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1999 Musso
SSANGYONG 1999 Musso Manuals
Manuals and User Guides for SSANGYONG 1999 Musso. We have
1
SSANGYONG 1999 Musso manual available for free PDF download: Service Manual
SSANGYONG 1999 Musso Service Manual (1463 pages)
Brand:
SSANGYONG
| Category:
Automobile
| Size: 22.13 MB
Table of Contents
Section 0B General Information
13
Engine
2
Suspension
5
Heating, Ventilation
10
Body and Accessories
12
Table of Contents
13
Specifications
17
Vehicle Dimensions and Weights
17
Standard Bolt Specifications
18
Maintenance and Repair
19
Maintenance and Lubrication
19
Normal Vehicle Use
19
Explanation of Scheduled Maintenance Services
19
Scheduled Maintenance Charts (Gasoline Engine)
20
Scheduled Maintenance Charts (Diesel Engine)
22
Owner Inspections and Services
24
While Operating the Vehicle
24
At each Fuel Fill
24
At Least Twice a Month
24
At Least Monthly
24
At Least Twice a Year
24
Each Time the Oil Is Changed
25
At Least Annually
25
Recommended Fluids and Lubricants
26
General Description and System Operation
27
General Repair Instructions
27
Vehicle Identification Number System
28
Vehicle Lifting Procedures
31
Section 2
32
Engine Specifications
33
Component Locator
34
Front View
34
Side View
35
Performance Curve
36
E32 Engine
36
Special Tools
37
Special Tools Table
37
Diagnosis
38
Oil Leak Diagnosis
38
Engine Cranking at the Front of Crankshaft
39
Compression Pressure Test
40
Cylinder Pressure Leakage Test
42
General Information
44
Cleanliness and Care
44
On-Engine Service
44
Section 3
45
Engine Specifications
46
Component Locator
47
Front View
47
Side View
48
Performance Curve
49
E23 Engine
49
E20 Engine
50
Special Tools
51
Special Tools Table
51
Diagnosis
52
Oil Leak Diagnosis
52
Engine Cranking at the Front of Crankshaft
53
Compression Pressure Test
54
Cylinder Pressure Leakage Test
56
General Information
58
Cleanliness and Care
58
On-Engine Service
58
Section 4
59
Specifications
60
Engine Specifications
60
Sectional View
61
OM662LA Engine
61
OM661LA Engine
63
Performance Curve
65
OM662LA Engine
65
OM661LA Engine
66
Special Tools
67
Special Tools Table
67
Diagnosis
68
Oil Leak Diagnosis
68
Compression Pressure Test
69
Cylinder Pressure Leakage Test
71
General Information
73
Cleanliness and Care
73
On-Engine Service
73
Section 1B1 M162 Engine Mechanical
74
Specifications
75
Fastener Tightening Specifications
75
Special Tools
77
Special Tools Table
77
Maintenance and Repair
81
On-Vehicle Service
81
Engine Assembly
81
Crankcase Ventilation System
89
Alternator
91
Power Steering Pump and A/C Bracket
92
Hydraulic Engine Mounting Insulator
95
Poly V-Belt
98
Tensioning Device
100
Poly V-Belt Inspection
102
Cylinder Head Cover
104
Cylinder Head
108
Timing Gear Case Cover
111
Crankshaft Sealing Rear Cover
113
Belt Pulley and Vibration Damper
115
Crankshaft Front Radial Seal
118
Crankshaft Rear Radial Seal
119
Crankshaft
120
Flywheel / Driven Plate
126
Camshaft Adjuster
128
Camshaft Sprocket Bolt
131
Camshaft
132
Camshaft Timing Position
137
Valve Spring
140
Valve Stem Seal
144
Chain Tensioner
145
Timing Chain
148
Tensioning Rail
153
Cylinder Head Guide Rail
154
Crankcase Guide Rail
155
Crankshaft Sprocket
156
Piston
158
Connecting Rod
161
Piston Ring
