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-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-3
662LA MB
W4A040 3.871 2.247 1.4361.0005.5865.38
9 - 9.5
Auto Transmission (MB)
Application
Maker
Type or Model
Gear Ratio : 1st 2nd3rd 4th Reverse
Final Drive RatioOil Capacity (L)
2.3L DOHC MB
W4A040 3.871 2.247 1.4361.0005.5864.27
9 - 9.5 3.2L DOHC
MB
W4A040 3.871 2.247 1.4361.0005.5863.73
9 - 9.5
661LA
BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
5.38 9
Auto Transmission (BTRA)
Application
Maker
Type or Model
Gear Ratio : 1st 2nd 3rd 4thReverse
Final Drive RatioOil Capacity (L)662LA BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
4.89 9 2.3L DOHC
BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
5.86 9 3.2L DOHC
BTRA
M74 4WD
2.741 1.508 1.0000.7082.429
4.89 9
Tire and Wheel
Specifications
P235/75 R15, 255/70 R15 7JJ × 15
30 Psi 30 Psi 30 Psi 30 Psi
Application
Standard Tire SizeStandard Wheel SizeInflation Pressure At Full Lode
P235 / 75 : FrontRear
P255 / 75 : Front Rear
Application
Booster Size Master Cylinder Diameter (mm) Booster Ratio
Front Brake : Disc Type
Rear Brake : Disc Type
Specifications 8inch + 9inch 7inch + 8inch 8inch + 9inch
25.4
5.6 : 1
Ventilated
Solid
Brake
non-ABS ABS 5.0ABS 5.3

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-5
Application
Overall Length (mm) Overall Width (mm)Overall Height (mm)Wheel Base (mm)
Tread : Front (mm)Rear (mm)
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application
Manual : Curb Weight (kg)
Gross Vehicle Weight (kg)
Automatic : Curb Weight (kg)
Gross Vehicle Weight (kg)
Passenger Capacity
Vehicle Weights
Application
4656 18641735263015101520
661LA1860 2520 1916 2520 5 662NA
19682520 1989 2520 5 662LA
18902520 2005 2520 5 2.0L DOHC
19372520
--
5 2.3L DOHC
18502520 1942 25205 3.2L DOHC
19302520 2025 25205

0B-6 GENERAL INFORMATION
STANDARD BOLTS SPECIFICATIONS
Bolt*Torque (N
m / Ib-in)
Standard Limit
4T 7T 9T4T 7T
9T
M3 × 0.5
M4 × 0.7
M5 × 0.8
M6 × 1.0
M8 × 1.25
M10 × 1.25
M10 × 1.5
M12 × 1.25
M12 × 1.75
M14 × 1.5
M16 × 1.5
M18 × 1.5
M20 × 1.5
M22 × 0.5
M24 × 1.5
M24 × 2.0 0.5 N


 m
(4.5 lb-in)
1.2 N 

 m
(11 lb-in)
2.4 N 

 m
(22 lb-in) 4.0 N 

 m
(36 lb-in) 8.6 N 

 m
(77 lb-in)
18.6 N 

 m
(14 lb-in)
18.6 N 

 m
(14 lb-in)
34.3 N 

 m
(25lb-in)
32.3 N 

 m
(24 lb-in)
54.0 N 

 m
(40 lb-in)
81.3 N 

 m
(60 lb-in)
117.6 N 

 m
(87 lb-in)
166.6N 

 m
(123 lb-in)
225.4N 

 m
(167 lb-in)
284.2 N 

 m
(210 lb-in)
274.4 N 

 m
(203 lb-in) 0.9 N


 m
(8 lb-in)
2.0 N 

 m
(18 lb-in) 4.0 N 

 m
(36 lb-in)
6.7 N 

 m
(60 lb-in)
15.7 N 

 m
(12 lb-in)
32.3 N 

 m
(24 lb-in)
30.4 N 

 m
(22 lb-in)
56.8 N 

 m
(42 lb-in)
53.9 N 

 m
(40 lb-in)
89.2 N 

 m
(66 lb-in)
107.8 N 

 m
(80 lb-in)
196.0 N 

 m
(145 lb-in)
274.4 N 

 m
(203 lb-in)
372.4 N 

 m
(276 lb-in)
480.2 N 

 m
(355 lb-in)
460.6 N 

 m
(341 lb-in) 1.3 N


 m
(12 lb-in) 3.0 N 

 m
(27 lb-in)
5.6 N 

 m
(50 lb-in)
9.7 N 

 m
(87 lb-in)
22.5 N 

 m
(17 lb-in)
46.0 N 

 m
(34 lb-in)
44.1 N 

 m
(33 lb-in)
82.3 N 

 m
(61 lb-in)
77.4 N 

 m
(57 lb-in)
127.4 N 

 m
(94 lb-in)
196.0 N 

 m
(145 lb-in)
284.2 N 

 m
(210 lb-in)
392.0 N 

 m
(290 lb-in)
529.2 N 

 m
(392 lb-in)
686.0 N 

 m
(508 lb-in)
666.4 N 

 m
(493 lb-in) 0.7 N


 m
(6.3 lb-in) 1.6 N 

 m
(14 lb-in) 3.1 N 

 m
(28 lb-in) 5.4 N 

 m
(49 lb-in)
12.7 N 

 m
(9 lb-in)
25.5 N 

 m
(19 lb-in)
24.5 N 

 m
(18 lb-in)
45.0 N 

 m
(33 lb-in)
43.1 N 

 m
(32 lb-in)
71.6 N 

 m
(53 lb-in)
107.8 N 

 m
(80 lb-in)
156.8 N 

 m
(116 lb-in)
215.6 N 

 m
(160 lb-in)
294.0 N 

 m
(218 lb-in)
382.2 N 

 m
(283 lb-in)
372.4 N 

 m
(276 lb-in) 1.2 N


 m
(11 lb-in) 2.6 N 

 m
(23 lb-in) 5.2 N 

 m
(47 lb-in)
9.0 N 

 m
(81 lb-in)
20.6 N 

 m
(15.2 lb-in) 42.1 N 

 m
(31 lb-in)
41.2 N 

 m
(30 lb-in)
75.5 N 

 m
(56 lb-in)
71.5 N 

 m
(53 lb-in)
117.6 N 

 m
(87 lb-in)
186.2 N 

 m
(138 lb-in)
264.6 N 

 m
(196 lb-in)
362.6 N 

 m
(268 lb-in)
490.0 N 

 m
(362 lb-in)
637.0 N 

 m
(471 lb-in)
617.4 N 

 m
(457 lb-in) 17 N


 m
(15 lb-in)
4.0 N 

 m
(36 lb-in)
7.6 N 

 m
(68 lb-in)
12.7 N 

 m
(114 lb-in) 30.4 N 

 m
(22 lb-in)
60.8 N 

 m
(31 lb-in)
58.8 N 

 m
(44 lb-in)
107.8 N 

 m
(80 lb-in)
98.0 N 

 m
(73 lb-in)
166.6 N 

 m
(123 lb-in)
264.6 N 

 m
(196 lb-in)
372.4 N 

 m
(276 lb-in)
519.4 N 

 m
(384 lb-in) 705.6 N 

 m
(522 lb-in)
921.2 N 

 m
(682 lb-in)
891.8 N 

 m
(660 lb-in)
*Diameter × pitch in millimeters

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 -

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.

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