Daewoo MUSSO User manual

SERVICE
MANUAL
FOREWORD
This manual includes procedure for mainte-
nance, adjustment, service operation and re-
moval and installation of components.
All information, illustrations and specifications
containedinthismanualarebasedonthelatest
product information available at the time of
manual approval.
The right is reserved to make changes at any
time without notice.
SECTION INDEX
DRIVE LINE/AXLE
BRAKES
TRANSMISSION
STEERING
HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
RESTRAINTS
BODY AND ACCESSORIES
3
4
5
6
7
8
9
ENGINE
SUSPENSION
1
2
FRONT MATTER
GENERAL INFORMATION
0A
0B
INCHON, KOREA
DAEWOO MOTOR CO., LTD.
MUSSO

PERSONAL INJURY CAUTION
Appropriateservice methodsand properrepair procedureare essential
for the safe, reliable operation of all motor vehicles, as well as for the
personal safety of the person doing the repair. There are many
variations in procedures, techniques, tools and parts for servicing
vehicles, as well as in the skills of the people doing the work. This
manualcannotpossiblyanticipateallsuchvariationsandprovideadvice
or precautions for each. Anyone who deviates from the instructions
provided in this manual must ensure their own safety and preserve
thesafetyandintegrity ofthevehicle.The followinglistcontains general
precautionsthat shouldalways be followedwhile workingon avehicle.
•
Safety stands are required whenever a procedure calls for
underbody work.
•
Do not smoke when you work on a vehicle.
•
To prevent serious burns, do not touch any hot metal parts.
•
Set the parking brake when you work on the vehicle.
•
Turn the ignition switch OFF unless a procedure states
otherwise.
•
The engine may operate only in a well-ventilated area.
•
Avoid moving parts when the engine is running.
•
Safety glasses must be worn for eye protection.

MUSSO
Service Manual
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and re-
moval and installation of components for the MUSSO vehicle.
When reference is made in this manual to a brand name, number, or specific tool, an equiva-
lent product may be used in place of the recommended item.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make
changes at any time without notice.
Daewoo Motor Company, Limited
Overseas Technical Service Department
391-9 Chong Chon-2 Dong, Pu Pyung-Gu,
Inchon, Korea
Tel : [phone] ~ 4164
Fax : [phone]
E-mail : [email protected]
[email protected]
Daewoo Motor Company, Limited
All rights Reserved
No part of this publication may be reproduced, stored in any retrieval system or transmitted, in
any form or by any means, including but not limited to electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of Daewoo Motor Company, Lim-
ited

