SSANGYONG MUSSO 2003 Service Manual

1B3-16 OM600 ENGINE MECHANICAL
16. Remove the power steering pump lines.Notice Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump.
18. Vehicle with automatic transmission. Remove the hydraulic lines (19, 20) from oil cooler (2).
19. Disconnect the engine harness.
20. Disconnect the preheating time relay cable.

OM600 ENGINE MECHANICAL 1B3-17
26. Disconnect the starter motor wires and remove the startermotor.
21. Remove the fuel lines from the fuel filter and cover thefilter with plug.
22. Disconnect the brake booster hose from vacuum pump.
23. Disconnect the other vacuum lines.
24. Disconnect the ground cable.
25. Disconnect the alternator wires.

1B3-18 OM600 ENGINE MECHANICAL
27. Disconnect the preheating time relay sensor plug.
28. Disconnect the coolant temperature sensor plug.
29. Disconnect the accelerator cable from the control linkage.Installation Notice
Tightening Torque 8 - 18 Nm
30. Loosen the connection of control pressure cable (an arrow) used in auto transmission.

OM600 ENGINE MECHANICAL 1B3-19
33. Disconnect the exhaust pipe flange from the exhaustmanifold. Installation Notice
35. Remove the shift control cable.
36. Remove the transmission.
Tightening TorqueAxle 70 ~ 80 Nm T/C 81 ~ 89 Nm
Tightening Torque 20 - 34 Nm
31. Separate the exhaust pipe flange from the turbo charger.
Installation Notice
32. Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder. Installation Notice
Tightening Torque 30 Nm
Tightening Torque 30 Nm
34. Remove the propeller shaft from the transmission. Installation Notice

1B3-20 OM600 ENGINE MECHANICAL
37. Loosen the engine mounting bracket nut.Installation Notice
38. Remove the engine assembly from the vehicle by using a hoist or crane.
39. Installation should follow the removal procedure in the reverse order.
Tightening Torque 50 - 75 Nm

OM600 ENGINE MECHANICAL 1B3-21
POLY V-BELT
1 Nut .............................................................23Nm
2 Tensioning Lever
3 Bolt 4 Spring
5 Tensioning Lever
6 Poly V-Belt

1B3-22 OM600 ENGINE MECHANICALWith Air Conditioner
Removal & Installation Procedure
1. Remove the nut.
2. Push the tensioning lever in direction of arrow with a rod
(F12 ´ 180mm) and pull out the bolt to the rear.
3. Push back the tensioning lever (arrow direction) to release the spring tension and remove the belt.
4. Install the poly V-belt beginning at the tensioning pulley (7). 7 Tensioning Pulley
8 Crankshaft
9 Alternator
10 Coolant Pump 11 Guide Pulley
12 Power Steering Pump
13 Aircon. Compressor
Lengthe of Belt
Length (L)
Without Air Conditioner 2,100 mm 2,040 mm

OM600 ENGINE MECHANICAL 1B3-23
TENSIONING DEVICE Preceding Work : Removal of cooling fan
1 Bolt............................................................ 21Nm
2 Damper
3 Nut ............................................................. 21Nm
4 Tensioning Lever
5 Guide Rail Pin
6 Bolt
7 Poly V-Belt
8 Belt Pulley
9 Bolt ............................................................ 10Nm10 Tensioning Pulley
11 Socket Bolt ................................................ 29Nm
12 Closing Cover
13 Washer
14 Tensioning Lever
15 Fit Bolt ..................................................... 100Nm
16 Closing Cover
17 Spring
18 Bolt ............................................................ 20Nm

1B3-24 OM600 ENGINE MECHANICAL Removal & Installation Procedure
1. Remove the nut.Installation Notice
Tightening Torque 10 Nm
2. Push the tensioning lever in direction of arrow with a rod ( F12 ´ 180mm ) and push out the bolt to the rear.
3. Push back the tensioning lever to release the spring tension and remove the belt.
4. Remove the bolt (9) and then remove the belt pulley (8).
5. Remove the bolt (1, 18) and take off the damper (2). Notice
Pay attention to installation position of the damper.

OM600 ENGINE MECHANICAL 1B3-25
6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).Installation NoticeInsert spring (17) with color coding (blue/violet) facing up.
8. Pry off the closing cover (12) and remove the socket bolt(11) and then remove the tensioning pulley (10). Installation Notice
Tightening Torque 29 Nm
9. Pry off the closing cover (16) and remove the fit bolt (15).
10. Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice Apply Loctite on thread of fit bolt.
Tightening Torque 100 Nm
12. Installation should follow the removal procedure in the reverse order.