SSANGYONG 1999 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.

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

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