163
Engine Oil Specification
165
Oil Pan
166
Engine Oil and Oil Filter Element
168
Oil Filter
170
Oil Pump
172
Oil Pressure Relief Valve
174
Oil Non-Return Valve
175
Oil Dipstick Guide Tube
176
Unit Repair
177
Oil Gallery in Crankcase
177
Oil Gallery in Cylinder Head
179
Core Plugs in Crankcase
182
Cylinder Bore
184
Crankcase Mating Surface
186
Cylinder Head Mating Surface
188
Section 1B2 M161 Engine Mechanical
190
Specifications
191
Fastener Tightening Specifications
191
Special Tools
193
Special Tools Table
193
Maintenance and Repair
198
On-Vehicle Service
198
Engine Assembly
198
Crankcase Ventilation System
206
Alternator
210
Power Steering Pump and A/C Bracket
211
Hydraulic Engine Mounting Insulator
214
Poly V-Belt
217
Tensioning Deivce
219
Tensioning Device Shock Absorber
220
Poly V-Belt Inspection
221
Cylinder Head Cover
224
Cylinder Head
228
Timing Gear Case Cover
233
Crankshaft Sealing Rear Cover
236
Belt Pulley and Vibration Damper
238
Crankshaft Front Radial Seal
241
Crankshaft Rear Radial Seal
242
Crankshaft
243
Flywheel/Driven Plate
249
Camshaft Adjuster
251
Camshaft Sprocket Bolt
254
Camshaft
255
Camshaft Timing Position
258
Valve Spring
261
Valve Stem Seal
265
Chain Tensioner
266
Timing Chain
269
Tensioning Rail
274
Cylinder Head Guide Rail
275
Crankcase Guide Rail
276
Crankshaft Sprocket
277
Piston
279
Connecting Rod
282
Piston Ring
284
Oil Pan
286
Oil Pump
287
Oil Pressure Relief Valve
292
Oil Non-Return Valve
293
Oil Dipstick Guide Tube
294
Unit Repair
295
Core Plugs in Crankcase
295
Cylinder Bore
297
Crankcase Mating Surface
299
Cylinder Head Mating Surface
301
Section 1B3 Om600 Engine Mechanical
303
Special Tools
306
Special Tools Table
307
Specifications
306
Maintenance and Repair
314
On-Vehicle Service
314
Engine Assembly
314
Poly V-Belt
323
Tensioning Device
325
Poly V-Belt Alignment & Inspection
328
Prechamber
331
Milling of Prechamber Sealing Surface
334
TDC (TDC Sensor Bracket) Setting
337
Om600 Engine Mechanical 1B3-37 Cylinder Head
339
Cylinder Head
363
Timing Case Cover
365
Gasket
365
Bolt
365
Crankshaft End Cover
373
Vibration Damper and Hub
376
Crankshaft Front Radial Seal
382
Crankshaft Ball Bearing
384
Crankshaft
385
Machining of Flywheel
399
Flywheel Ring Gear
400
Hydraulic Valve Clearance Compensation Element Check
403
Cylinder Head Bolt
408
Valve Tappets
408
Valve Springs (Cylinder Head Installed)
411
Valve Stem Seals
414
Valve Seat Rings
424
Check and Machining of Valves
429
Machining of Valve Seat
434
Camshaft Timing Test
439
Camshaft
441
Camshaft Drive Sprocket
441
Chain Tensioner
447
Timing Chain
449
Tensioning Rail
453
Cylinder Head Guide Rail
454
Gasket
454
Timing Case Cover Guide Rail
458
Crankshaft Sprocket
460
Piston
465
Oil Filter
471
Oil Pan
473
Oil Spray Nozzle
476
Oil Pump
477
Unit Repair
479
Cylinder Head Pressure Leakage Test
479
Facing Cylinder Head Mating Surface
480
Replacement of Crankcase Core Plug
482
Facing Crankcase Contacting Surface
484
Oil Gallery Steel Ball
485
Cylinder Bore Measurement
489
Section 1D1 M162 Engine Cooling
490
Specifications
491
Fastener Tightening Specifications
491
Special Tools
492
Special Tools Table
492
Diagnosis
493
System Leakage Test
493
Coolant Drain and Fill up
494
Maintenance and Repair
494
On-Vehicle Service
