1991-2000 DAEWOO MUSSO SSANGYONG MUSSO Service Manual
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๐ท๏ธ Basic Information Identification Make: SsangYong / Daewoo Model: Musso Model Years Covered: 1991-2000 Common Names: SsangYong Musso, Daewoo Musso ๐ Introduction Market Position Vehicle Segment: Mid-size SUV (Sport Utility Vehicle) Competitive Analysis Key Competitors Era: Jeep Cherokee (XJ), Toyota Land Cruiser Prado (J70/J90), Mitsubishi Pajero/Montero (V20/V30), Nissan Patrol (Y60), Land Rover Discovery (Discovery 1) Key Features Body On Frame Construction: Robust body-on-frame construction, inherited from its Mercedes-Benz M104 chassis development origins. Off Road Capability: Renowned for its off-road prowess, featuring a sturdy chassis and capable drivetrain. Engine Options: Available with robust diesel and gasoline engines, emphasizing durability and torque. Manual Benefit: Enables DIY repairs, saving money and providing a hands-on experience with vehicle maintenance. Manual Quality: Contains the exact same information used by dealership technicians, ensuring accuracy and factory-level detail. ๐ Manual Details Coverage Areas Manual Scope: Complete official full service repair manual for all models and all repairs A-Z Page Count Page Count: Not specified, but described as comprehensive and covering A-Z Manual Type Manual Type: Service and Repair Manual Language Language: English Format File Format: PDF Download ๐ Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system Drivetrain: Transmission (manual and automatic), transfer case, driveshafts, differentials, axles Chassis: Suspension (front and rear), steering system, braking system, wheels and tires Electrical: Wiring schematics, electrical components, charging system, starting system, lighting, instrumentation, power accessories Body And Trim: Body construction, interior trim, exterior trim, doors, windows, glass, HVAC system Procedures Included Maintenance: Routine inspections, fluid changes, filter replacements, lubrication Diagnostics: Troubleshooting common problems, fault diagnosis procedures Repair: Step-by-step repair instructions for all major components and systems Overhaul And Rebuild: Detailed instructions for complete engine, transmission, and other component overhauls Installation: Instructions for replacement of parts and accessories Technical Depth Depth Of Information: Factory highly detailed, complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications. ๐ Manual Specifications File Format File Format: PDF Print Quality Print Ability: Full Printable Binding Type Binding Type: Digital Download (Printable PDF) Paper Type Paper Type: Not Applicable (Digital) Zoom Functionality Zoom In Out: YES Software Requirements Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: All Versions of Windows & Mac โ๏ธ Engine Specifications Primary Engine Engine Options: Various inline-4, inline-5, and V6 gasoline and diesel engines. Common Gasoline Engine 1: 2.3L (2295cc) 4-cylinder gasoline Common Gasoline Engine 2: 3.2L (3199cc) 6-cylinder (M104 derivative) gasoline Common Diesel Engine 1: 2.3L (2299cc) 4-cylinder turbodiesel Common Diesel Engine 2: 2.9L (2874cc) 5-cylinder turbodiesel Performance Horsepower Range: Approx. 100-170 hp (depending on engine and year) Torque Range: Approx. 145-235 lb-ft (depending on engine and year) Fuel System Gasoline Injection Type: Multi-point fuel injection (MPI) Diesel Injection Type: Direct injection (DI) or indirect injection (IDI) with turbocharging ๐ง Transmission Standard Transmission Options: 5-speed manual transmission, 4-speed automatic transmission Optional Gear Ratios: Detailed gear ratios available for both manual and automatic transmissions in the manual. Features Drivetrain Layout: Part-time 4WD system with a 2-speed transfer case. ๐ Dimensions Exterior Wheelbase: Approx. 2650 mm (104.3 inches) Length: Approx. 4650 mm (183.1 inches) Width: Approx. 1865 mm (73.4 inches) Height: Approx. 1700 mm (66.9 inches) Weights Curb Weight: Varies by configuration, typically 1800-2000 kg (3968-4409 lbs) ๐ก๏ธ Safety Features Ratings Crash Test Results: Limited publicly available crash test data for this specific era and model. Manual provides chassis strength and safety component details. Active Features Braking System: Front ventilated discs, rear drums or discs (depending on trim and year). ABS availability varies. Passive Features Structural Integrity: Body-on-frame construction contributes to structural integrity. Seat Belts: Standard seat belts, with manual providing adjustment and maintenance information. ๐ก Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player or CD player. Manual covers removal and installation of head units. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on some models. Manual includes ABS system diagnosis and repair. Connectivity Wiring Schematics: Extensive wiring schematics are included, essential for diagnosing electrical issues and understanding vehicle systems. ๐ง Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months for gasoline, and 5,000-10,000 miles (8,000-16,000 km) for diesel, depending on operating conditions. Manual provides specific recommendations. Timing Belt Replacement: For specific engine types (e.g., gasoline inline-5), replacement typically recommended around 60,000-90,000 miles (100,000-150,000 km). Manual will specify. Fluid Specifications Engine Oil Type: Varies by engine; common recommendations include API SG/SH/SJ or higher for gasoline, and ACEA B3/B4 or specific diesel grades for diesel engines. Manual will list exact specifications (e.g., 10W-30, 15W-40). Coolant Type: Ethylene glycol based antifreeze. Manual will specify concentration and type (e.g., green or long-life coolant). Transmission Fluid Type: ATF Dexron-III or equivalent for automatic transmissions, GL-4 or GL-5 gear oil for manual transmissions and transfer cases. Manual will provide specific part numbers. Known Issues Common Wear Items: Potential...