TABLE OF CONTENTS
Section0A Front Matter
Section0B GeneralInformation
Section 1 Engine
Section1A1 M162 GeneralEngineInformation
Section1B1 M162 EngineMechanical
Section1D1 M162 EngineCooling
Section1E1 M162 Engine Electrical
Section1F1 M162 EngineControls
Section1G1 M162 EngineIntake&Exhaust
Section1A2 M161 GeneralEngineInformation
Section1B2 M161 EngineMechanical
Section1D2 M161 EngineCooling
Section1E2 M161 Engine Electrical
Section1F2 M161 EngineControls
Section1G2 M161 EngineIntake&Exhaust
Section1A3 OM600GeneralEngineInformation
Section1B3 OM600EngineMechanical
Section1D3 OM600EngineCooling
Section1E3 OM600Engine Electrical
Section1F3 OM600EngineControls
Section1G3 OM600EngineIntake&Exhaust
Section2 Suspension
Section2A SuspensionDiagnosis
Section2B WheelAlignment
Section2C FrontSuspension
Section2D RearSuspension
Section2E TiresandWheels
Section 3 Drive Line / Axle
Section3A FrontDriveAxle
Section3C PropellerShaft
Section3D Rear DriveAxle
Section 4 Brakes
Section4A HydraulicBrakes
Section4B MasterCylinder
Section4C PowerBooster
Section4D FrontDiscBrakes
Section4E RearDiscBrakes
Section4F AntilockBrakeSystem
Section4G ParkingBrakes
Section 5 Transmission
Section5A AutomaticTransmission
Section5B ManualTransmission
Section5C Clutch
Section5D1 TransferCase(PartTime 4480)
Section5D2 Transfer Case(TOD)
Section 6 Steering
Section6A PowerSteeringSystem
Section6E SteeringWheel andColumn
Section 7 HVAC(Heating, Ventilation &Air
Conditioning)
Section7B/C ManualControl/SemiautoTempera-
tureControlHeationg,Ventilation,
andAirConditioningSystem
Section7D Full AutomaticTemperatureControl
Heationg,Ventilation,andAirCondi-
tioningSystem
Section 8 Restraints
Section8A SeatBelts
Section8B SupplementalRestraint System
(SRS)
Section 9 Bodyand Accessories
Section9A Body Wiring System
Section9B LightingSystems
Section9D Wipers/WasherSystems
Section9E Instrumentation/DriverInformation
Section9F Audio
Section9H Seats
Section9L GlassandMirrors
Section9N FrontandUnderBody
Section9O BumpersandFenders
Section9P Doors
Section9Q Roof
Section9R BodyFrontEnd
Section9T RemoteKeless EntryandAnti-Theft
System
Section9U Control UnitsandSystem
Section9W ImmobilizerSystem

ISSUED BY
OVERSEASTECH. SERVICE
DAEWOO MOTOR CO., LTD.
391-9CHONG CHON-2DONG,PU PYUNG-GU,
INCHON,KOREA
TELEPHONE : [phone]~4164
FACSIMILE : 82-32-509-4160
MUSSO
SERVICE MANUAL

SECTION1A1M162 GENERAL ENGINE INFORMATION
SECTION1B1M162 ENGINE MECHANICAL
SECTION1D1M162 ENGINE COOLING
SECTION1E1 M162 ENGINE ELECTRICAL
SECTION1F1 M162 ENGINE CONTROLS
SECTION1G1M162 ENGINE INTAKE & EXHAUST
SECTION1A2M161 GENERAL ENGINE INFORMATION
SECTION1B2M161 ENGINE MECHANICAL
SECTION1D2M161 ENGINE COOLING
SECTION1E2 M161 ENGINE ELECTRICAL
SECTION1F2 M161 ENGINE CONTROLS
SECTION1G2M161 ENGINE INTAKE & EXHAUST
SECTION1A3OM600GENERAL ENGINE INFORMATION
SECTION1B3OM600ENGINE MECHANICAL
SECTION1D3OM600ENGINE COOLING
SECTION1E3 OM600ENGINE ELECTRICAL
SECTION1F3 OM600ENGINE CONTROLS
SECTION1G3OM600ENGINE INTAKE & EXHAUST
ENGINE
CONTENTS

SUSPENSION
CONTENTS
SECTION 2A SUSPENSION DIAGNOSIS
SECTION 2B WHEEL ALIGNMENT
SECTION 2C FRONT SUSPENSION
SECTION 2D REAR SUSPENSION
SECTION 2E TIRES AND WHEELS

DRIVE LINE / AXLE
CONTENTS
SECTION 3A FRONT DRIVE AXLE
SECTION 3C PROPELLER SHAFT
SECTION 3D REAR DRIVE AXLE

BRAKE
CONTENTS
SECTION 4A HYDRAULIC BRAKES
SECTION 4B MASTER CYLINDER
SECTION 4C POWER BOOSTER
SECTION 4D FRONT DISC BRAKES
SECTION 4E REAR DISC BRAKES
SECTION 4F ANTILOCK BRAKE SYSTEM
SECTION 4GPARKING BRAKE