494
Coolant Connection Fitting
496
Water Pump
497
Thermostat
499
Oil Cooler Pipe Line
500
Cooling Fan
501
Cooling Fan and Viscous Clutch
501
Cooling Fan Shroud
503
Radiator
504
Section 1D2 M161 Engine Cooling
506
Specifications
507
Fastener Tightening Specifications
507
Special Tools
508
Special Tools Table
508
Diagnosis
509
System Leakage Test
509
Maintenance and Repair
510
On-Vehicle Service
510
Cooling Fan and Viscous Clutch
512
Coolant Pump
514
Thermostat
516
Thermostat Housing Assembly
517
Removal and Installation of Cooling Fan Shroud
519
Removal and Installation of Radiator
520
Section 1D3 Om600 Engine Cooling
522
Diagnosis
523
Cooling Circulation
523
Thermostat Operation
524
Cooling System Leakage Test
525
Drain and Filling of Coolant
526
Maintenance and Repair
526
On-Vehicle Service
526
Coolant Pump
527
Tensioning Lever
527
Coolant Pump Housing
529
Cooling Fan Clutch
531
Bolt
532
Radiator
533
Cooling Sub-System
535
Thermostat
537
Section 1E1 M162 Engine Electrical
539
Specifications
540
Battery Specifications
540
Fastener Tightening Specifications
540
Special Tools
541
Special Tools Table
541
Maintenance and Repair
542
On-Vehicle Service
542
Alternator
542
Starting Motor
543
Nut
544
Battery
544
Spark Plug
545
Ignition Cable
547
Unit Repair
550
Battery
550
Section 1E2 M161 Engine Electrical
551
Specifications
552
Battery Specifications
552
Fastener Tightening Specifications
552
Starting Motor Specifications
552
Special Tools
553
Special Tools Table
553
Maintenance and Repair
554
On-Vehicle Service
554
Alternator
554
Starting Motor
555
Battery
556
Spark Plug
557
Ignition Cable
559
Unit Repair
562
Battery
562
Section 1E3 Om600 Engine Electrical
563
Specifications
564
Glow Plug
564
Alternator
568
Starter Motor
570
Section 1F1 M162 Engine Controls
571
Specifications
572
Maintenance and Repair
564
On-Vehicle Service
564
Fastener Tightening Specifications
572
Special Tools
573
Special Tools Table
573
Schematic and Routing Diagrams
574
Diagnosis
576
Self Diagnosis Socket Pin Numbers and Descriptions
576
Self Diagnosis Failure Code
577
Test Box Connection
580
Fuel Injection System Test (MSE3.62)
581
Ignition System Test
591
Idling Control and Electronic Pedal System Test
596
Air Conditioner Control System Test
598
Fuel Pressure and Internal Leakage Test
599
Fuel Pump Test
601
Injector Test
603
Maintenance and Repair
605
On-Vehicle Service
605
Ecu
605
Fuel Pressure Regulator
616
Fuel Distributor
620
Injector
624
Fuel Filter
627
Fuel Pump
628
Purge Switchover Valve
632
Vacuum System
634
Crankshaft Position Sensor
635
Camshaft Position Sensor
637
Hot Film Air Mass (HFM) Sensor
639
Oxygen Sensor
642
Knock Sensor
644
Coolant Temperature Sensor
645
Accelerator Pedal Module
648
Section 1F2 M161 Engine Controls
650
Specifications
651
Fastener Tightening Specifications
651
Special Tools
652
Special Tools Table
652
Schematic and Routing Diagrams
653
Diagnosis
655
Self Diagnosis Socket Pin Numbers and Descriptions
655
Self Diagnosis Failure Code (for E23 ENG) . 1F2-7
656
Test Box Connection
659
Fuel Injection System Test
660
Ignition System Test
669
Idling Control and Electronic Pedal System Test
674
Air Conditioner Control System Test
676
Fuel Pressure and Internal Leakage Test
677
Fuel Pump Test
679
Injector Test
