it to OT so that No. 1 cylinder ’ s
piston would be at TDC.
Install the bearing caps according to the numbers on the bearing caps.
Tightening Torque 22.5 - 27.5 Nm
2. Install the exhaust camshaft bearing caps (2, 3, 5) and the
intake camshaft bearing caps (9, 10, 12). Tighten the bolts with specified torque and install the remaining bearing caps. Notice