TRANSMISSION
CONTENTS
SECTION 5A AUTOMATIC TRANSMISSION
SECTION 5B MANUAL TRANSMISSION
SECTION 5C CLUTCH
SECTION 5D1TRANSFER CASE (PART TIME 4408)
SECTION 5D2TRANSFER CASE (TOD)

STEERING
CONTENTS
SECTION 6A POWER STEERING SYSTEM
SECTION 6E STEERING WHEEL AND COLUMN

HVAC (HEATING, VENTILATION &
AIR CONDITIONING)
CONTENTS
SECTION 7B/CMANUAL CONTROL/SEMIAUTO
TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM
SECTION 7D FULL AUTOMATIC
TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM

RESTRAINTS
CONTENTS
SECTION 8A SEAT BELTS
SECTION 8B SUPPLEMENTAL RESTRAINT
SYSTEM (SRS)

BODY AND ACCESSORIES
CONTENTS
SECTION 9A BODY WIRING SYSTEM
SECTION 9B LIGHTING SYSTEM
SECTION 9C HORNS
SECTION 9D WIPERS/WASHER SYSTEM
SECTION 9E INSTRUMENTATION/DRIVER INFORMATION
SECTION 9F AUDIO SYSTEM
SECTION 9H SEATS
SECTION 9L GLASS AND MIRRORS
SECTION 9N FRAME AND UNDERBODY
SECTION 9OBUMPERS AND FASCIAS
SECTION 9P DOORS
SECTION 9QROOF
SECTION 9R BODY FRONT END
SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT
SYSTEM
SECTION 9U CONTROL UNITS AND SYSTEM
SECTION 9WIMMOBILIZER SYSTEM

SECTION 0B
GENERAL INFORMATION
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 0B-1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1
Vehicle Dimensions and Weights . . . . . . . . . . 0B-5
Standard Bolt Specifications . . . . . . . . . . . . . . 0B-6
Maintenance and Repair . . . . . . . . . . . . . . . 0B-7
Maintenance and Lubrication . . . . . . . . . . . . . . 0B-7
NormalVehicleUse . . . . . . . . . . . . . . . . . . . . . 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
MaximumSpeed (Km/h)
Minimum Turning Radius (m)
661LA
143
5.7
662NA
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
MaximumSpeed (Km/h)
Minimum Turning Radius (m)
Performance-AutumaticTransaxle(MB)
2.3L DOCH
171
5.7
3.2L DOCH
190
5.7
Application
MaximumSpeed (Km/h)
Minimum Turning Radius (m)
Performance-AutumaticTransaxle(BTRA)
661LA
143
5.7
662NA
138
5.7
662LA
156
5.7
2.3L DOCH
171
5.7
3.2L DOCH
188
5.7

0B-2 GENERALINFORMATION
661LA
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
MaximumPower(ps/rpm)
Maximum Torque (kg.m/rpm)
Engine
662NA
5Cylinder
DIESEL
89
92.4
2874
22:1
95/4000
19.6/2400
662LA
5Cylinder
DIESEL
89
92.4
2874
22:1
120/4000
25.5/2400
2.0L DOCH
4Cylinder
GASOLINE
89.9
78.7
1998
9.6:1
135/5500
19.3/4000
2.3L DOCH
4Cylinder
GASOLINE
90.9
88.4
2295
10.4:1
149/5500
22.4/4000
3.2L DOCH
6Cylinder
GASOLINE
89.9
84
3199
10:1
222/5500
31.6/3750
661LA
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.4
Application
Ignition Type
Ignition Timing (BOTH)
Ignition Sequence
Spark Plug Gap (mm)
Spark Plug Maker
Spark Plug Type
IgnitionSystem
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
150
9.2
662NA
225
150
9.2
662LA
240
150
9.2
2.0L DOHC
225
150
9.2
2.3L DOHC
225
150
9.2
3.2L DOHC
240
155
9.3
Application
Type
Outside Diameter (mm)
Inside Diameter (mm)
Thickness
Fluid
Single Dry Diaphram
Common use :Brake Fluid
Application
Maker
Type or Model
Gear Ratio : 1st
2nd
3rd
4th
5th
Reverse
Final Drive Ratio
Oil Capacity (L)
ManualTransmission
662NA
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.4
662LA
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.27
3.4
2.0L DOHC
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.4
2.3L DOHC
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
4.55
3.4
3.2L DOHC
TREMEC
T5
3.969
2.341
1.457
1.000
0.851
3.705
3.73
3.4

