lock SSANGYONG MUSSO 2003 Service Manual

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.

GENERAL INFORMATION 0B-13
Weather-Strip Lubrication Apply a thin film silicone grease using a clean cloth. EACH TIME THE OIL IS CHANGED Brake System Inspection This inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc.
Inspect the disc brake pads for wear. Inspect the rotors for surface condition. Inspect other brake parts, theparking brake, etc., at the same time. Inspect the brakes more often if habit or conditions result in frequent braking. Steering, Suspension and Front Drive Axle Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears or leakage. Replace
the seals if necessary. Exhaust System Inspection Inspect the complete system (including the catalytic converter if equipped). Inspect the body near the exhaustsystem. Look for broken, damaged, missing, or out-of- position parts as well as open seams, holes, loose connections, or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment. Throttle Linkage Inspection Inspect the throttle linkage for interference or binding, damaged, or missing parts. Lubricate all linkage joints and throttle cable joints, the intermediate throttle shaft
bearing, the return spring at throttle valve assembly, and the accelerator pedal sliding face with suitable grease. Check the throttle cable for free movements. Engine Drive Belts Inspect all belts for cracks, fraying, wear and proper tension. Adjust or replace the belts as needed. Hood Latch Operation When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood
must close firmly. AT LEAST ANNUALLY Lap and Shoulder Belts Condition and Operation Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and the anchors. Movable Head Restraint Operation On vehicles with movable head restraints, the restraints must stay in the desired position. Spare Tire and Jack Storage Be alert to rattles in the rear of the vehicle. The spare tire, all the jacking equipment, and the tools must besecurely stowed at all times. Oil the jack ratchet or the screw mechanism after each use. Key Lock Service
Lubricate the key lock cylinder. Body Lubrication Service Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the latches, the glove box and the console doors, and anyfolding seat hardware. Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control.
At least every spring clean the underbody. First, loosen the sediment packed in closed areas of the vehicle. Then
flush the underbody with plain water. Engine Cooling System Inspect the coolant and freeze protection fluid. If the fluid
is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the propermixture in order to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or
deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation.

GENERAL INFORMATION 0B-15
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
If a floor jack is used, the following precautions are recommended.
Park the vehicle on level ground, “ block” the front or rear wheels, set the jack against the frame, raise the vehicle and support it with chassis stands and then perform the service operation.
Before performing the service operation, disconnectthe negative battery cable in order to reduce the chance of cable damaged and burning due to short- cir cuiting.
Use a cover on the body, the seats and the floor to protect them against damage and contamination.
Handle brake fluid and antifreeze solution with care as they can cause paint damage.
The use of proper tools, and the recommended essential and available tools where specified, are important for efficient and reliable performance of the service repairs.
Use genuine DAEWOO parts.
Discard used cotter pins, gaskets, O-rings, oil seals, lock washers and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused.
Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
Keep attaching bolts and nuts separated, as they vary in hardness and design depending on theposition of the installation.
Clean the parts before inspection or reassembly.
Also clean the oil parts, etc. Use compressed air tomake certain they are free of restrictions.
Lubricate rotating and sliding faces of parts with oil or grease before installation.
When necessary, use a sealer on gaskets to prevent leakage.
Carefully observe all specifications for bolt and nut torques.
When service operation is completed, make a final check to be sure service was done properly and theproblem was corrected.

0B-18 GENERAL INFORMATION
Engine Number Location Diesel Engine The engine number is stamped on the cylinder block in front of injection pump.
IL6 3200 The engine number is stamped on the lower rear side
of the alternator.
Gasolind Engine Number1 6 2 9 9 0 1 0 012345
Serial Number
0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M
99 : 3.2L 97 : 2.3L94 : 2.0L
0 : Common
1 : Left - Hand Drive
2 : Right - Hand Drive
ENGINE TYPE
0 : MUSSO
Diesel Engine Number 662 920 1 0 012345
Serial Number
0 : Manual T/M
1 : Hydr - Auto Coupling
2 : Automatic T/M
910 : Non-Intercooler Engine 920 : Intercooler Engine
0 : Common
1 : Left - Hand Drive
2 : Right - Hand Drive
661 : 2299cc662 : 2874cc

GENERAL INFORMATION 0B-19
VEHICLE LIFTING PROCEDURES
To raise the vehicle, place the lifting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle. If any other hoist method is used, take special care to avoid damaging the fuel tank, the filter neck, the exhaust
system, or the underbody.
Vehicle Lifting Points
Using Jack
(Rearward of Front Tire)
Using Jack
(Forward of Rear Tire)
2300 DOHC The engine number is stamped on the upper rear left- hand side of the cylinder block.

GENERAL ENGINE INFORMATION 1A1-13
GENERAL INFORMATION
CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces withtolerances that are measured in the ten-thousanths ofan inch. When any internal engine parts are serviced,care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on initialoperation. Proper cleaning and protection of machinedsurfaces and friction areas is part of the repairprocedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for
service, they should be kept in order. They should beinstalled in the same locations, and with the same matingsurfaces, as when they were removed. Battery cables should be disconnected before any majorwork is performed on the engine. Failure to disconnectcables may result in damage to wire harness or other electrical parts. ON-ENGINE SERVICE 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 this cable will help prevent personalinjury and damage to the vehicle. The ignition mustalso be in LOCK unless otherwise noted. Notice:
Any time the air cleaner is removed, the intake
opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.

SECTION 1B1
M162 ENGINE MECHANICAL
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 this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B1-2Fastener Tightening Specifications . . . . . . . . 1B1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8
Crankcase Ventilation System . . . . . . . . . . 1B1-16
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18
Power Steering Pump and A/C Bracket . . . 1B1-19
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59
TABLE OF CONTENTS
Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104 Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Cylinder Head Mating Surface . . . . . . . . . 1B1-115

1B1-6 M162 ENGINE MECHANICAL116 589 20 33 00
Sliding Hammer
602 589 00 40 00 Engine Lock 103 589 00 33 00
Puller
SPECIAL TOOLS TABLE (Co n t
’d)
601 589 03 43 00
Sleeve
001 589 65 09 00
Socket Wrench Insert
001 589 74 21 00 Torque Wrench 000 589 04 14 00
Clamping Strap
000 589 88 33 00
Puller

1B1-10 M162 ENGINE MECHANICAL
10. Remove the upper mounting bolts of radiator and thenremove the radiator.
7. Loosen the cylinder block drain plug and then drain thecoolant completely. Installation Notice
Tightening Torque 30 Nm
Notice Replace the seal before installation of the drain plug.
8. Remove the cooling fan shroud.
9. Disconnect the each hose from radiator.