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Daewoo MUSSO Manuals
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Daewoo MUSSO manuals available for free PDF download: Service Manual
Daewoo MUSSO Service Manual (1465 pages)
Brand:
Daewoo
| Category:
Automobile
| Size: 22.12 MB
Table of Contents
Section 0B General Information
15
Service Manual
3
Table of Contents
15
Specifications
18
Vehicle Dimensions and Weights
19
Maintenance and Repair
21
Maintenance and Lubrication
21
Normal Vehicle Use
21
Explanation of Scheduled Maintenance Services
21
Scheduled Maintenance Charts (Gasoline Engine)
22
Scheduled Maintenance Charts (Diesel Engine)
24
Owner Inspections and Services
26
While Operating the Vehicle
26
At each Fuel Fill
26
At Least Twice a Month
26
At Least Monthly
26
At Least Twice a Year
26
Each Time the Oil Is Changed
27
At Least Annually
27
Recommended Fluids and Lubricants
28
General Description and System Operation
29
General Repair Instructions
29
Vehicle Identification Number System
30
Vehicle Lifting Procedures
33
Section 2
34
Engine Specifications
35
Component Locator
36
Front View
36
Side View
37
Performance Curve
38
E32 Engine
38
Special Tools
39
Special Tools Table
39
Diagnosis
40
Oil Leak Diagnosis
40
Engine Cranking at the Front of Crankshaft
41
Compression Pressure Test
42
Cylinder Pressure Leakage Test
44
General Information
46
Cleanliness and Care
46
On-Engine Service
46
Section 3
47
Engine Specifications
48
Component Locator
49
Front View
49
Side View
50
Performance Curve
51
E23 Engine
51
E20 Engine
52
Special Tools
53
Special Tools Table
53
Diagnosis
54
Oil Leak Diagnosis
54
Engine Cranking at the Front of Crankshaft
55
Compression Pressure Test
56
Cylinder Pressure Leakage Test
58
General Information
60
Cleanliness and Care
60
On-Engine Service
60
Section 4
61
Specifications
62
Engine Specifications
62
Sectional View
63
OM662LA Engine
63
OM661LA Engine
65
Performance Curve
67
OM662LA Engine
67
OM661LA Engine
68
Special Tools
69
Special Tools Table
69
Diagnosis
70
Oil Leak Diagnosis
70
Compression Pressure Test
71
Cylinder Pressure Leakage Test
73
General Information
75
Cleanliness and Care
75
On-Engine Service
75
Section 1B1 M162 Engine Mechanical
76
Specifications
77
Fastener Tightening Specifications
77
Special Tools
79
Special Tools Table
79
Maintenance and Repair
83
On-Vehicle Service
83
Engine Assembly
83
Crankcase Ventilation System
91
Alternator
93
Power Steering Pump and A/C Bracket
94
Hydraulic Engine Mounting Insulator
97
Poly V-Belt
100
Tensioning Device
102
Poly V-Belt Inspection
104
M162 Engine Mechanical 1B1-31 Cylinder Head Cover
106
Cylinder Head Cover
106
Cylinder Head
110
Timing Gear Case Cover
113
Crankshaft Sealing Rear Cover
115
Belt Pulley and Vibration Damper
117
Crankshaft Front Radial Seal
120
Crankshaft Rear Radial Seal
121
Crankshaft
122
Flywheel / Driven Plate
128
Bolt (M6 X 65, 8 Pieces)
129
Bolt (M6 X 50, 4 Pieces)
130
Camshaft Adjuster
130
Camshaft Sprocket Bolt
133
Camshaft
134
Camshaft Timing Position
139
Valve Spring
142
Thrust Piece
142
Valve Stem Seal
146
Chain Tensioner
147
Timing Chain
150
Tensioning Rail
155
Cylinder Head Guide Rail
156
Crankcase Guide Rail
157
Crankshaft Sprocket
158
Piston
160
Connecting Rod
163
Piston Ring
165
Engine Oil Specification
167
Oil Pan
168
Engine Oil and Oil Filter Element
170
Oil Filter
172
Oil Pump
174
Oil Pressure Relief Valve
176
Oil Non-Return Valve
177
Oil Dipstick Guide Tube
178
Unit Repair
179
Oil Gallery in Crankcase
179
Oil Gallery in Cylinder Head
181
Core Plugs in Crankcase
184
Cylinder Bore
186
Crankcase Mating Surface
