gas type SSANGYONG MUSSO 2003 Service Manual

0B-2 GENERAL INFORMATION661LA
4Cylinder
DIESEL 89
92.4
2299 22:1
101/4000
21.5/2400
Application
Engine Type Bore (mm) Stroke (mm)
Total Displacement (cc) Compression Ratio Maximum Power (ps/rpm)
Maximum Torque (kg.m/rpm)
Engine
662NA
5Cylinder
DIESEL 89
92.4
2874 22:1
95/4000
19.6/2400662LA
5Cylinder
DIESEL 89
92.4
2874 22:1
120/4000
25.5/24002.0L DOCH 4Cylinder
GASOLINE 89.9 78.7
19989.6:1
135/5500
19.3/40002.3L DOCH 4Cylinder
GASOLINE 90.9 88.4
2295
10.4:1
149/5500
22.4/40003.2L DOCH 6Cylinder
GASOLINE 89.9
84
3199 10:1
222/5500
31.6/3750
661LA
TREMEC
T5
3.969 2.341 1.457 1.0000.8513.705 4.55
3.4
Application
Ignition Type
Ignition Timing (BOTH)Ignition Sequence Spark Plug Gap (mm) Spark Plug Maker
Spark Plug Type Ignition System
Clutch - Manual Type 2.0L DOHC
6° ± 2°
1-3-4-2
0.8 ± 0.1
2.3L DOHC
6° ± 2°
1-3-4-2
0.8 ± 0.1 2.0L DOHC
8° ± 2°
1-5-3-6-2-4 0.8 ± 0.1
Distributorless Ignition Bosch, Chapion, Beru
F8DC4(BOSCH)
C11YCC(CHAMPION) 14F8DU4(BERU)
661LA 225 1509.2
662NA
225 1509.2 662LA
2401509.2 2.0L DOHC
2251509.2 2.3L DOHC
2251509.2 3.2L DOHC
2401559.3
Application
TypeOutside Diameter (mm) Inside Diameter (mm) ThicknessFluid
Single Dry Diaphram
Common use :Brake Fluid
Application
Maker
Type or Model
Gear Ratio : 1st 2nd3rd 4th 5thReverse
Final Drive RatioOil Capacity (L)
Manual Transmission
662NA
TREMEC
T5
3.969 2.341 1.457 1.0000.8513.705 4.55
3.4 662LA
TREMEC T5
3.9692.341 1.457 1.0000.8513.705 4.27
3.4 2.0L DOHC
TREMEC T5
3.9692.341 1.457 1.0000.8513.705 4.55
3.4 2.3L DOHC
TREMEC
T5
3.9692.341 1.457 1.0000.8513.705 4.55
3.4 3.2L DOHC
TREMEC T5
3.9692.341 1.457 1.0000.8513.705 3.73
3.4

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-16 GENERAL INFORMATIONVEHICLE IDENTIFICATION NUMBER SYSTEM
K P T P 0 A 1 9 S W P 122357
12~17.Production Serial Number: 000001- 999999
11.Plant Code P : PyongTaek Plant
10.Model Year
M : 1991
N : 1992
P : 1993
R : 1994
S : 1995
T : 1996
V : 1997
W : 1998X : 1999 Y : 2000
9. Check Digit Constant “S”
8. Engine Type 3 : 2299cc, In-line 4Cylinder, Diesel (OM601)
4 : 2874cc, In-line 5Cylinder, Diesel (OM602)
8 : 1998cc, In-line 4Cylinder, Gasoline (E20)
6 : 2295cc, In-line 4Cylinder, Gasoline (E23)
9 : 3199cc, In-line 6Cylinder, Gasoline (E32)
A : 2299cc, In-line 4Cylinder, Diesel (OM601)
B : 2874cc, In-line 5Cylinder, Diesel (OM602)
C : 2299cc, In-line 4Cylinder, Diesel (SY662LA)
D : 2874cc, In-line 5Cylinder, Diesel (SY662LA)
7. Restraint System 0 : NO Seat Belt,1 : 3-Point Seat Belts, 2 : 2-Point Seat Belts
6 . Trim Level A : Standard, B : Deluxe, C : Super Deluxe
5. Body Type
0 : 5-Door1 : 4-Door 2 : 3-Door
4. Line Models P : Musso, LHD, R : Musso, RHD
3. Vehicle Type
T (Passengr Cars)
2. Name of Mamufacturer : P
1. Nation : K

GENERAL INFORMATION 0B-17
Manufacturer’ s Plate
Manufacturer’ s Plate Location
1.Type Approval No. 2.Vehicle Identification Number.
Diesel Engine
Gasoline Engine

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

1A1-2 GENERAL ENGINE INFORMATION
Application
Idle Speed (rpm)
Fuel Injection Pressure (kg/cm²)Oil Capacity (liter)
Lubrication Type
Oil Filter TypeFuel ENGINE SPECIFICATIONS (Cont'd)
E32 Engine7 00 ± 5 0 3 - 48.2
Forced by Gear Pump
Full Flow with Paper Filter
Unleaded Gasoline
MSE 3.62S/3.53S (Motors teuer Elektronik : German)
MSE : Engine Control Electronic
3.62S : 6 Cylinder Version
3.53S : 4 Cylinder Version

