seats SSANGYONG MUSSO 2003 Service Manual

0B-12 GENERAL INFORMATIONOWNER INSPECTIONS AND SERVICES
WHILE OPERATING THE VEHICLE Horn Operation Blow the horn occasionally to make sure it works. Check all the button locations. Brake System Operation Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking. Also, if the brake warning light goes on, or flashes, something may be wrong with part of the brake system. Exhaust System Operation Be alert to any changes in the sound of the system or the smell of the fumes. These are signs that the system may be leaking or overheating. Have the system
inspected and repaired immediately. Tires, Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds. This may mean a wheelneeds to be balanced. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or a wheel alignment. Steering System Operation Be alert to changes in the steering action. An inspection is needed when the steering wheel is hard to turn or
has too much free play, or is unusual sounds are noticedwhen turning or parking. Headlight Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.
AT EACH FUEL FILL A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and
repaired immediately. Engine Oil Level
Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back down all the way.
4. Pull out the oil level indicator and look at the oil level on it. 5. Add oil, if needed, to keep the oil level above the
lower mark. Avoid overfilling the engine, since this may cause engine damage.
6. Push the indicator all the way back down into the engine after taking the reading.
If you check the oil level when the oil is cold, do not runthe engine first. The cold oil will not drain back to the pan fast enough to give a true oil level reading. Engine Coolant Level and Condition Check the coolant level in the coolant reservoir tank
and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST TWICE A MONTH Tire And Wheel Inspection and Pressure Check Check the tire for abnormal wear or damage. Also check for damaged wheels. Check the tire pressure when the tires are cold ( check the spare also, unless it is astowaway). Maintain the recommended pressures. Refer
to “Tire and Wheel” is in section 0B.
AT LEAST MONTHLY Light Operation Check the operation of the license plate light, the headlights (including the high beams), the parking lights,the fog lights, the taillight, the brake lights, the turn
signals, the backup lights and the hazard warning flasher. Fluid Leak Check Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR Power Steering System Reservoir Level Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 6A,
Power Steering System. Brake Master Cylinder Reservoir Level Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which mayneed to be serviced. Check the breather hole in the reservoir cover to be free from dirt and check for an open passage.

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.

1B3-30 OM600 ENGINE MECHANICAL
Tools Required
2. Install the sliding hammer into the prechamber.Sliding Hammer 667 589 03 63 00
Removal & Installation Procedure
1. Using the serration wrench (4), remove the threaded ring
(1).
Serration Wrench 603 589 00 09 00
3. Remove the perchamber (2). Notice
After removing the prechamber, cover over the bores with clean rag.
603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer
4. Inspect the prechamber.
Notice If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced, the sealing surfaces in the cylinder head must be remachined.

1B3-126 OM600 ENGINE MECHANICAL
17. Drive in new valve seat ring (2) with a proper wooden drift.
18. Install the valve guide (3) with a proper drift and assemblingtool. Notice The valve guide must be driven in from the cylinder head
cover.
Drift (Intake) 8mm
Drift (Exhaust) 9mm
19. Machine the valve seats.
15. Hang the cylinder head (1) to the lifting device and heat in a water tank to approx. 80 °C.
16. Cool down new valve seat ring (2) into the cooling box with liquid nitrogen. Notice Do not touch the cooled valve seat rings with hand.
Super Cooling Box 345 589 00 63 00

1B3-130 OM600 ENGINE MECHANICAL
10. Measure distance ‘z’ (cylinder head cover parting surface
- valve stem).
5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve guide.
7. Insert the valves (1) into the valve guides according to
marking.
8. Measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7 mm
Notice If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
Diameter ‘w’ 38 ± 0.2 mm
or 37.6 ± 0.2 mm

3D-10 REAR DRIVE AXLE
6. Separate the lower shock absorber from the axle housing.Installation Notice
7. Remove the upper arm mounting nuts and remove the upper arm form the axle housing. Installation Notice
Tightening Torque 50 - 65 Nm
8. Remove the stabilizer bar. Installation Notice
Tightening Torque 150 - 180 Nm
9. Remove the lateral rod mounting nuts and remove the lateral rod from the axle housing. Installation Notice
Tightening Torque 30 - 45 Nm
10. Lowering the axle housing slowly, remove the coil springs and spring seats.
11. Installation should follow the removal precedure in the reverse order.
Tightening Torque 150 - 180 Nm

TRANSFER CASE (TOD) 5D2-47
Assembly Procedure Assembly
Before assembly, lubricate all parts with Automatic Transmission Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.Drive the bearing in staight, making sure it is not cocked in the bore. Install the internal snap ring that retains the bearing to the front case.
2. If removed, install the front yoke to flange seal in the front case bore.
3. If removed, install the yoke to flange seal into the mounting adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following steps: Press a new needle bearing, then a new bushing in the input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of thetransfer case. The stepped face of the thrust washer shouldface toward the bearing.
Slide the sun gear, thr ust plate and thrust washer into
position on the input shaft. Press the bearing over the input shaft. Install the external snap ring to the input shaft.

SECTION 9H
SEATS
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.TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9H-1 General Specifications . . . . . . . . . . . . . . . . . . 9H-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-2
Schematic and Routing Diagrams . . . . . . . . 9H-3 Power Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-3
Seat Warmer . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-4Seat Belt & Tension Reducer Circuit . . . . . . . . 9H-5
Component Locator . . . . . . . . . . . . . . . . . . . 9H-6 Front Seat & Rear Seat . . . . . . . . . . . . . . . . . 9H-6
Maintenance and Repair . . . . . . . . . . . . . . . 9H-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 9H-7
SPECIFICATIONS
GENERAL SPECIFICATIONS
Slide
Tilt Height
Tilt and Height(up)SlideSlide
Tilt and Height Load Rating
Operating Temperature RangeSwitch Operating Force
Application
Deseription
DC11 - 15V
-30°C - 80°C
20 ± 7mm/sec
10.6 ± 5mm/sec 7 ± 2mm/sec
Tilt:35 ± 2mm, Height:35 ± 2mm
Forward:230mmLess Then 7A Less Then 7A DC12V 1A
-30°C - 80°C 0.3 - 0.7Kgf
Operating Voltage
Operating Temperature Range Seat Operating Speed(at 13.5V) Seat Operating Distance Operating Current(at 13.5V) Seat Heater Switch

9H-2 SEATSDIAGNOSIS
When the power seat does not work :

SEATS 9H-3
POWER SEAT
SCHEMATIC AND ROUTING DIAGRAMS