Hood SSANGYONG MUSSO 2003 Service Manual

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.

0B-14 GENERAL INFORMATIONUsage
Engine Oil (Change with filter) Engine Coolant Brake / Clutch Fluid Power Steering System Parking Brake Cable Hood Latch AssemblyHood and Door Hinges Fuel Door Hinge Rear Compartment Lid Hinges Weatherstrips
RECOMMENDED FLUIDS AND LUBRICANTS
Capacity 8.2 L 7.5 L9.5 L 8.0 L
11.3 L
10.5 L
10.5 - 11.0 L
9.5 - 10.0 L
Approx. 0.5L level must be maintained between MAX & MIN level 1.0 L
As required As required As required As required Fluid/Lubricant
Quality class - API ; SH grade or above
ACEA ; A2 or A3 MB sheet ; 229.1
Viscosity - MB sheet ; 224.1
Quality class - API ; CG grade or above ACEA ; B2 or B3MB sheet ; 228.1, 228.3, 228.5, 229.1
Viscosity - MB sheet ; 224.1 ALUTEC P-78
DOT-3 & SAE J 1703 ATF DEXRON-II Grease Grease
Spray type grease
Silicone grease
3.2L DOHC 2.3L DOHC 662LA 661LA 3.2L DOHC 2.3L DOHC 662LA 661LA

M162 ENGINE MECHANICAL 1B1-9
4. Disconnect the coupling of HFM sensor and remove the aircleaner cross pipe.
6. Loosen the radiator drain cock and drain the coolant. Notice Open the coolant reservoir cap.
5. Remove the air cleaner cover. Remove the mounting bolts
and air cleaner housing and element assembly.
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice
Tightening Torque 28 - 47 Nm

1B2-10 M161 ENGINE MECHANICAL
4. Disconnect the coupling of HFM sensor and remove the aircleaner cross pipe.
6. Loosen the radiator drain cock and drain the coolant. Notice Open the coolant reservoir cap.
5. Remove the air cleaner cover. Remove the mounting bolts
and air cleaner housing and element assembly.
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice
Tightening Torque 28 - 47 Nm

OM600 ENGINE MECHANICAL 1B3-13
4. Remove the radiator drain cock and drain the coolant.Notice Open the coolant reservoir tank cap.
3. Remove the skid plate.
Installation Notice
Tightening Torque 28 - 47 Nm
5. Remove the drain plug (1) and seal (2) from the cylinder block and drain the coolant completely.
6. After draining, replace the seal and reinstall the drain plug.
Installation Notice
7. Disconnect the lower coolant hose from the radiator.
Tightening Torque 30 Nm
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.

STEERING WHEEL AND COLUMN 6E-3
Removal & Installation Procedure
1. Remove the horn pad from the steering wheel anddisconnect the connectors .
2. Place an alignment marks on the column shaft end and fixing nut and then remove the fixing nut. Installation Notice
3. Remove the steering wheel.
4. Remove the combination switch upper cover .
Tightening Torque 50 - 80 Nm
5. Release the crash pad panel. Notice Remove the hood release wire and the other switch connectors.

9A-12 BODY WIRING SYSTEM
15 LH Damper........................................................... ECS
16 Ground 1
17 Ground 2
18 Locking Hub Solenoid
19 Condenser Fan Relay .........................................Gasoline E/G
20 LH Position Lamp
21 LH Head Lamp
22 LH Head Lamp Leveling Device ...........................Leveling Device
23 Thermo Switch 2 .................................................. Gasoline E/G with HFM
24 Thermo Switch 3 .................................................. Gasoline E/G with HFM & Air Conditioner
25 LH Front Fog Lamp
26 LH Horn ............................................................... Black Out Driving Lamp (Domestic)
27 Condenser Fan Motor .........................................Diesel E/G
28 Black Out Driving Lamp .......................................Black Out Driving Lamp (Domestic)
29 LH Horn ............................................................... Leveling Device
30 LH Condenser Fan Motor ....................................Gasoline E/G with Air Conditioner
31 Thermo Switch 1 .................................................. Diesel E/G or Gasoline E/G with HFM
32 Resistor ............................................................... Gasoline E/G with Air Conditioner
33 Thermo Switch 4 .................................................. Gasoline E/G with HFM & Air Conditioner
34 Ambient Censor ................................................... Air Conditioner
35 RH Condenser Fan Motor ....................................Gasoline E/G
36 RH Horn
37 RH Front Fog Lamp
38 RH Position Lamp
39 RH Head Lamlp
40 RH Head Lamp Leveling Device ..........................Leveling Device
41 Wheeling Sensor ................................................. ECS
42 Wheel Speed Sensor (FR) ..................................ABS 5.0, 5.3 or ABD 5.0, 5.3
43 RH Damper .......................................................... ECS
44 Alternator Extension Connector ...........................Gasoline E/G
45 Alternator ............................................................. Gasoline E/G
46 Alternator Extension Joint box ..............................Diesel E/G
47 Alternator Extension Connector ...........................Diesel E/G
48 Ground 3
49 Fusible Link Box ................................................... Gasoline E/G
49-1 Fusible Link Box ................................................... Diesel E/G
50 Receiver Dryer ..................................................... Gasoline E/G with Air Conditioner
50-1 Receiver Dryer ..................................................... Diesel E/G with Air Conditioner
51 Hood Switch ......................................................... Diesel E/G with Black Out Driving Lamp
52 Front Washer Motor ............................................. Gasoline E/G
53 Main Wiring Connector

SECTION 9R
BODY FRONT END
TABLE OF CONTENTS
Maintenance and Repair . . . . . . . . . . . . . . . 9R-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9R-2 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9R-2
Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R-5

9R-2 BODY FRONT ENDMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
HOOD
1 Hood
2 Sping3 Hood Hinge Assembly
4 Bolt

BODY FRONT END 9R-3
Removal & Installation Procedure
1. Remove the hood striker assembly.Notice When installing, tighten the bolt after setting the hole
between wratch and hood striker assembly. Installation Notice
Tightening Toque 8 - 11 Nm
2. Remove the hood Mounting bolt and hood lifter assembly. Installation Notice
3. Remove the hood lock, hood relese from the clip.
4. Remove the cable holder screw.
5. Pull the cable nut toward driver side.
6. Installation should follow the removal procedure in the reverse order.
Tightening Toque 14 - 26 Nm