681
Maintenance and Repair
683
On-Vehicle Service
683
Ecu
683
Fuel Pressure Regulator
694
Fuel Distributor
698
Injector
703
Fuel Filter
706
Fuel Pump
707
Purge Switchover Valve
711
Vacuum System
713
Crankshaft Position Sensor
715
Camshaft Position Sensor
717
Hot Film Air Mass (HFM) Sensor
719
Oxygen Sensor
722
Knock Sensor
724
Coolant Temperature Sensor
725
Accelerator Pedal Module
728
Section 1F3 Om600 Engine Controls
730
Specifications
731
Maintenance and Repair
731
On-Vehicle Service
731
Fuel System
731
Fuel Injection Pump Coding
732
Fuel Tank
733
Vacuum Control System Test
734
Vacuum Pump(Sectional View)
739
Vacuum Pump Test
740
Vacuum Pump
742
Vacuum Unit Replacement
744
Idle Speed Adjustment
745
Fuel Pump Test
747
Fuel Pump
750
Gasket
750
Injection Nozzle Test
751
Injection Nozzles
754
Injection Nozzle Repair
756
Repair Procedure
757
Removal and Installation of Injection Timing Device
759
Injection Timing Device
764
Start of Delivery Test (Position Sensor, RIV Method)
766
Test Procedure
767
Fuel Injection Pump
775
Section 1G1 M162 Engine Intake & Exhaust
781
Specifications
782
Maintenance and Repair
782
On-Vehicle Service
782
Air Cleaner
782
Intake Air Duct
784
Intake Manifold
785
Resonance Flap
787
Exhaust Manifold
789
Section 1G2 M161 Engine Intake & Exhaust
792
Specifications
793
Maintenance and Repair
793
On-Vehicle Service
793
Air Cleaner
793
Air Intake Shield
795
Intake Air Duct
796
Intake Manifold
798
Exhaust Manifold
800
Section 1G3 Om600 Engine Intake & Exhaust
803
Specifications
804
Schematic and Routing Diagrams
804
Maintenance and Repair
805
On-Vehicle Service
805
Intake and Exhaust Manifold
807
Turbocharger
810
Intercooler
811
Turbocharger Assembly
813
Section 2A Suspension Diagnosis
816
Specifications
817
General Specifications
817
Diagnosis
818
General Diagnosis
818
Input & Output Devices and Damping
820
System Layout
820
Damping Force Control Logic
821
Normal Control
821
Self-Diagnosis
822
Actuator Inspection
823
Schematic and Routing Diagrams
824
Diagnosis Test
827
Self Diagnosis Test
827
Section 2B Wheel Alignment
829
Specifications
830
Diagnosis
830
Tire Diagnosis
830
Radial Tire Lead/Pull
831
Vibration Diagnosis
833
2B-6 Wheel Alignment
834
Maintenance and Repair
834
On-Vehicle Service
834
Camber
837
Caster
837
General Description and System Operation
837
Toe
837
Section 2C Front Suspension
838
Component Locator
840
Front Suspension
840
Maintenance and Repair
841
On-Vehicle Service
841
Front Stabilizer Bar
841
Torsion Bar
843
Front Lower and Upper Arm
845
Front Shock Absorber
847
Axle Vertical Acceleration Sensor (Wheel G Sensor)
849
Vertical and Lateral Sensor
850
Ecs (Ecu)
851
Rear Shock Absorber
860
Section 2E Tires and Wheels
862
Specifications
862
Diagnosis
863
Radial Tire
864
Wheel Disc
864
Wheels and Tires
866
Identification
864
Component Locator
871
Maintenance and Repair
874
On-Vehicle Service
874
Propeller Shaft
893
Sectiond Rear Drive Axle
899
Noise
901
Component Locator
903
Maintenance and Repair
904
On-Vehicle Service
904
Axle Shaft
904
Axle
907
Unit Repair
909
Axle Housing
909
Section 4A Hydraulic Brakes
916
Poor Braking
917
Increasing Pedal Stroke
918
Poor Braking of Parking Brake
918
Component Locator
919
Abs
919
Abs / Abd
920
Non-Abs/Abd
921
