1998 SSANGYONG MUSSO Workshop Repair Manual

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
1864
1735
2630
1510
1520
661LA
1860
2520
1916
2520
5662NA
1968
2520
1989
2520
5662LA
1890
2520
2005
2520
52.0L DOHC
1937
2520
-
-
52.3L DOHC
1850
2520
1942
2520
53.2L DOHC
1930
2520
2025
2520
5

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 ´ 2.00.5 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.
lGasoline Engine : 60,000km (36,000 miles)
lDiesel Engine : 45,000km (24,000 miles)
Spark Plug Replacement
Replace spark plugs with same type.
lType : BOSCH : F8DC4
BERU : 14F-8DU4
Champion : C11YCC
lGap : 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. While
the 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:
lTo carry passengers and cargo within the limitation
of the tire inflation prassure. Refer to “Tire and Wheel”
in section 2E.
lTo be driven on reasonable road surfaces and within
legal 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 temperature
weather 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.
lGasoline Engine : 15,000km (10,000 miles)
lDiesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
lGasoline Engine : 60,000km (36,000 miles)
lDiesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty
conditions.
Tire Rotation (Left - Hand Drive Type)

0B-8 GENERAL INFORMATION
SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)
Engine
Months
MAINTENANCE
ITEMMAINTENANCE INTERVALKilometers 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. Change
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 timing
Spark plugs
Charcoal canister & vapor linesI
I
I
I
-
I
-
-I
R
I
I
-
I
I
I
I
-I
R
I
I
-
I
I
I
R
-I
R
I
I
-
I
I
I
I
II
R
I
R
R
I
R
I
R
-I
R
I
I
-
I
I
I
-I
R
I
I
-
I
I
I
R
II
R
I
I
-
I
I
I
I
-I
R
I
R
R
I
R
I
R
-

GENERAL INFORMATION 0B-9
Chassis and Body
Months
MAINTENANCE
ITEMMAINTENANCE INTERVALKilometers 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
I
I
I
I
I-
-
-
I
I
-
II
I
I
I
I
I
II
R
I
I
I
I
II
I
I
I
R
I
RI
I
I
I
I
I
II
R
I
I
R
I
RI
I
I
I
I
I
II
R
I
I
I
I
I
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 latchI
I
I
I
II
I
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
I
IR
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
I
IR
R
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
I
Transfer case fluidRIII
Inspect & ADJUST when abnormal condition is noted
I
I
I
I
I
I
I
I
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 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 INFORMATION
SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)
Engine
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
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, change
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
II
R
I
I
I
I
I
R
I
I
I
I
I
I
II
R
I
I
I
R
II
R
I
R
I
I
I
I
II
R
I
I
I
I
II
R
I
R
I
I
I
R
II
R
I
I
I
I
II
R
I
I
R
I
I
II
R
I
R
I
I
R
II
R
I
I
I
I
I
I
I

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
II
I
I
I
I
I
II
I
I
I
I
I
II
R
I
I
I
I
II
I
I
I
I
I
II
I
I
I
R
I
RI
R
I
I
I
I
II
I
I
I
I
I
II
I
I
I
I
I
II
R
I
I
I
I
II
I
I
I
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
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
I
Transfer case fluid (3)R
IR
I II
I
I
I
I
II
I
I
I
I
I
I
I
I
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 INFORMATION
OWNER 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 wheel
needs 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 noticed
when 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 run
the 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 a
stowaway). 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 may
need to be serviced. Check the breather hole in the
reservoir cover to be free from dirt and check for an
open passage.