fuel SSANGYONG MUSSO 2003 Service Manual

SECTION 0B
GENERAL INFORMATION
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 0B-1Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1
Vehicle Dimensions and Weights . . . . . . . . . . 0B-5
Standard Bolt Specifications . . . . . . . . . . . . . . 0B-6
Maintenance and Repair . . . . . . . . . . . . . . . 0B-7
Maintenance and Lubrication . . . . . . . . . . . . . . 0B-7 Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . 0B-7 Explanation of Scheduled Maintenance
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-7
Scheduled Maintenance Charts
(Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . 0B-8 Scheduled Maintenance Charts
(Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . 0B-10
Owner Inspections and Services . . . . . . . 0B-12 TABLE OF CONTENTS
While Operating the Vehicle . . . . . . . . . . . . . 0B-12
At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . 0B-12
At Least Twice A Month . . . . . . . . . . . . . . . . 0B-12
At Least Monthly . . . . . . . . . . . . . . . . . . . . . . 0B-12
At Least Twice a Year . . . . . . . . . . . . . . . . . . 0B-12
Each Time the Oil is Changed . . . . . . . . . . . 0B-13
At Least Annually . . . . . . . . . . . . . . . . . . . . . 0B-13
Recommended Fluids and Lubricants . . . . . 0B-14
General Description and System
Operation . . . . . . . . . . . . . . . . . . . . . . . . 0B-15
General Repair Instructions . . . . . . . . . . . . . 0B-15
Vehicle Identification Number System . . . . . . 0B-16
Vehicle Lifting Procedures . . . . . . . . . . . . . . 0B-19
SPECIFICATIONS TECHNICAL DATA
Transaxle Performance
Application
Maximum Speed (Km/h)
Minimum Turning Radius (m)
661LA 143
5.7662NA 145
5.7 662LA
156
5.7 2.0L DOCH
168
5.7 2.3L DOCH
176
5.7 3.2L DOCH
190
5.7
Application
Maximum Speed (Km/h)
Minimum Turning Radius (m)
Performance-Autumatic Transaxle (MB)
2.3L DOCH171
5.7 3.2L DOCH
190
5.7
Application
Maximum Speed (Km/h)
Minimum Turning Radius (m)
Performance-Autumatic Transaxle (BTRA)
661LA1435.7 662NA
1385.7 662LA
1565.7 2.3L DOCH
1715.7 3.2L DOCH
1885.7

0B-4 GENERAL INFORMATIONSpecifications RACK & PINION0 - 4 mm
2° 30’ ± 30’
0° ± 30’
1L
Application
Gear TypeWheel Alignment: Front Toe-inFront CasterFront Camber
Oil Capacity
Steering System
Application
Front Type
Rear Type
Suspension
Specifications
Double Wishbone
5 - Link
Application
Fuel Pump Type
Fuel Filter TypeFuel Capacity
Specifications
Electric Motor Pump Cartridge70 L
Fuel System
Lubricating Type
Oil Pump Type
Oil Filter Type Oil Capacity (L) (Including Oil Filter)
Lubricating System
661LA
8.0662NA 9.0 662LA
9.5 2.0L DOHC
7.2 2.3L DOHC
7.5 3.2L DOHC
8.2
External Gear pump
Combination(Full & Part) Full Flow
Cooling Type
Coolant Capacity (L)
Radiator Type
Water Pump Type
Cooling System
661LA 9.5-10662NA 10.5 662LA
10.5-11 2.0L DOHC
10.5 2.3L DOHC
10.5 3.2L DOHC
11.3
Forced Circulation
Centrifugal
Application
Battery (MF) GeneratorStarter
Electric System
661LA
75A
2.2kw662NA
75A
2.2kw 662LA
75A
2.2kw 2.0L DOHC
11 5 A
1.2kw 2.3L DOHC
115A
1.2kw 3.2L DOHC
115A
1.7kw
12V - 90AH12V - 75AH

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)

0B-8 GENERAL INFORMATIONSCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)
Engine
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
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R - Replace or change.
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition. Chan ge
engine oil and the filter every 7,500 km or 6 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving condition.
(3) Refer to “Recommended fluids and lubricants”.
Drive belt
Engine oil & filter (1) (3)Cooling system hose & connections
Engine coolant (3) Fuel filter
(2)
Fuel line & connections
Air cleaner (2)Ignition timingSpark plugsCharcoal canister & vapor lines
I III
- I
-- I
R II
- IIII
- I
R II
-
III
R - I
R II
- IIIII I
R I
RR I
R
I
R - I
R II
- I I I
- I
R II
- III
R I I
R II
- IIII
- I
R I
RR I
R I
R -

0B-10 GENERAL INFORMATIONSCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)
Engine
Months -
MAINTENANCE ITEM MAINTENANCE 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
NOTE 1 :
Injection Timing : Adjust as required :- When excessive smoke is visible (black or white)- Poor performance/economy
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.R - Replace or change. (1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition, chan ge
engine oil every 5,000km or 3 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving conditing.
(3) Refer to “Recommended fluids and lubricants”.
Drive belt Engine oil & fillter (1) (3)Cooling system hose & connections
Engine coolant (3)
Fuel filter (2) Fuel line & connections Glow plug Pre - fuel filter
Air cleaner (2)Ignition timing (see NOTE 1)
I
R
I
I
R
I I II
I
R I I I IIII I
R I I I
R I I
R I
R I IIII I
R I I I II I
R I
R
III
R I I
R I I I II I
R I I
R
I II I
R I
R I I
R I I
R I I I IIII

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-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

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.

SECTION 1
ENGINE
SECTION 1A1(M162 ENGINE)
GENERAL ENGINE INFORMATION
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A1-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A1-1
Component Locator . . . . . . . . . . . . . . . . . . 1A1-3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-3
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-4
Performance Curve . . . . . . . . . . . . . . . . . . 1A1-5
E32 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A1-6
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A1-6Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
1A1-7
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A1-7
Engine Cranking at The Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A1-8
Compression Pressure Test . . . . . . . . . . . . . 1A1-9
Cylinder Pressure Leakage Test . . . . . . . . . 1A1-11
General Information . . . . . . . . . . . . . . . . . 1A1-13
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A1-13
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A1-13
Application
Engine Model Displacement (CC) Cylinder (Bore x Stroke) (mm)Fuel Injection / Ignition SystemCompression RatioNumber of Cylinders
Camshaft Valve Arrangement
Camshaft Drive TypeMax. Output (ps/rpm)
Max. Torque (kg• m/rpm)Firing Order
Ignition Type
Ignition Timing
Valve Timing Intake Open/Close ExhaustOpen/Close
Valve Clearance Adjustment SPECIFICATIONS
ENGINE SPECIFICATIONS E32 EngineM162.990 3199
89.9 x 84.0
MSE 3.62S 10 : 1
6
DOHC
Chain-Driven
222 / 5500
31.6 / 3750
1-5-3-6-2-4
Distributorless Double Ignition BTDC 8° ± 2°
ATDC 11° / ABDC 34°
BBDC 31° / BTDC 14° Automatic Control
TABLE OF CONTENTS