GENERAL ENGINE INFORMATION 1A1-7
OIL LEAK DIAGNOSIS Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing thenecessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following proceduresmay help you in locating and repairing most leaks. Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from. 2.1 After running the vehicle at normal operating temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate location of the leak by the drippings on the
paper.
3. Visually check around the suspected component. Check around all the gasket mating surfaces forleaks. A mirror is useful for finding leaks in areas thatare hard to reach.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steamor spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the suspected component.
4.5 If you still cannot locate the leak, try using the powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder) to the suspected area.
3. Operate the vehicle under normal operating conditoins.
4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.
Black Light and Dye Method A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.
Repairing the Leak Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If agasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak,check for the following conditions and correct them asthey may cause a leak. Gaskets
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The fasteners are tightened improperly or the threads are dirty or damaged.
The flanges or the sealing surface is warped.
There are scratches, burrs or other damage to thesealing surface.
The gasket is damaged or worn.
There is cracking or porosity of the component.
An improper seal was used (where applicable).
Seals
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The seal bore is damaged (scratched, burred or nicked).
The seal is damaged or worn.
Improper installation is evident.
There are cracks in the components.
The shaft surface is scratched, nicked or damaged.
A loose or worn bearing is causing excess seal wear.
DIAGNOSIS

1A2-2 GENERAL ENGINE INFORMATION
E20 Engine
Application
Idle Speed (rpm)
Fuel Injection Pressure (kg/cm²)Oil Capacity (liter)
Lubrication Type
Oil Filter Type Fuel ENGINE SPECIFICATIONS (Cont'd)
E23 Engine750 ± 503.2 - 4.2 7.5
Forced by Gear Pump
Full Flow with Paper Filter Unleaded Gasoline
MSE 3.62S/3.53S (Motors teuer Elektronik : German)
MSE : Engine Control Electronic 3.62S : 6 cylinder version3.53S : 4 cylinder version

Diesel Gasoline (M161) Gasoline (M162)
Diesel Gasoline
Application
Joint Type Number of Spider Front FrontRear Front Rear
Front (Full-Time)
Front (Part-Time)Rear Front Rear
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 General Specifications . . . . . . . . . . . . . . . . . . 3C-1
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2 M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2 Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
3C-3
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
Single or Single & Double Cardan Single Cardan
Constant Velocity(CV) & Double Carden Single Cardan
3 22
CV Joint : 1, Double Spiders : 1 2
Diesel Gasoline
Shaft Dimensions (L×O.D ×I.D)
When CompressedFully FrontRearFrontRear Front Rear- --M/T & MB A/T
BTRA A/T (2p-Type) TONGIL KSC-
576
×59.5 ×63.5
973 ×
63.5 ×659.5
583.5 ×
44.7×50.8
973 ×
63.5 ×459.5
380.8 ×
63.5×59.5
591.5 ×
63.5×59.5
601.6 ×
50.8×44.7
579.6 ×
50.8×44.7
776.8 ×
63.5×59.5

5A-24 AUTOMATIC TRANSMISSION
Transmission Control Unit(TCU)
The TCU is an in-vehicle micro-processor based transmission management system. It is usually mounted in the
vehicle cabin, under the instrument panel, under the seat, behind the side kick panels or under the floor in the
footwell on the passenger side. Different control units are supplied for different vehicle applications.The TCU contains:
Processing logic circuits which include a central microcontroller and a back-up memory system.
Input circuits.
Output circuits which control external devices such as the variable pressure solenoid (VPS), on/off solenoid
drivers, a diagnostics output and the driving mode indicator light.
The various items which make up the TCU are discussed below.
Processing Logic
Shift schedule and calibration information is stored in an erasable programmable read only memory (EEPROM).
Throttle input calibration constants and the diagnostics information are stored in electrically erasable programmable
read only memory (EEPROM) that retains the memory even when power to the TCU is disconnected. In operation the software continuously monitors the input values and uses these, via the shift schedule, to determine the required gear state, At the same time it monitors, via the solenoid outputs, the current gear state. Whenever the
input conditions change such that the required gear state is different to the current gear state, the TCU initiates a
gear shift to bring the two states back into line.
Once the TCU has determined the type of gear shift required the software accesses the shift logic, estimates the
engine torque output, adjusts the variable pressure solenoid ramp pressure then executes the shift.
The TCU continuously monitors every input and output circuit for short or open circuits and operating range. When
a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and
implements a limp mode, The actual limp mode used depends upon the failure detected with the object to maintain
maximum driveability without damaging the transmission. In general input failures are handled by providing a default
value. Output failures, which are capable of damaging the transmission, result in full limp mode giving only third or
fourth gear and reverse. For further details of limp modes and memory retention refer to the Diagnostic Section.
The TCU is designed to operate at ambient temperatures between -40 and 85°C . It is also protected against
electrical noise and voltage spikes, however all the usual precautions should be observed, for example when arc welding or jump starting. TCU Inputs
To function correctly, the TCU requires engine speed, road speed, transmission sump temperature, throttle position
and gear position inputs to determine the variable pressure solenoid current ramp and on/off solenoid states. This
ensures the correct gear selection and shift feel for all driving conditions. The inputs required by the TCU are as follows: Engine Speed
The engine speed signal is derived from the tachometer signal line, a dedicated sensor or a Controlled Area Network (CAN).
Road Speed
4WD (Diesel) - The shaft speed signal is derived from the speedo sensor located on the transfer case. This signal is transmitted directly to the TCU.
4WD (Gasoline) - The speedo sensor sends the shaft speed signal to the engine control module (ECM). The
information is then transferred to the TCU via the CAN.
Transmission Sump Temperature
The transmission sump temperature sensor is a thermistor located in the solenoid wiring loom within the transmission.
This sensor is a typical NTC resistor with low temperatures producing a high resistance and high temperatures