flat tire SSANGYONG MUSSO 2003 Service Manual

GENERAL INFORMATION 0B-3
662LA MB
W4A040 3.871 2.247 1.4361.0005.5865.38
9 - 9.5
Auto Transmission (MB)
Application
Maker
Type or Model
Gear Ratio : 1st 2nd3rd 4th Reverse
Final Drive RatioOil Capacity (L)
2.3L DOHC MB
W4A040 3.871 2.247 1.4361.0005.5864.27
9 - 9.5 3.2L DOHC
MB
W4A040 3.871 2.247 1.4361.0005.5863.73
9 - 9.5
661LA
BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
5.38 9
Auto Transmission (BTRA)
Application
Maker
Type or Model
Gear Ratio : 1st 2nd 3rd 4thReverse
Final Drive RatioOil Capacity (L)662LA BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
4.89 9 2.3L DOHC
BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
5.86 9 3.2L DOHC
BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
4.89 9
Tire and Wheel
Specifications
P235/75 R15, 255/70 R15 7JJ × 15
30 Psi 30 Psi 30 Psi 30 Psi
Application
Standard Tire SizeStandard Wheel SizeInflation Pressure At Full Lode
P235 / 75 : FrontRear
P255 / 75 : Front Rear
Application
Booster Size Master Cylinder Diameter (mm) Booster Ratio
Front Brake : Disc Type
Rear Brake : Disc Type
Specifications 8inch + 9inch 7inch + 8inch 8inch + 9inch
25.4
5.6 : 1
Ventilated
Solid
Brake
non-ABS ABS 5.0ABS 5.3

GENERAL INFORMATION 0B-7
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
Fuel Filter Replacement
Replace the engine fuel filter every.
Gasoline Engine : 60,000km (36,000 miles)
Diesel Engine : 45,000km (24,000 miles)
Spark Plug Replacement Replace spark plugs with same type.
Type : BOSCH : F8DC4
BERU : 14F-8DU4
Champion : C11YCC
Gap : 0.8 ± 0.1 mm
Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed. Brake System Service Check the disc brake pads or the drum brake linings.
Check the pad and the lining thickness carefully. Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. Whilethe tires and wheels are removed, inspect the brakes.
NORMAL VEHICLE USE The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons:

To carry passengers and cargo within the limitation
of the tire inflation prassure. Refer to “Tire and Wheel” in section 2E.
To be driven on reasonable road surfaces and withinlegal operating limits.
EXPLANATION OF SCHEDULED MAINTENANCE SERVICES The services listed in the maintenance schedule are
further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants. Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil. Engine Oil Viscosity Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold
weather performance; however, higher temperatureweather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage. Cooling System Service Drain, flush and refill the system with new coolant. Refer to “Recommended Fluids And Lubricants” in this section. Air Cleaner Element Replacement
Clean the air cleaner element every.
Gasoline Engine : 15,000km (10,000 miles)
Diesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
Gasoline Engine : 60,000km (36,000 miles)
Diesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty conditions.
Tire Rotation (Left - Hand Drive Type)

GENERAL INFORMATION 0B-9
Chassis and Body
Months
MAINTENANCE ITEM MAINTENANCE INTERVAL
Kilometers or time in months, whichever comes first
120
105
90
75
60
45
30
15
1
96
84
72
60
48
36
24
12
-
x1,000 km
Exhaust pipes & mountings Brake/Clutch fluid
(3)(4)
Parking brake/Brake pads F & R (5)Brake line & connections (including booster)
Manual transmission oil (3) Clutch & brake pedal free play
Front & Rear Differential Fluid (3)I
R
IIIII- --II
-
I IIIIII I
I
R I II I I IIII
R I
R IIIII I II
R
II
R I
R IIIIII II
R I IIII
Automatic transmission fluid (MB W4A040) (6) Automatic transmission fluid (BTRA M74)Chassis & underbody bolts & nuts tight/secure Tire condition & inflation pressure
Wheel alignment (7) Steering wheel & linkage
Power steering fluid & lines* (3)Drive shaft boots Seat belts, buckles & anchors Lubricate locks, hinges & bonnet latchIIII I I IIII I III I I IIII I IIII
R
III I IIII IIII I IIIIIIIII I III I
R R
III I IIII IIII I IIII
Transfer case fluidRII
I
Inspect & ADJUST when abnormal condition is noted
I
I II I IIII
Chart Symbols :
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.R - Replace or change.
(3) Refer to “Recommended fluids and lubricants”.
(4) Change the brake / clutch fluid every 15,000 km if the vehicle is mainly driven under severe conditions:- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low - speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transaxle fluid and filter every 75,000 km if the vehicle is mainly driven under severe conditions. - In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or- In hilly or mountainous terrain, or- When doing frequent trailer towing, or- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

