2003 SSANGYONG MUSSO torque

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

1B1-84 M162 ENGINE MECHANICAL
Tools Required
615 589 01 33 00 Puller Removal & Installation Procedure
1. Put the assembly mark at the crankshaft sprocket (4) andthe timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain. Also, align the assembly marks on camshaft sprocketand timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7) from the oil pump. Installation Notice
Puller (04) 615 589 01 33 00
3. Remove the oil pump roller chain (9).
4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the puller (04, special tool). Notice
Make sure not to lose the crankshaft pulley key(5) when removing.
Install the crankshaft sprocket(4) after warming it up.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 29 - 35 Nm

1B1-86 M162 ENGINE MECHANICAL
Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.Notice Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice Remove the snap ring using a clean cloth as shown in the right picture so that the piston, piston ring, and the snapring don ’t get damaged.
Installation Procedure

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

M162 ENGINE MECHANICAL 1B1-95
ENGINE OIL AND OIL FILTER ELEMENT
4. Remove the drain plug (arrow) and drain the engine oil.Notice Leave the oil filler cap 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). Notice Make 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

1B1-98 M162 ENGINE MECHANICAL
Tightening Torque 23 Nm
Notice Replace the oil filter gasket.
4. Installation should follow the removal procedure in the reverse order.
5. Check engine oil level.
6. Run the engine at idle and check the engine for leaks.
3. Remove the oil filter bolt and then remove the oil filter.
Installation Notice
Removal & Installation Procedure
1. Drain the coolant from the crank case.
2. Remove the each coolant line and hose.