1991-2000 Ssangyong Musso & Musso Sport Service & Repair Manual

SERVICE MANUAL FOREWORD This manual includes procedure for maintenance, adjustment, service operation and re- moval and installation of components. All information, illustrations and specifications contained in this manual are based on the latest 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 Appropriate service methods and proper repair procedure are 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 manual cannot possibly anticipate all such variations and provide advice or precautions for each. Anyone who deviates from the instructions provided in this manual must ensure their own safety and preserve the safety and integrity of the vehicle. The following list contains general precautions that should always be followed while working on a vehicle. • 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 : 82-32-509-4161 ~ 4164 Fax : 82-32-509-4160 E-mail : m8610452@dwmc.co.kr m9610883@dwmc.co.kr 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 Section 0A Front Matter Section 0B General Information Section 1 Engine Section 1A1 M162 General Engine Information Section 1B1 M162 Engine Mechanical Section 1D1 M162 Engine Cooling Section 1E1 M162 Engine Electrical Section 1F1 M162 Engine Controls Section 1G1 M162 Engine Intake & Exhaust Section 1A2 M161 General Engine Information Section 1B2 M161 Engine Mechanical Section 1D2 M161 Engine Cooling Section 1E2 M161 Engine Electrical Section 1F2 M161 Engine Controls Section 1G2 M161 Engine Intake & Exhaust Section 1A3 OM600 General Engine Information Section 1B3 OM600 Engine Mechanical Section 1D3 OM600 Engine Cooling Section 1E3 OM600 Engine Electrical Section 1F3 OM600 Engine Controls Section 1G3 OM600 Engine Intake & Exhaust Section 2 Suspension Section 2A Suspension Diagnosis Section 2B Wheel Alignment Section 2C Front Suspension Section 2D Rear Suspension Section 2E Tires and Wheels Section 3 Drive Line / Axle Section 3A Front Drive Axle Section 3C Propeller Shaft Section 3D Rear Drive Axle Section 4 Brakes 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 4G Parking Brakes Section 5 Transmission Section 5A Automatic Transmission Section 5B Manual Transmission Section 5C Clutch Section 5D1 Transfer Case (Part Time 4480) Section 5D2 Transfer Case (TOD) Section 6 Steering Section 6A Power Steering System Section 6E Steering Wheel and Column Section 7 HVAC (Heating, Ventilation & Air Conditioning) Section 7B/C Manual Control/Semiauto Tempera- ture Control Heationg, Ventilation, and Air Conditioning System Section 7D Full Automatic Temperature Control Heationg, Ventilation, and Air Condi- tioning System Section 8 Restraints Section 8A Seat Belts Section 8B Supplemental Restraint System (SRS) Section 9 Body and Accessories Section 9A Body Wiring System Section 9B Lighting Systems Section 9D Wipers/Washer Systems Section 9E Instrumentation/Driver Information Section 9F Audio Section 9H Seats Section 9L Glass and Mirrors Section 9N Front and Under Body Section 9O Bumpers and Fenders Section 9P Doors Section 9Q Roof Section 9R Body Front End Section 9T Remote Keless Entry and Anti-Theft System Section 9U Control Units and System Section 9W Immobilizer System

ISSUED BY OVERSEAS TECH. SERVICE DAEWOO MOTOR CO., LTD. 391-9 CHONG CHON-2DONG, PU PYUNG-GU, INCHON, KOREA TELEPHONE : 82-32-509-4161~4164 FACSIMILE : 82-32-509-4160 MUSSO SERVICE MANUAL

SECTION 1A1 M162 GENERAL ENGINE INFORMATION SECTION 1B1 M162 ENGINE MECHANICAL SECTION 1D1 M162 ENGINE COOLING SECTION 1E1 M162 ENGINE ELECTRICAL SECTION 1F1 M162 ENGINE CONTROLS SECTION 1G1 M162 ENGINE INTAKE & EXHAUST SECTION 1A2 M161 GENERAL ENGINE INFORMATION SECTION 1B2 M161 ENGINE MECHANICAL SECTION 1D2 M161 ENGINE COOLING SECTION 1E2 M161 ENGINE ELECTRICAL SECTION 1F2 M161 ENGINE CONTROLS SECTION 1G2 M161 ENGINE INTAKE & EXHAUST SECTION 1A3 OM600 GENERAL ENGINE INFORMATION SECTION 1B3 OM600 ENGINE MECHANICAL SECTION 1D3 OM600 ENGINE COOLING SECTION 1E3 OM600 ENGINE ELECTRICAL SECTION 1F3 OM600 ENGINE CONTROLS SECTION 1G3 OM600 ENGINE 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 4G PARKING BRAKE

TRANSMISSION CONTENTS SECTION 5A AUTOMATIC TRANSMISSION SECTION 5B MANUAL TRANSMISSION SECTION 5C CLUTCH SECTION 5D1 TRANSFER CASE (PART TIME 4408) SECTION 5D2 TRANSFER CASE (TOD)

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1991-2000 Ssangyong Musso & Musso Sport Service & Repair Manual

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