GENERAL INFORMATION 0B-11
Chassis and Body
Months -
MAINTENANCE ITEMMAINTENANCE INTERVAL
Kilometers or time in months, whichever comes first
100
90
80
70
60
50
40
30
20
10
1
60
54
48
42
36
30
24
18
12
6
x1,000 km
Exhaust pipes & mountings
Brake/clutch fluid (3) (4)
Parking brake/Brake pads (F & R) (5) Brake line & connections (including booster)
Manual transmission fluid (3)Clutch & brake pedal free play
F & R Differential fluid (3)
I I I IIIIIIIIIIIII I
R
IIIII IIIIIII IIII
R I
R I
R
IIIII IIIIIIIIIIIIII I
R
IIIII IIII
R I
R
Automatic transmission fluid (BTRA M74) (6) Chassis & underbody bolts & nuts tight/secure Tire condition & inflation pressure
Wheel alignment (7) Steering wheel & linkage
Power steering fluid & lines* (3) Drive shaft boots Seat belts, buckles & anchors Lubricate locks, hinges & bonnet latchI II I IIII III I IIII IIII I III I
I II I IIII III I IIIIIII I IIII III II II III I IIIIIII I IIII
Transfer case fluid (3)
RI R
I
I
I
I I I II IIII I IIII
Inspect & ADJUST when abnormal condition is noted
II I
Chart Symbols :
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.R - Replace or change.
(3) Refer to “Recommended fluids and lubricants”.
(4) Change the brake / clutch fluid more regularly if the vehicle is mainly driven under severe conditions :- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low - speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transmission fluid every 70,000 km if the vehicle is mainly driven under severe conditions. - In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or- In hilly or mountainous terrain, or- When doing frequent trailer towing, or- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

SUSPENSION DIAGNOSIS 2A-3
DIAGNOSIS
GENERAL DIAGNOSIS
Checks
Loosened Mountings Damaged or Worn wheel BearingDamaged Shock Absorber
Damaged Tire Action
Retightening ReplaceReplaceReplace
Abnormal Noises
Checks
Broken Stabilizer Bar Faulty Shock Absorber Action
ReplaceReplace
Vehicle Rolling
Checks
Over Inflated Tire Faulty Shock Absorber Loosened wheel Nut Bent or Broken Coil Spring
Damaged TireWorn Bushing Action
Pressure Adjustment
Replace
Tighten as Specified ReplaceReplaceReplace
Poor Riding
Problems in the steering, the suspension, the tires, and the wheels involve several systems. Consider all systems when you diagnose a complaint. Some problems, suchas abnormal or excessive tire wear and scuffed tires,may by the result of hard driving. Always road test the
vehicle first. If possible, do this road test with the
customer. Proceed with the following preliminary checks. Correct any substandard conditions.
Checks
Incorrect Wheel Alignment Excessive Resistance of Lower Arm Ball Joint
Insufficient Tire PressureFaulty Power Steering
Action Repair
Replace Adjust
Repair or Replace
Hard Steering
Checks
Deformed Arm Assembly Worn BushingBent or Broken Coil SpringDifference Between L/H & R/H Heights Action
ReplaceReplaceReplace Adjust
Vehicle Pulls to Right or Left