GENERALINFORMATION 0B-3
662LA
MB
W4A040
3.871
2.247
1.436
1.000
5.586
5.38
9 - 9.5
AutoTransmission(MB)
Application
Maker
Type or Model
Gear Ratio :1st
2nd
3rd
4th
Reverse
Final Drive Ratio
Oil Capacity (L)
2.3L DOHC
MB
W4A040
3.871
2.247
1.436
1.000
5.586
4.27
9 - 9.5
3.2L DOHC
MB
W4A040
3.871
2.247
1.436
1.000
5.586
3.73
9 - 9.5
661LA
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
5.38
9
AutoTransmission (BTRA)
Application
Maker
Type or Model
Gear Ratio :1st
2nd
3rd
4th
Reverse
Final Drive Ratio
Oil Capacity (L)
662LA
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
4.89
9
2.3L DOHC
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
5.86
9
3.2L DOHC
BTRA
M74 4WD
2.741
1.508
1.000
0.708
2.429
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 Size
Standard Wheel Size
Inflation Pressure At Full Lode
P235 / 75 : Front
Rear
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
f 25.4
5.6 : 1
Ventilated
Solid
Brake
non-ABS
ABS 5.0
ABS 5.3

0B-4 GENERALINFORMATION
Specifications
RACK&PINION
0 - 4 mm
2°30’±30’
0° ± 30’
1L
Application
Gear Type
Wheel Alignment:
Front Toe-in
Front Caster
Front Camber
Oil Capacity
Steering System
Application
Front Type
Rear Type
Suspension
Specifications
Double Wishbone
5 - Link
Application
Fuel Pump Type
Fuel Filter Type
Fuel Capacity
Specifications
Electric Motor Pump
Cartridge
70 L
FuelSystem
Lubricating Type
Oil Pump Type
Oil Filter Type
Oil Capacity (L) (Including Oil Filter)
LubricatingSystem
661LA
8.0
662NA
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
CoolingSystem
661LA
9.5-10 662NA 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)
Generator
Starter
ElectricSystem
661LA
75A
2.2kw
662NA
75A
2.2kw
662LA
75A
2.2kw
2.0L DOHC
115A
1.2kw
2.3L DOHC
115A
1.2kw
3.2L DOHC
115A
1.7kw
12V - 90AH 12V - 75AH

GENERALINFORMATION 0B-5
Application
Overall Length (mm)
Overall Width (mm)
Overall Height (mm)
Wheel Base (mm)
Tread: Front (mm)
Rear (mm)
VEHICLE DIMENSIONS AND WEIGHTS
VehicleDimensions
Application
Manual : Curb Weight (kg)
Gross Vehicle Weight (kg)
Automatic : Curb Weight (kg)
Gross Vehicle Weight (kg)
Passenger Capacity
VehicleWeights
Application
4656
1864
1735
2630
1510
1520
661LA
1860
2520
1916
2520
5
662NA
1968
2520
1989
2520
5
662LA
1890
2520
2005
2520
5
2.0L DOHC
1937
2520
-
-
5
2.3L DOHC
1850
2520
1942
2520
5
3.2L DOHC
1930
2520
2025
2520
5

0B-6 GENERALINFORMATION
STANDARD BOLTS SPECIFICATIONS
Bolt* Torque (N·m / Ib-in)
Standard Limit
4T 7T 9T 4T 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