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1991-1999 Daewoo Musso/SsangYong Musso Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo/SsangYong Model: Musso Model Years Covered: 1991-1999 Codes Chassis Code General: KFC 👋 Introduction Market Position Segment: Compact to Mid-size SUV Positioning: Robust and capable...
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1991-1999 Daewoo Musso/SsangYong Musso Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daewoo/SsangYong
Model:
Musso
Model Years Covered:
1991-1999
Codes
Chassis Code General:
KFC
👋 Introduction
Market Position
Segment:
Compact to Mid-size SUV
Positioning:
Robust and capable SUV, often marketed for its off-road prowess and utility.
Competitive Analysis
Key Competitors Era:
Jeep Cherokee (XJ), Toyota 4Runner, Mitsubishi Pajero/Montero, Ford Explorer, Land Rover Discovery.
Key Features
Vehicle Features:
Body-on-frame construction, available 4WD, diverse engine options including robust diesels, spacious interior for its class.
📋 Manual Details
Coverage Areas
Manual Title:
1991-1999 Daewoo Musso/SsangYong Musso Service Repair Manual
Primary Coverage:
Comprehensive service and repair for Daewoo/SsangYong Musso models (1991-1999)
Exclusion Note:
Excludes wiring diagrams/schematics
Page Count
Estimated Page Count:
Refer to product listing for precise page count (typically extensive for comprehensive manuals of this era)
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Likely PDF or similar digital format; physical copies are also possible for this era
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, cooling, electrical, controls, intake & exhaust for all listed engine variants
Drivetrain Systems:
Suspension (diagnosis, alignment, front, rear, wheels/tires), Drive Axle (front, rear, propeller shaft), Brakes (hydraulic, master cylinder, booster, front/rear discs, ABS, parking), Transmission (automatic, manual, clutch, transfer case - Part Time 4480 and TOD)
Chassis And Body Systems:
Steering (power steering, wheel/column), HVAC (manual, semi-auto, full auto controls), Restraints (seat belts, SRS), Body and Accessories (body wiring, lighting, wipers/washers, instrumentation, audio, seats, glass/mirrors, underbody, bumpers/fenders, doors, roof, front end, remote keyless entry, anti-theft, control units, immobilizer)
Procedures Included
Maintenance Procedures:
Routine servicing, inspections, adjustments, fluid changes, filter replacements
Repair Procedures:
Overhauling, disassembly, reassembly, component replacement, troubleshooting for all covered systems
Diagnostic Procedures:
System diagnosis, fault finding, component testing
Technical Depth
Depth:
Comprehensive, suitable for qualified technicians; covers detailed repair and overhaul procedures
📊 Manual Specifications
File Format
Digital Format Details:
Searchable text, printable pages, high-resolution images/diagrams (if digital)
Print Quality
Print Quality Details:
Clear, legible text and diagrams, durable paper (if physical copy)
Binding Type
Binding:
Comb binding, coil binding, or perfect binding (common for service manuals)
Paper Type
Paper Type:
Durable, high-quality paper suitable for workshop environments
⚙️ Engine Specifications
Primary Engine
Engine Options:
2299cc In-line 4 Diesel (OM601), 2874cc In-line 5 Diesel (OM602), 1998cc In-line 4 Gasoline (E20), 2295cc In-line 4 Gasoline (E23), 3199cc In-line 6 Gasoline (E32), 2299cc In-line 4 Diesel (SY662LA), 2874cc In-line 5 Diesel (SY662LA)
Engine Details Om601
Engine Code Om601:
OM601
Displacement Om601:
2299 cc
Configuration Om601:
In-line 4-Cylinder
Fuel Type Om601:
Diesel
Engine Details Om602
Engine Code Om602:
OM602
Displacement Om602:
2874 cc
Configuration Om602:
In-line 5-Cylinder
Fuel Type Om602:
Diesel
Engine Details E20
Engine Code E20:
E20
Displacement E20:
1998 cc
Configuration E20:
In-line 4-Cylinder
Fuel Type E20:
Gasoline
Engine Details E23
Engine Code E23:
E23
Displacement E23:
2295 cc
Configuration E23:
In-line 4-Cylinder
Fuel Type E23:
Gasoline
Engine Details E32
Engine Code E32:
E32
Displacement E32:
3199 cc
Configuration E32:
In-line 6-Cylinder
Fuel Type E32:
Gasoline
Engine Details Sy662La
Engine Code Sy662La:
SY662LA
Displacement Sy662La:
2299 cc / 2874 cc
Configuration Sy662La:
In-line 4-Cylinder Diesel / In-line 5-Cylinder Diesel
Fuel Type Sy662La:
Diesel
Performance
Hp And Torque Range:
Specific HP and torque figures vary significantly by engine. The manual provides detailed specifications for each variant. Diesel engines typically focus on torque for towing and off-road capability.