Maintenance and Repair
922
On-Vehicle Service
922
Bleeding the Brakes
922
Brake Pedal
924
LCRV (Load Conscious Reducing Valve)
927
Section 4F Antilock Brake System
948
Schematic and Routing Diagrams
949
Component Locator
953
ABD System Description
954
Self Diagnosis
956
Defect Codes
960
Maintenance and Repair
966
On-Vehicle Service
966
Hydraulic Circuit
968
Parking Brake
975
Section 5A Automatic Transmission
978
Specifications
979
Model Part Numbers and Applications
979
Model Specifications
979
Clutch Pack Details
980
Special Tools
981
Special Tools Table
981
Schematic and Routing Diagrams
982
Shift Pattern Diagram
984
661LA Power Mode
985
662LA Normal Mode
986
662LA Power Mode
987
662LA Low Mode
988
E32 Power Mode
989
E32 Normal Mode
990
E32 Low Mode
991
E23 Power Mode
992
E23 Normal Mode
993
E23 Low Mode
994
Introduction
995
Operator Interfaces
997
Gear Select Lever Operation
997
Driving Mode Selector
998
Control Systems
999
General
999
Electronic Control System
999
Hydraulic Control System
1008
Power Train System
1019
Torque Converter
1020
Clutch Packs
1021
Bands
1022
One Way Clutches
1022
Planetary Gear Set
1022
Parking Mechanism
1023
Power Flows
1024
Introduction
1024
Power Flow - Park and Neutral
1025
Power Flow - Reverse
1026
Power Flow - Drive 4 (Overdrive)
1034
Diagnosis
1037
Diagnostic System
1037
Mechanical Tests
1046
Self Diagnosis Test
1052
Adjustments
1056
Hydraulic System
1056
Electronic Adjustments
1057
Maintenance and Repair
1059
On-Vehicle Service
1059
Unit Repair
1062
Rebuild Warnings
1062
Disassembly Procedure
1062
Assembly Procedure
1071
Section 5B Manual Transmission
1108
Specifications
1108
General Specifications
1108
Gear Train
1110
External View
1110
Power Flow
1111
Diagnosis
1112
Transmission Leakage
1114
Diagnosis Table
1115
Component Locator
1116
Transmission
1121
Unit Repair
1124
Major Unit
1124
Main Shaft
1134
Input Shaft
1139
Counter Shaft
1141
Extension Housing
1142
Shift Cover
1143
Section 5C Clutch
1154
Specifications
1154
General Specifications
1154
Special Tools
1156
Diagnosis
1157
Clutch Slips
1157
Poor Disengagement
1157
Clutch Noisy
1158
Component Locator
1159
Clutch Assembly
1159
Clutch Disc
1162
Master Cylinder
1166
Clutch Pedal
1168
Diagnostic Tests
1222
Steering System
1264
Steering Column
1271
Conditioning System
1275
Specifications
1276
Cooling Capacity
1276
Compressor
1276
Condenser
1276
Receiver Drier
1276
Dual Pressure Switch
1276
Evaporator
1277
Heater Unit
1277
Fastener Tightening Specifications
1277
Diagnosis
1278
Defectives in Fan Motor Circuit
1279
Defectives in Compressor Circuit
1279
Component Locator
1280
Ventilation
1280
Air Conditioner System
1282
Diesel Engine
1282
Gasoline Engine
1283
Maintenance and Repair
1284
Refrigerant Charging
1284
Condenser
1288
Receiver Drier
1292
Compressor
1295
Heater and Air Conditioner Control Box
1299
Section 8A Seat Belts
1301
Component Locator
1302
Front Seat Belt
1302
Rear Seat Belt
1303
General Description and System Operation
1304
Driver Seat Belt Warning
1304
Operation and Functional Checks
1304
Front Wiper and Washer
1369
Rear Wiper and Washer
1371
Combination Meter
1376
Rear Bumper
1413
Front Door
1417
Rear Door
1418
Sun Roof
1423
Immobilizer Antenna
1462
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