2B-2 WHEEL ALIGNMENT
DIAGNOSIS
TIRE DIAGNOSIS Irregular and Premature Wear Irregular and premature tire wear has many causes. Some of them are incorrect inflation pressures, lack of regular rotation, poor driving habits, or improper wheelalignment. Rotate the tires if :
The front tire wear is different from the rear.
The left and right front tire wear is unequal.
The left and right rear tire wear is unequal, Check wheel alignment if :
The left and right front tire wear is unequal.
The wear is uneven across the tread of either fronttire.
The front tire treads are scuffed with “feather” edgeson the side of the tread ribs or blocks.
Tread Wear Indicators The original equipment tires have built-in tread wear indicators to show when the tires need replacement. These indicators appear as bands when the tire tread
depth becomes shallow. Tire replacement isrecommended when the indicators appear in three ormore grooves at six locations.
Radial Tire Waddle
Waddle is side-to-side movement at the front or rear of the vehicle. It is caused by the steel belt not being straightwithin the tire, or by excessive lateral runout of the tireor wheel. The vehicle must be road tested to determine which end of the vehicle has the faulty tire. The rear end of the vehicle will shake from side to side or “waddle” if the
waddle tire is on the rear of the vehicle. From the driver’ sseat, it feels as though someone is pushing on the sideof the vehicle. If the faulty tire is on the front of the vehicle, the waddle is more visual. The front sheet meld appears to be moving back and forth, and the drivers seat feelslike the pivot point in the vehicle.
Waddle can be diagnosed using the method of substituting known good tire and wheel assemblies onthe problem vehicle
1. Road test the vehicle to determine if the waddle is coming from the front or the rear of the vehicle.
2. Install good tires and wheels from a similar vehicle in place of those on the offending end of the problem vehicle. If the source of the waddle is not obvious, change the rear tires.

WHEEL ALIGNMENT 2B-5
VIBRATION DIAGNOSIS Wheel imbalance causes most highway speed vibration problems. A vibration can remain after dynamicbalancing because:
A tire is out of round.
A rim is out of round.
A tire stiffness variation exists.
Measuring tire and wheel free runout will uncover only part of the problem, All three causes, known as loadedradial runout, must be checked using method of substituting known good tire and wheel assemblies on the problem vehicle. Preliminary Checks Prior to performing any work, always road test the car and perform a careful visual inspection for:

Obvious tire and wheel runout.
Obvious drive axle runout.
Improper tire inflation.
Incorrect trim height.
Bent or damaged wheels.
Debris build-up on the tire or the wheel.
Irregular or excessive tire wear.
Improper tire bead seating on the rim,
Imperfections in the tires, including: tread deformations, separations, or bulges from impactdamage. Slight sidewall indentations are normal and
will not affect ride quality.
Tire Balancing Balance is the easiest procedure to perform and should be done first if the vibration occurs at high speeds. Do an off-vehicle, two-plane dynamic balance first to correct
any imbalance in the tire and wheel assembly. An on-vehicle finish balance will correct any brake drum,
rotor, or wheel cover imbalance, If balancing does not correct the high-speed vibration, or if the vibration occurs at low speeds, runout is the probable cause.

2B-6 WHEEL ALIGNMENT
MAINTENANCE AND REPAIR ON VEHICLE SERVICE WHEEL ALIGNMENT
Vehicle Height
1. Check the tire for proper inflation.
2. Measure ‘A’ from the center of the lower arm rear mounting
bolt end to the ground.
3. Measure ‘B’ from the center of the steering knuckle shaft to the ground.
4 . If the dif ference between ‘A’ and ‘B’ is not within specification,
adjust vehicle height using torsion bar height control bolt.
‘B’ - ‘A’
Notice Before wheel alignment, adjust vehicle height first.31 - 36mm
Toe-in
1. Measure toe-in.
Specification0 - 4mm
2. If toe-in is not within specification, loosen the tie rod nuts and adjust it by turning the tie rod.

2E-2 TIRES AND WHEELSDIAGNOSIS
WEAR PATTERN DIAGNOSIS
Wear Pattern Possible Cause Remedy
Wear on Both Tread Shoulders Under Inflation
Wear on Tread Center Over Inflation
Tread Torn Out Under Inflation
One-sided Tread Wear Incorrect Camber or Toe-in
Feather Edging of Tread Incorrect Toe-in
Spotty Tread Wear Out of Wheel Balance
Spotty Wear-wear Localized on Shoulder Sections Out of Wheel Balance Play in Hub Bearings Play in Ball Joint Defective Shock Absorber
Adjust AdjustAdjustAdjustAdjustAdjust Adjust
Check play
Adjust preload
Check Check

2E-6 TIRES AND WHEELS
4. Tire pressure inspection. Tire pressure.
Check tread contact with road.
Notice
If underinflated, tire may come away from the wheel
during rapid steering.
An overinflated tire will cause a hard riding and uneven
wear.
Front & Rear
(P235/75R15) 2.1kg/cm (30PSI)
2
5. Wheel balance. Balance weights should be on each side. When the wheel
is out of balance or a tire has been repaired, be sure to balance the wheel again.
If total weight is over 150g, readjust the balance by
reinstalling the tire on the wheel.
Balance weight should not protrude from the wheel rim
over 3mm.
For aluminum wheel, use aluminum wheel balance weight
only.