Detailed gear ratios available for both manual and automatic transmissions in the manual.
Features
Drivetrain Layout:
Part-time 4WD system with a 2-speed transfer case.
๐ Dimensions
Exterior
Wheelbase:
Approx. 2650 mm (104.3 inches)
Length:
Approx. 4650 mm (183.1 inches)
Width:
Approx. 1865 mm (73.4 inches)
Height:
Approx. 1700 mm (66.9 inches)
Weights
Curb Weight:
Varies by configuration, typically 1800-2000 kg (3968-4409 lbs)
๐ก๏ธ Safety Features
Ratings
Crash Test Results:
Limited publicly available crash test data for this specific era and model. Manual provides chassis strength and safety component details.
Active Features
Braking System:
Front ventilated discs, rear drums or discs (depending on trim and year). ABS availability varies.
Passive Features
Structural Integrity:
Body-on-frame construction contributes to structural integrity.
Seat Belts:
Standard seat belts, with manual providing adjustment and maintenance information.
๐ก Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player or CD player. Manual covers removal and installation of head units.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on some models. Manual includes ABS system diagnosis and repair.
Connectivity
Wiring Schematics:
Extensive wiring schematics are included, essential for diagnosing electrical issues and understanding vehicle systems.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months for gasoline, and 5,000-10,000 miles (8,000-16,000 km) for diesel, depending on operating conditions. Manual provides specific recommendations.
Timing Belt Replacement:
For specific engine types (e.g., gasoline inline-5), replacement typically recommended around 60,000-90,000 miles (100,000-150,000 km). Manual will specify.
Fluid Specifications
Engine Oil Type:
Varies by engine; common recommendations include API SG/SH/SJ or higher for gasoline, and ACEA B3/B4 or specific diesel grades for diesel engines. Manual will list exact specifications (e.g., 10W-30, 15W-40).
Coolant Type:
Ethylene glycol based antifreeze. Manual will specify concentration and type (e.g., green or long-life coolant).
Transmission Fluid Type:
ATF Dexron-III or equivalent for automatic transmissions, GL-4 or GL-5 gear oil for manual transmissions and transfer cases. Manual will provide specific part numbers.
Known Issues
Common Wear Items:
Potential for wear on suspension bushings, ball joints, and steering components due to off-road use and age. Diesel engine glow plug reliability can be a concern. Overheating on early gasoline models if cooling system maintenance is neglected.
Manual Utility For Issues:
The manual provides detailed diagnostic procedures and repair instructions for addressing these common wear items and potential issues.
๐ Vehicle History
Brand Heritage
Ssangyong Origins:
SsangYong Motor Company has roots dating back to the Ha Dong-hwan Motor Company, established in 1954, with a history of producing military vehicles and SUVs.
Model Evolution
Musso Development:
Developed in partnership with Mercedes-Benz, inheriting its robust chassis and engine technology, particularly for the early gasoline variants.
Production
Production Period:
1993-2006 (with the 1991-2000 range covered by this manual).
Daewoo Acquisition:
SsangYong was part of the Daewoo Group during the period this manual covers, hence the 'Daewoo Musso' designation in some markets.
๐ Awards & Recognition
Recognitions
Industry Recognition:
While specific awards are not widely documented, the Musso was recognized for its robust chassis and Mercedes-Benz engineering influence.