2003 SSANGYONG MUSSO length

1B3-164 OM600 ENGINE MECHANICAL Service Data
Piston clearance Piston crown protrusion in TDC position Connecting rod bushing diameterMax. 0.12 mm
0.735 - 0.965 mm
26.012 - 26.018 mm
Connecting Rod Bolt Dimensions
Thread Stretch shaft(C) diameter (new)Minimum stretch shaft diameter (C)Length(L)(new)
Tools Required
000 589 04 14 00 Tensioning Strap 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder M9 x 1
7.4 -0.1
mm
7.1 mm
52 -0.3
mm

OM600 ENGINE CONTROLS 1F3-31
Tools Required 601 589 00 08 00Flange
601 589 05 21 00 Locking Screw
116 589 20 33 00 Sliding Hammer
116 589 02 34 00 Threaded Bolt
667 589 04 63 00 Retaining Plate Removal & Installation Procedure
1. Remove the bolts (2) and then remove the cylinder head cover (1) and gasket (3). Installation Notice
Tightening Torque 10 Nm
Notice Replace the gasket.Rotate the engine 1 revolution by hand and check TDC marking of the crankshaft and camshaft.
2. Loosen the camshaft sprocket bolt (14). Notice Do not remove the bolt. Installation Notice Notice If max. length of bolt exceeds 53.6mm, replace it.
Tightening Torque 25Nm + 90 °
3. Loosen the bolt (11) (left-hand thread).
Notice Do not remove the bolt.

SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
General Specifications . . . . . . . . . . . . . . . . . . 2A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
General Diagnosis . . . . . . . . . . . . . . . . . . . . . 2A-3
Input & Output Devices and Damping Force Control Logic . . . . . . . . . . . . . . . . . 2A-5
Input & Output Devices . . . . . . . . . . . . . . . . . . 2A-5
System Layout . . . . . . . . . . . . . . . . . . . . . . . . 2A-5Damping Force Control Logic . . . . . . . . . . . . . 2A-6
Normal Control . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Actuator Inspection . . . . . . . . . . . . . . . . . . . . . 2A-8
Schematic and Routing Diagrams . . . . . . . . 2A-9
ECS Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9
Self Diagnosis Test . . . . . . . . . . . . . . . . . . 2A-12
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . 2A-12
SPECIFICATIONS
GENERAL SPECIFICATIONS
188
Application
Front
3-stage Variable Damping Force Control Type Rear
ECS Control Type
344 - 350
Shock Absorber517 - 523
Max. Length (mm)
245 ± 3
Compressed Length (mm) 102
Stroke (mm)331 ± 3

SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTSSPECIFICATIONS
GENERAL SPECIFICATIONS
Type
Spring Type
Torsion Bar Shock Absorber
Stabilizer Type
Double Wishbone
Torsion Bar Spring 1,040 mm
24.5 mm
Cylindrical Reciprocation Type
Torsion Bar Spring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-1General Specifications . . . . . . . . . . . . . . . . . . 2C-1
Fastener Tightening Specifications . . . . . . . . . 2C-2
Component Locator . . . . . . . . . . . . . . . . . . . 2C-3
Front Suspension . . . . . . . . . . . . . . . . . . . . . . 2C-3
Maintenance and Repair . . . . . . . . . . . . . . . 2C-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2C-4
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . 2C-4
Application Description
Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Front Lower and Upper Arm . . . . . . . . . . . . . . 2C-8
Front Shock Absorber . . . . . . . . . . . . . . . . .
2C-10
Axle Vertical Acceleration Sensor (Wheel G Sensor) . . . . . . . . . . . . . . . . . . . 2C-12
Vertical and Lateral Sensor . . . . . . . . . . . . . . 2C-13
ECS (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-14
Length Outer Diameter(
)

3C-2 PROPELLER SHAFT
1 Flange Yoke
2 Cross and Bearing Assembly (with Snap Ring)
3 Cross and Bearing Assembly (with Snap Ring)
4 Slip Yoke Assembly
5 Grease Nipple
6 Dust Cap
7 Oil Seal
8 Split Washer
9 Slip Tube Shaft
10 Tube
Notice Only the length of shaft is different and the components of front/rear shaft are the same.(The deadener is inserted to the inside of tube of rear shaft, both ends) COMPONENT LOCATOR
M/T & A/T (PART-TIME T/C)
1. Gasolin : E32 - Fromt Propeller Shaft
2. Diesel/Gasolin : E23,20 - Fromt Propeller Shaft
: A/T + Full - Time T/C
3. Gasolin - Rear Propeller Shaft
Diesel - Fromt & Rear Propeller Shaft
: M/T & A/T + FPart - Time T/C
11 Tube Yoke
12 Flange Yoke
13 Diesel : Cross and Bearing Assembly (with Snap Ring)
Gasoline : CV Joint (DOJ)
14 Diesel : Double Cardan
Gasoline : Stub Shaft
15 Tube
16 Cross and Bearing Assembly (with Snap Ring)
17 Center Couping Yoke
18 Boots Band