188
Chamfering Procedure
189
Cylinder Head Mating Surface
190
Section 1B2 M161 Engine Mechanical
192
Specifications
193
Fastener Tightening Specifications
193
Special Tools
195
Special Tools Table
195
Maintenance and Repair
200
On-Vehicle Service
200
Engine Assembly
200
Crankcase Ventilation System
208
Alternator
212
Power Steering Pump and A/C Bracket
213
Hydraulic Engine Mounting Insulator
216
Poly V-Belt
219
Tensioning Deivce
221
Tensioning Device Shock Absorber
222
Poly V-Belt Inspection
223
Cylinder Head Cover
226
Cylinder Head
230
Gasket
233
Timing Gear Case Cover
235
Crankshaft Sealing Rear Cover
238
Belt Pulley and Vibration Damper
240
Crankshaft Front Radial Seal
243
Crankshaft Rear Radial Seal
244
Crankshaft
245
Flywheel/Driven Plate
251
Camshaft Adjuster
253
Camshaft Sprocket Bolt
256
Camshaft
257
Camshaft Timing Position
260
Valve Spring
263
Valve Stem Seal
267
Chain Tensioner
268
Timing Chain
271
Tensioning Rail
276
Cylinder Head Guide Rail
277
Crankcase Guide Rail
278
Crankshaft Sprocket
279
Piston
281
Connecting Rod
284
Piston Ring
286
Oil Pan
288
Engine Oil and Oil Filter Element
290
Oil Pump
292
Oil Pressure Relief Valve
294
Oil Non-Return Valve
295
Oil Dipstick Guide Tube
296
Core Plugs in Crankcase
297
Unit Repair
297
Cylinder Bore
299
Crankcase Mating Surface
301
Cylinder Head Mating Surface
303
Section 1B3 Om600 Engine Mechanical
305
Specifications
306
Special Tools
308
Special Tools Table
308
Specifications
308
Maintenance and Repair
316
On-Vehicle Service
316
Engine Assembly
316
Poly V-Belt
325
Tensioning Device
327
Poly V-Belt Alignment & Inspection
330
Prechamber
333
Milling of Prechamber Sealing Surface
336
TDC (TDC Sensor Bracket) Setting
339
Om600 Engine Mechanical 1B3-37 Cylinder Head
341
Cylinder Head
365
Timing Case Cover
367
Crankshaft End Cover
375
Vibration Damper and Hub
378
Crankshaft Front Radial Seal
384
Crankshaft Ball Bearing
386
Crankshaft
387
Machining of Flywheel
401
Flywheel Ring Gear
402
Hydraulic Valve Clearance Compensation Element Check
405
Valve Tappets
410
Valve Spring Check
413
Valve Springs (Cylinder Head Installed)
413
Valve Stem Seals
416
Check and Replacement of Valve Guides
420
Valve Seat Rings
426
Check and Machining of Valves
431
Exhaust Valve
432
Machining of Valve Seat
436
Camshaft Timing Test
441
Camshaft
443
Chain Tensioner
449
Timing Chain
451
Tensioning Rail
455
Cylinder Head Guide Rail
456
Timing Case Cover Guide Rail
460
Crankshaft Sprocket
462
Piston
467
Oil Filter
473
Gasket
473
Oil Pan
475
Oil Spray Nozzle
478
Oil Pump
479
Unit Repair
481
Cylinder Head Pressure Leakage Test
481
Bolt
481
Facing Cylinder Head Mating Surface
482
Replacement of Crankcase Core Plug
484
Facing Crankcase Contacting Surface
486
Oil Gallery Steel Ball
487
Cylinder Bore Measurement
491
Section 1D1 M162 Engine Cooling
492
Special Tools
494
Special Tools Table
494
Diagnosis
495
System Leakage Test
495
Coolant Drain and Fill up
496
Clamp
497
Maintenance and Repair
496
On-Vehicle Service
496
Coolant Connection Fitting
498
Bolt
499
Water Pump
499
Thermostat
501
Oil Cooler Pipe Line
502
Cooling Fan and Viscous Clutch
503
Cooling Fan Shroud
505
Radiator
505
Section 1D2 M161 Engine Cooling
508
Special Tools
510
Special Tools Table
510
Diagnosis
511
System Leakage Test
511
Maintenance and Repair
512
On-Vehicle Service
512
Cooling Fan and Viscous Clutch
514
Coolant Pump
516
Thermostat
518
Thermostat Housing Assembly
519
Removal and Installation of Cooling Fan Shroud
521
Removal and Installation of Radiator
522
Section 1D3 Om600 Engine Cooling
524
Diagnosis
525
Cooling Circulation
525
