oil type SSANGYONG MUSSO 2003 Owner's Manual

Type Clutch Pedal Clutch Disc Clutch Master Cylinder Clutch Release Cylinder Clutch FluidDescription
Hydraulic
Suspended 158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm 9.2 mm
19.8 mm
15.87 mm
14.0 mm
17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

Model
TypeGear Ratio Oil Manufacturer WeightPart-Time 4408 (E)
E.S.O.F. Type
1 : 1
2.48 : 1
ATF S-3, S-4 or DEXRON II, III
1.2 L
Check : Every 15,000 km
Replace : Every 50,000 km Borg Warner30 kg
SECTION 5D1
TRANSFER CASE (PART TIME 4408)
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D1-1
General Specifications . . . . . . . . . . . . . . . . . 5D1-1
Schematic and Routing Diagram . . . . . . . . 5D1-2 Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4 System Description . . . . . . . . . . . . . . . . . . . . 5D1-4
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8Diagnostic Diagram . . . . . . . . . . . . . . . . . . .
5D1-9
Maintenance and Repair . . . . . . . . . . . . . 5D1-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Maintenance of Transfer Case Lubricant . . 5D1-10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
High LowSpecification Capacity Lubrication
Application
Description

Application
Steering Wheel Steering Gear Box Oil Pump Steering Column
Minmum Turning Radius Oil SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke Outer Diameter
Type Gear Ratio Inner Steering AngleOuter Steering Angle
TypeMaximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type Capacity Change Interval
Description
4
396 mm
Rack and Pinion

33°37'
31°50' Vane
75-82 kg/cm 2
4.646° 6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt Pressure Hose BoltReturn Pipe Nut Slotted Nut Steering Gearbox Bolt
N m
30 - 40 12 - 1812 - 1835 - 45 35 - 45

7D-2 FATC-HAVC
Application
Size (WxHxT) Capacity
Type Description
650x339.2x22.0 11,000 Kcal/h
Parallel Flow
Condenser
Application
Material CapacityDesiccant Description
Aluminum 250cc
XH-9 or equivalent 35g
Receiver Drier
Application
Motor Type Motor Size Description
Magnetic
70 x
145
Blower Unit
Application
Replacement Description
Every 10,000 km (replace earlier if air pollution is heavy)
Air Filter
Application
Model
Type
Displacement (cc/rev.) Pulley Oil Description
FK-II(DKV 14C) Vane rotary 140.5
143.0
ZXL 200 PG (PAG Oil)
Compressor
Application
Heater Core Type Heating CapacityHeater Core Size (LxWxT) Description
2 - ROW
4,600 Kcal/h (AT 300CMH)
219.5 X 151.8 X 52
Heater Unit
Application
Type High (OFF)Low (ON) Description
Direct
OFF : 27±2Kgf/cm 2
, DIFF : 6±2Kgf/cm 2
OFF : 1.8±2Kgf/cm 2
, ON : 1.9±0.3Kgf/cm 2
Pressure Switch

5-196 ELECTRICAL WIRING DIAGRAMS
45. IMMOBILIZER (GSL HFM-ROLLING CODE TYPE) CIRCUITb. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
IMMOBILIZERUNIT
a. CONNECTOR INFORMATION
1234
5678
911 10 12
C101
W/H MAIN C104
W/H ENGINE C110
W/H MAIN C111
W/H ECM MAIN
C206B
W/H MAIN C208
W/H T/M C208B
W/H MAIN FUEL PUMP
A B RECEIVER UNIT
135 2 46
10
1
20 11
30 21
40 31
12 34
1
4 52
8
14
7
93
15
13
10
11 6
12
12 34
1 2
34
5 6
78
911 10 123
2
1
65
4
Inside The Engine Room Fuse Block Under The Engine Room Fuse Block Behind The ABS Module (HFM)Center The Engine Room Dash Panel Upper The T/C (GSL) Upper The T/C Upper The T/C (GSL) Behind The ClusterRight The I/P Fuse Block Upper The ECM Beside The TCCU
Main - EngineEngine - Main Main - Engine Main Engine Main - ECM MainMain - Fuel Tank Main - T/M Main - T/M Main MainMain Main
C101 (21Pin, Colorless) C104 (15Pin, Black) C110 (6Pin, Black) C111 (40Pin, Black) C206B (4Pin, Black) C208 (16Pin, Black)C208B (15Pin, Black) S202 (Gray) G201 G203 G205
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
30
15C BAT+
ACC
31 GND
G205
G203 G205 G201
C104 ECM(HFM)
"29"
OVPR "6"
F17
S202 1
RY
RL
B+ ACC
B+
GND GND GND ACC LY B W
23
A11 A8
B2 B6 B4 B5
LgW RW
LgW RW
LgW RW
A6
BBB
RY B W
A9 85
110
A12
WY
BG BG BG
BW BWBW
B
B
B
BR BR
Fuel Pump
2 1
PR
PR
6
(E23 A/T)
StartLock
Switch "2" (E32 A/T)
StartLock
Switch "D"
BG
BG
(HFM
E20,E23 M/T) PNP
Relay "87"
"5"
Hazard Switch
"8" "6"
Door Lock Relay
"4"
Stics "3"
Stics
"6"
"21"
ECM
(HFM)
"86"
Starter Motor
Relay "ST"
Starter Motor
Injector,
Ignition Coil
BL
I C U
RECEIVER UNIT
BY BY (E32 M/T)
Ignition
Switch (ST)
"4"
ECM "21"
BY
R
G
12
6
10A
60A
F9
20A
F4
15A
Fuel Pump
Relay
86
30
11
BR LR
B
85
87
C208B
2
C103
1
C208
3
F1
10A
C101
13 C110
4
C110
1
C113
14
1C206B C206B
2
M
: E32
Ef2
E
f8 80A
60A
C103
2
Ef2
E
f9
80A
1234 5678
9 101112
13 14 15 16