AUTOMATIC TRANSMISSION 5A-67
Table 6.1.3 - Diagnostic Trouble Messages
Description / Cause
There have been no faults recorded since the TCU was last cleared. If
the fault history has never been cleared, then there have been no
faults recorded since the TCU was originally powered up.There is an internal fault within the TCU.
The voltage measured by the TCU corresponding to the battery sup-
ply voltage has been outside the range of the maximum operatingvoltage of 16.5 volts.
The minimum operating voltage depends on the transmission tem-
perature but is typically between 8-9 V for a warm transmission.
The voltage measured by the TCU from the throttle potentiometer has been outside acceptable levels.
This would typically indicate a loose connection in the wiring to, or
within, the throttle sensor which has caused the signal at the TCU to
read 0V or 5V.
The voltage measured by the TCU across the temperature Input ter-
minals has been outside acceptable levels.
This would typically be caused by a loose connection or short to ground
in the wiring to, or within, the temperature sensor which has caused
the signal at the TCU to read 0V or 5V. The voltage measured by the TCU across the shift lever input termi- nals has been outside acceptable levels for a significant length of
time. This would typically be caused by a loose connection or short to
ground in the wiring to, or within, the inhibitor switch which has caused
the signal at the TCU to read 0V or 5V.
The signal from the ignition, of ignition pulses, has either been non- existent or has been unreliable.
There are two reasons this fault could occur. The first is due to a lack
of ignition pulses when other TCU inputs would indicate that the en-
gine is running, that is the gear lever is in a driving position, the throttle is applied and vehicle speed increasing. The second cause of this (aunt is the frequency of the pulses of theignition pulse input to the TCU indicate an unachievable engine speed.
The pulses from the shaft speed sensor have either been non-exis-tent or have been unreliable.
There are three reasons this fault could occur. The first is due to a sudden loss of speedometer pulses at a time when they were fre quent,thus indicating an unachievable degree of deceleration of the drive
line. The second cause of this fault is that the frequency of the pulses
on the shaft speed sensor input to the TCU indicate an unachievable
propeller shaft speed. The third is the presence of a high engine speed
in a driving gear with no speedometer pulses.
Condition
Test Pass
Transmission Control Module Fault
Battery Voltage InputFault Throttle Input Fault
Temperature Input FaultShift Lever Position Input Fault(Inhibitor/PRNDL Switch) Engine Speed Sensor Fault Shaft Speed Sensor Fault(Speedo Sensor)Solenoid 1 2 3 4567 8

SECTION 5D2
TRANSFER CASE (TOD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1General Specifications . . . . . . . . . . . . . . . . . 5D2-1
Schematic and Routing Diagrams . . . . . . . 5D2-2 TOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-2
T.C.C.U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-3
Function Description . . . . . . . . . . . . . . . . . 5D2-4
TOD Control Unit . . . . . . . . . . . . . . . . . . . 5D2-12
Control Unit Diagram . . . . . . . . . . . . . . . . 5D2-14
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-15 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 5D2-15
Diagnostic Trouble Codes (DTC's) . . . . . . . 5D2-17
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
ModelLength (mm)Weight (kg)Shift ModeGear Ratio Oil
Max. Torque
High Low SpecificationCapacityInterval TOD(Torque On Demand) Transfer Case (4423E)
343.036.6
4H and 4L
1 : 1
2.48 : 1
ATF S-3, S-4 or Dexron II, III 1.4 L
Inspect Every 15,000km, Replace Every 50,000km 550 lbft ( 76kg m)
.
= .
.
= .
Application Description
Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-18
Eliminate the Memorized Fault Code . . . . .
5D2-20
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-21
Maintenance and Repair . . . . . . . . . . . . . 5D2-33
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D2-33
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-33
Transfer Case (TOD) . . . . . . . . . . . . . . . . . 5D2-34
Speed Sensor in Front and Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 5D2-38
Replacement of Oil . . . . . . . . . . . . . . . . . . . 5D2-40
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D2-41 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D2-41