Thermostat Operation
526
Cooling System Leakage Test
527
Drain and Filling of Coolant
528
Maintenance and Repair
528
On-Vehicle Service
528
Coolant Pump
529
Coolant Pump Housing
531
Cooling Fan Clutch
533
Radiator
535
Cooling Sub-System
537
Thermostat
539
Section 1E1 M162 Engine Electrical
541
Specifications
542
Battery Specifications
542
Fastener Tightening Specifications
542
Special Tools
543
Special Tools Table
543
Maintenance and Repair
544
On-Vehicle Service
544
Alternator
544
Starting Motor
545
Battery
546
Spark Plug
547
Ignition Cable
549
Unit Repair
552
Battery
552
Section 1E2 M161 Engine Electrical
553
Specifications
554
Starting Motor Specifications
554
Battery Specifications
554
Fastener Tightening Specifications
554
Special Tools
555
Special Tools Table
555
Maintenance and Repair
556
On-Vehicle Service
556
Alternator
556
Starting Motor
557
Battery
558
Spark Plug
559
Ignition Cable
561
Unit Repair
564
Battery
564
Section 1E3 Om600 Engine Electrical
565
Specifications
566
Maintenance and Repair
566
On-Vehicle Service
566
Glow Plug
566
Alternator
570
Washer
572
Starter Motor
572
Section 1F1 M162 Engine Controls
573
Special Tools
575
Special Tools Table
575
Schematic and Routing Diagrams
576
Diagnosis
578
Self Diagnosis Socket Pin Numbers and Descriptions
578
Self Diagnosis Failure Code
579
Test Box Connection
582
Fuel Injection System Test (MSE3.62)
583
Ignition System Test
593
Idling Control and Electronic Pedal System Test
598
Air Conditioner Control System Test
600
Fuel Pressure and Internal Leakage Test
601
Fuel Pump Test
603
Injector Test
605
Maintenance and Repair
607
On-Vehicle Service
607
Ecu
607
Fuel Pressure Regulator
618
Bolt
622
Fuel Distributor
622
Injector
626
Fuel Filter
629
Fuel Pump
630
Purge Switchover Valve
634
Vacuum System
636
Crankshaft Position Sensor
637
Camshaft Position Sensor
639
Hot Film Air Mass (HFM) Sensor
641
Oxygen Sensor
644
Knock Sensor
646
Coolant Temperature Sensor
647
Accelerator Pedal Module
650
Section 1F2 M161 Engine Controls
652
Special Tools
654
Special Tools Table
654
Schematic and Routing Diagrams
655
Diagnosis
657
Self Diagnosis Socket Pin Numbers and Descriptions
657
Self Diagnosis Failure Code (for E23 ENG) . 1F2-7
658
Test Box Connection
661
Fuel Injection System Test
662
Ignition System Test
671
Idling Control and Electronic Pedal System Test
676
Air Conditioner Control System Test
678
Fuel Pressure and Internal Leakage Test
679
Fuel Pump Test
681
Injector Test
683
Maintenance and Repair
685
On-Vehicle Service
685
Ecu
685
Fuel Pressure Regulator
696
Fuel Distributor
700
Injector
705
Fuel Filter
708
Fuel Pump
709
Purge Switchover Valve
713
Vacuum System
715
Crankshaft Position Sensor
717
Camshaft Position Sensor
719
Hot Film Air Mass (HFM) Sensor
721
Oxygen Sensor
724
Knock Sensor
726
Coolant Temperature Sensor
727
Accelerator Pedal Module
730
Section 1F3 Om600 Engine Controls
732
Specifications
733
Maintenance and Repair
733
On-Vehicle Service
733
Fuel System
733
Fuel Injection Pump Coding
734
Fuel Tank
735
Vacuum Control System Test
736
Vacuum Pump(Sectional View)
741
Vacuum Pump Test
742
Vacuum Pump
744
Vacuum Unit Replacement
746
Idle Speed Adjustment
747
Fuel Pump Test
749
Fuel Pump
752
Injection Nozzle Test
753
Fuel Injection Nozzle
756
Injection Nozzles
756
Nozzle Washer
756
Injection Nozzle Repair
758
Cylinder Head Bolt
761
Cylinder Head Cover
761
10 Washer
761
Gasket
761
Removal and Installation of Injection Timing Device
761
Injection Timing Device
766
Start of Delivery Test (Position Sensor, RIV Method)
768
Bolt
777
Fuel Injection Pump
777
Section 1G1 M162 Engine Intake & Exhaust
