2003 SSANGYONG MUSSO steering

1B2-22 M161 ENGINE MECHANICALPOWER STEERING PUMP AND A/C BRACKET Preceding Work : Removal of cooling fan and shroud Removal of drive belt
1 Nut ................................................. 35.2-28.8 Nm
2 Washer
3 Belt Pulley
4 Bolt (M8 X 91, 2 pieces) .................22.5-27.5 Nm
5 Power Steering Pump
6 Bracket
7 Washer
8 Bolt (M8 X 20, 2 pieces) .................22.5-27.5 Nm 9 Washer
10 Bolt (M8 X 105,4 pieces) ................22.5-27.5 Nm
11 A/C Compressor
12 Bolt (M8 X 50, 5 pieces, M8 X 80,
5 pieces) ........................................ 22.5-27.5 Nm
13 A/C Bracket
14 Vent Hose
15 Bracket Gasket ...................................... Replace

M161 ENGINE MECHANICAL 1B2-23
Removal & Installation Procedure
1. Remove the belt pulley after removal of poly v-belt.Installation Notice
2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump. Installation Notice
Notice Pull the tensioning pulley counterclockwise as shown in the figure.
4. Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A/C compressor. Notice Discharge all the refrigerant before removing the pipes.
Tightening Torque 40.5 - 49.5 Nm
Tightening Torque 22.5 - 27.5 Nm

M161 ENGINE MECHANICAL 1B2-29
Poly V-belt Arrangement
1 Belt Tensioning Pulley
2 Crankshaft Belt Pulley
3 A/C Compressor Pulley5 Alternator Pulley
7 Power Steering Pump Pulley
8 Water Pump Pulley

M161 ENGINE MECHANICAL 1B2-45
Tools Required
001 589 72 21 00 Torque Wrench
116 589 2 0 33 00 Sliding Hammer
116 589 01 34 00 Threaded Bolt Removal & Installation Procedure
1. Remove the power steering belt pulley and A/C compressorbracket.
2. Remove the oil line from power steering pump.
3. Rotate the crankshaft so that the piston of number, cylinder is at ATDC20 °
Sliding Hammer 116 589 20 33 00Threaded Pin 116 589 02 34 00
4. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
5. Remove the chain tensioner. Installation Notice
Tightening Torque 78 - 88 Nm
6. Remove the intake and exhaust camshaft sprocket (remove the camshaft adjuster assembly in E23 engine). Installation Notice
Tightening Torque 1st step 18 - 22 Nm
2nd step 85
° - 95 °
Notice The flange bolt is designed to be used only once, so always replace with new one.
7. Remove the guide rail pin using the sliding hammer (02) and the threaded pin (03). NoticeApply the sealant on guide rail pin when installation.

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.

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 1B3-63
TIMING CASE COVER
Preceding Work : Removal of the cooling fanRmoval of the V-belt tensioning device Removal of the vibration damper and hub Removal of the alternator
1 Bolt............................................................ 10Nm
2 Cylinder Head Cover
3 Gasket ................................................... Replace
4 Socket Bolt ................................................ 25Nm
5 Fuel Filter
6 Square Nut
7 Oil Pan
8 Socket Bolt ................................................ 10Nm
9 Bolt .................................................... M6 : 10Nm
M8 : 23Nm 10 Power Steering Pump
11 Bolt
12 Belt Pulley 13 Bolt
............................................................ 32Nm
14 Timing Case Cover
15 Bolt ............................................................ 23Nm
16 Alternator Bracket
17 Bolt ............................................................ 45Nm
18 Bolt ............................................................ 25Nm
19 Bolt ............................................................ 10Nm
20 Closing Cover
21 Socket Bolt ................................................ 23Nm
22 Guide Pulley
23 Bolt .............................................................. 9Nm
24 Guide Pulley Bracket
25 Nut ............................................................. 23Nm

OM600 ENGINE MECHANICAL 1B3-65
11. Remove the alternator bracket (16).
9. Disconnect the pipes of power steering pump and removethe belt pulley. Notice
Be careful not to lose the key.
10. Remove the nut and pull out the bolt and then remove the power steering pump.
12. Remove the fuel filter.