Fuel System
Fuel Delivery Diesel:
Indirect Injection (likely with rotary or inline injection pumps, depending on the specific OM60x variant)
Fuel Delivery Gasoline:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
Transmission Options:
Manual Transmission, Automatic Transmission
Manual Transmission
Manual Maker:
Tremec
Manual Model:
T5
Automatic Transmission
Automatic Maker:
BTRA
Automatic Model:
W4A040 or M74 4WD
Features
Transfer Case Options:
Part Time 4480, TOD (Torque-On-Demand)
📐 Dimensions
Exterior
Body Style:
5-door SUV
Wheelbase Typical:
Approximately 2650 mm (varies slightly by specific model/year)
Weights
Curb Weight Range:
Generally 1800 kg to 2000 kg+ depending on engine and drivetrain configuration.
🛡️ Safety Features
Ratings
Safety Ratings Era:
Safety standards and testing varied significantly during the 1991-1999 period. Official NCAP or IIHS ratings for this specific model might be limited or unavailable. The manual covers SRS (Supplemental Restraint System) components.
Active Features
Active Safety Features:
Optional ABS (Antilock Brake System) mentioned.
Passive Features
Passive Safety Features:
Seat belts, potential for front airbags (covered under SRS in the manual).
💡 Technology Features
Infotainment
Infotainment Systems Era:
Basic for the period. Likely featured analog radio, cassette player, and optional CD player. Manual covers audio system components.
Driver Assistance
Driver Assistance Features:
ABS was an optional advanced feature for its time. No electronic stability control or advanced driver aids.
Connectivity
Connectivity Features:
Remote keyless entry and anti-theft system covered in the manual, indicating basic security technology.
🔧 Maintenance
Service Intervals
General Guidelines:
The manual provides detailed service intervals. Typical intervals for this era would include: Oil and Filter Change: 5,000-10,000 km (3,000-6,000 miles) or 6-12 months. Air Filter: 20,000-40,000 km (12,000-24,000 miles). Fuel Filter: 40,000-60,000 km (24,000-36,000 miles). Spark Plugs (Gasoline): 40,000-80,000 km (24,000-48,000 miles). Timing Belt (if applicable, check specific engine): 80,000-100,000 km (48,000-60,000 miles). Coolant Flush: Every 2-4 years. Transmission Fluid: 40,000-80,000 km (24,000-48,000 miles). Differential/Transfer Case Fluid: 50,000-100,000 km (30,000-60,000 miles).
Fluid Specifications
Engine Oil Type Diesel:
API CD or higher, SAE 15W-40 or 10W-30 depending on climate. Manual will specify exact viscosity and capacity.
Engine Oil Type Gasoline:
API SG/SH or higher, SAE 10W-30 or 5W-30. Manual will specify exact viscosity and capacity.
Coolant Type:
Ethylene Glycol based antifreeze, mixed with distilled water. Manual will specify ratio and type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Auto:
Dexron II or equivalent (BTRA W4A040 typically uses this). Manual will specify exact type and capacity.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90. Manual will specify exact type and capacity.
Transfer Case Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90. Manual will specify exact type and capacity.
Power Steering Fluid:
ATF (Automatic Transmission Fluid) or dedicated power steering fluid. Manual will specify.
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, brake components, exhaust system, turbocharger (if equipped with turbo diesel), glow plugs (diesel engines).
Diesel Engine Considerations:
Glow plug system reliability, injection pump maintenance, potential for injector issues with poor fuel quality. OM60x series are generally robust but require diligent maintenance.
Gasoline Engine Considerations:
Performance of the smaller gasoline engines might be considered adequate rather than powerful. Coil pack or distributor issues on some older gasoline engines.
📚 Vehicle History
Brand Heritage
Daewoo Automotive:
Daewoo Motors was a South Korean automobile manufacturer founded in 1982, though its roots go back further. It was acquired by General Motors in 2002.
Ssangyong Automotive:
SsangYong Motor Company is a South Korean automobile manufacturer. The Musso was originally developed by SsangYong Motor Company, known for its SUVs and trucks, and later marketed under the Daewoo brand in some markets.
Model Evolution
Musso Development:
The SsangYong Musso was first introduced in 1993, designed by Ken Greenley. It was based on the chassis of the Mercedes-Benz W124 E-Class.
Engine Collaboration:
The use of Mercedes-Benz OM601 and OM602 diesel engines highlights an earlier technical collaboration between SsangYong and Mercedes-Benz.
Production
Production Period:
1993-2006 (overall, with this manual covering the 1991-1999 period).
🏆 Awards & Recognition
Recognitions
Model Awards:
Specific awards for the Daewoo/SsangYong Musso during this period are not widely documented in major automotive publications. Its reputation was more built on its utility and robust construction, especially with the diesel engines.
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