783
Specifications
784
Maintenance and Repair
784
On-Vehicle Service
784
Air Cleaner
784
Intake Air Duct
786
Nut
786
Intake Manifold
787
Resonance Flap
789
Exhaust Manifold
791
Section 1G2 M161 Engine Intake & Exhaust
794
Specifications
795
Maintenance and Repair
795
On-Vehicle Service
795
Air Cleaner
795
Air Intake Shield
797
Intake Air Duct
798
Intake Manifold
800
Exhaust Manifold
802
Section 1G3 Om600 Engine Intake & Exhaust
805
Schematic and Routing Diagrams
806
Air Cleaner and Inlet Duct & Hose
807
Specifications
806
Maintenance and Repair
807
On-Vehicle Service
807
Intake and Exhaust Manifold
809
Charge Air System Diagram
812
Turbocharger
812
Intercooler
813
Turbocharger Assembly
815
Section 2A Suspension Diagnosis
818
Specifications
819
General Specifications
819
Diagnosis
820
General Diagnosis
820
Input & Output Devices and Damping
822
System Layout
822
Damping Force Control Logic
823
Normal Control
823
Self-Diagnosis
824
Actuator Inspection
825
Schematic and Routing Diagrams
826
Diagnosis Test
829
Self Diagnosis Test
829
Section 2B Wheel Alignment
831
Specifications
832
Diagnosis
832
Tire Diagnosis
832
Radial Tire Lead/Pull
833
Vibration Diagnosis
835
2B-6 Wheel Alignment
836
Maintenance and Repair
836
On-Vehicle Service
836
Camber
839
Caster
839
Four Wheel Alignment
839
General Description and System Operation
839
Toe
839
Section 2C Front Suspension
840
Component Locator
842
Front Suspension
842
Maintenance and Repair
843
On-Vehicle Service
843
Front Stabilizer Bar
843
Torsion Bar
845
Front Lower and Upper Arm
847
Front Shock Absorber
849
Axle Vertical Acceleration Sensor (Wheel G Sensor)
851
Vertical and Lateral Sensor
852
Ecs (Ecu)
853
Sectiond Rear Suspension
854
Specifications
855
Diagnosis
855
Noise (During Straight Driving)
855
Oil Leakage
855
Noise (During Turning)
855
Heating
856
Component Locator
857
Maintenance and Repair
858
Rear Shock Absorber
862
Section 2E Tires and Wheels
864
Diagnosis
865
Identification
866
Radial Tire
866
Wheel Disc
866
Component Locator
867
Wheel and Tire
867
Maintenance and Repair
868
Wheels and Tires
868
Front Axle
873
On-Vehicle Service
876
Sectiond Rear Drive Axle
901
Specifications
902
General Specifications
902
Diagnosis
903
Heating
903
Noise (During Straight Driving)
903
Noise (During Turning)
903
Oil Leakage
903
Vibration
904
Noise
904
Component Locator
905
Gasket
906
Maintenance and Repair
906
On-Vehicle Service
906
Axle Shaft
906
Axle
909
Unit Repair
911
Axle Housing
911
Section 4A Hydraulic Brakes
918
Poor Braking
919
Increasing Pedal Stroke
920
Poor Braking of Parking Brake
920
Component Locator
921
Abs
921
Abs / Abd
922
Non-Abs/Abd
923
Maintenance and Repair
924
On-Vehicle Service
924
Brake Pedal
926
LCRV (Load Conscious Reducing Valve)
929
Trouble Shooting
930
Section 4D Front Disc Brakes
941
Specifications
942
Maintenance and Repair
942
On-Vehicle Service
942
Front Disc Brake
942
Unit Repair
945
Front Disc Brake
945
Section 4E Rear Disc Brakes
946
Specifications
947
Maintenance and Repair
947
On-Vehicle Service
947
Rear Disc Brake
947
Unit Repair
949
Rear Disc Brake
949
Section 4F Antilock Brake System
950
Specifications
951
Schematic and Routing Diagrams
951
Component Locator
955
ABD System Description
956
Self Diagnosis
958
Defect Codes
962
Maintenance and Repair
968
On-Vehicle Service
968
Wheel Speed Sensor
968
Hydraulic Circuit
970
Section 4G Parking Brake
976
Specifications
976
Fastener Tightening Specifications
976
Component Locator
977
4G-2 Parking Brake
977
Maintenance and Repair
978
On-Vehicle Service
978
Parking Brake
978
Section 5A Automatic Transmission
