tow 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.

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.

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

M162 ENGINE MECHANICAL 1B1-13
20. Disconnect following sensors connector.HFM sensor.
Coolant temperature sensor.
2 knock sensors.
Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition coil connector.
22. Remove the harness cover and disconnect the 6 injection valve connectors. Disconnect the main harness
23. Separate the hose toward engine from canister purge solenoid valve.
24. Remove the automatic transmission oil cooler line.

1B2-14 M161 ENGINE MECHANICAL
20. Disconnect following sensors connector.HFM sensor.
Coolant temperature sensor.
2 knock sensors.
Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition coil connector.
22. Remove the harness cover and disconnect the 6 injection valve connectors. Disconnect the main harness.
23. Separate the hose toward engine from canister purge solenoid valve.
24. Remove the automatic transmission oil cooler line.

1B2-64 M161 ENGINE MECHANICAL
7. Unscrew the bolt (3) from the armature (4) and removethe roll pin, and remove the armature. Installation Notice
Tightening Torque 35 Nm
8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice
Tightening Torque 60 - 70 Nm
Notice Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft. Installation Notice
Tightening Torque 1st step 20 Nm
2nd step + 95
°
Notice The flange bolt is designed to be used only once, so always replace with new one.
12. Installation should follow the removal procedure in the reverse order.
13. Check and adjust the camshaft timing.

OM600 ENGINE MECHANICAL 1B3-167
6. Coat the cylinder bore, connecting rod bearing journal,connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap (7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a wooden stick (18). Notice The arrow on the piston crown must point toward the front of vehicle.
9. Insert the connecting rod bearing shells (9, 10). Notice Be careful of the difference in upper and lower bearing shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice Position so that the retaining lugs are on the same side of the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connecting rod bolts.
Limit ‘ C ’ 7.1mm

1F3-28 OM600 ENGINE CONTROLS
Tools Required 001 589 65 09 00 Socket Wrench Insert000 589 00 68 00 Cleaning Set Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzletensioning nut (8). Notice Use protective jaws for clamping.
2. Disassemble the fuel injection nozzle.
Socket Wrench Insert 001 589 65 09 00
3. Clean the nozzle needle (6) and nozzle body (7) with an abradant.
4. Clean the nozzle seat with cleaning cutter.
Cleaning Set 000 589 00 68 00
5. Immerse nozzle needle (6) and nozzle body (7) in filtered diesel fuel. When the nozzle body is held vertical, the weight of the nozzle needle must cause it to slide down toward thenozzle needle seat.
6. Assemble the injection nozzle so that the tip of the thrust (4) pin is facing toward the nozzle holder.
Tightening Torque 80 Nm
Notice Nozzle needle (6) and nozzle body (7) should always be
replaced as a pair.