980
Specifications
981
Model Specifications
981
Clutch Pack Details
982
Special Tools
983
Special Tools Table
983
Schematic and Routing Diagrams
984
Shift Pattern Diagram
986
661LA Normal Mode
986
661LA Power Mode
987
662LA Normal Mode
988
662LA Power Mode
989
662LA Low Mode
990
E32 Power Mode
991
E32 Normal Mode
992
E32 Low Mode
993
E23 Power Mode
994
E23 Normal Mode
995
E23 Low Mode
996
Introduction
997
Operator Interfaces
999
Gear Select Lever Operation
999
Driving Mode Selector
1000
Control Systems
1001
General
1001
Electronic Control System
1001
Hydraulic Control System
1010
Power Train System
1021
Torque Converter
1022
Clutch Packs
1023
Bands
1024
One Way Clutches
1024
Planetary Gear Set
1024
Parking Mechanism
1025
Power Flows
1026
Introduction
1026
Power Flow - Park and Neutral
1027
Power Flow - Reverse
1028
Power Flow - Drive 4 (Overdrive)
1036
Diagnosis
1039
Diagnostic System
1039
Mechanical Tests
1048
Self Diagnosis Test
1054
Adjustments
1058
Hydraulic System
1058
Electronic Adjustments
1059
Maintenance and Repair
1061
On-Vehicle Service
1061
Unit Repair
1064
Rebuild Warnings
1064
Disassembly Procedure
1064
Assembly Procedure
1073
Front and Rear Band Adjustment
1107
Section 5B Manual Transmission
1110
Specifications
1110
General Specifications
1110
External View
1112
Gear Train
1112
Power Flow
1113
Diagnosis
1114
Transmission Locked in One Gear
1115
Transmission Noise
1115
Transmission Leakage
1116
Diagnosis Table
1117
Component Locator
1118
Maintenance and Repair
1120
On-Vehicle Service
1120
Transmission
1123
Unit Repair
1126
Major Unit
1126
Main Shaft
1136
Input Shaft
1141
Counter Shaft
1143
Extension Housing
1144
Shift Cover
1145
Inspection of Components
1149
Pre-Installation Checks
1154
Section 5D1 Transfer Case (Part Time 4408)
1173
Specifications
1173
General Specifications
1173
Schematic and Routing Diagram
1174
Diagnosis
1175
Self-Diagnosis
1176
System Description
1176
Self-Diagnosis Test
1180
Diagnostic Diagram
1181
Maintenance and Repair
1182
On-Vehicle Service
1182
Maintenance of Transfer Case Lubricant
1182
Transfer Case
1183
Unit Repair
1186
Transfer Case
1186
Section 5D2 Transfer Case (Tod)
1210
Specifications
1210
General Specifications
1210
Schematic and Routing Diagrams
1211
Tod
1213
Function Description
1213
TOD Control Unit
1221
Control Unit Diagram
1223
Diagnosis
1224
Diagnostic Tests
1224
Diagnostic Trouble Codes (Dtc's)
1226
Replacement of Oil
1249
Transfer Case
1250
Steering System
1266
Steering Column
1273
General Description
1306
Combination Meter
1378
Unit Repair
1250
Daewoo MUSSO Service Manual (32 pages)
Brand:
Daewoo
| Category:
Automobile
| Size: 0.84 MB
Table of Contents
Table of Contents
3
General Information
5
Specifications
5
Dimensions and Weights
9
Standard Bolts Specifications
10
Maintenance and Lubrication
11
Engine Oil Viscosity
11
Air Cleaner Element Replacement
11
Tire and Wheel Inspection and Rotation
11
Scheduled Maintenance Charts (Gasoline Engine)
12
Scheduled Maintenance Charts (Diesel Engine)
14
Owner Inspections and Services
16
At each Fuel Fill
16
At Least Monthly
16
At Least Twice a Year
16
Each Time the Oil Is Changed
17
Recommended Fluids and Lubricants
18
General Description and System Operation
19
General Repair Instructions
19
Vehicle Identification Number System
20
Manufacturer's Plate
21
Gasoline Engine Number
22
Diesel Engine Number
22
Engine Number Location
22
Vehicle Lifting Procedures
23
Engine
25
Engine Specifications
27
Component Locations
29
Engine Diagrams
29
Engine Performance Curve
31
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