1993–1999, 1999–2004 Daewoo Musso Service & Repair Manual

This Daewoo Motor Co. service manual covers maintenance, diagnosis, and repair for the 1993–2004 Musso, with separate gasoline and OM600 diesel sections and configuration-specific drivetrain information.

• Engine repair: M161 and M162 gasoline engines and OM600 diesels, including cylinder-head work, timing-chain service, compression testing, and internal inspection.

• Fuel and cooling: Diesel injection-nozzle testing and repair, RIV start-of-delivery checks, cooling-system leak testing, thermostat service, and water-pump replacement.

• Transmission and 4WD: T5WC manual and BTRA M74 overhaul procedures, clutch service, and Part Time 4408 and TOD transfer-case diagnosis and repair.

• Brakes and chassis: ABS/ABD fault diagnosis, hydraulic-unit bleeding, steering-pressure checks, wheel alignment, suspension repairs, and front/rear differential inspection.

• Electrical and body systems: ECU and TCU circuit diagrams, Supplemental Restraint System (SRS) diagnosis, immobilizer troubleshooting, body wiring, and manual/semiautomatic HVAC service.

Suited to technicians and mechanics with scan-tool experience and the equipment needed for internal engine and transmission work.

Engine Mechanical Work and Fuel-System Testing

The gasoline sections distinguish the M161 E20/E23 engines from the M162 E32. OM600 engine procedures focus on OM661LA and OM662LA; 662NA is included in the general vehicle and axle specification tables.

Mechanical coverage extends to crankshafts, pistons, cylinder bores, and camshaft timing, with prechamber and valve-seat work in the diesel chapters. Engine performance curves and OM662LA sectional views accompany torque, clearance, bore/stroke, compression-ratio, and ignition-timing data.

Diesel pump-timing coverage includes the position-sensor and digital-tester RIV methods, with position sensor 617 589 08 21 00 identified in the tool requirements. Intake and exhaust manifold service, turbocharger/intercooler work, and scheduled maintenance charts round out the engine coverage.

Transmission Overhaul and Transfer-Case Diagnosis

Automatic transmission: Detailed overhaul instructions apply to the BTRA M74, including clutch packs, valve-body components, band adjustment, TCU pin descriptions, and shift-pattern diagrams. MB W4A040 specifications and wiring references are included, but this file does not provide a separate W4A040 overhaul procedure.

The BTRA teardown notes warn that hammering the output shaft can permanently damage the thrust-bearing surfaces. The chapter also distinguishes electronic faults from hydraulic and mechanical symptoms.

Manual transmission and 4WD: T5WC coverage includes shaft and synchronizer inspection and pre-installation checks. Part Time 4408 and TOD 4423E sections cover internal repair and control-system diagnosis; the TOD shift motor and oil pump are serviced as assemblies.

TOD fault-code tables link SCAN-100 results to connector, wiring, sensor, and control-unit tests, helping trace a 4WD warning before selecting replacement components. Part Time 4408 service notes also flag case-thread damage from impact tools on the oil plugs.

Brake, Suspension, and Body-System Service

ABS and ABS/ABD 5.0/5.3 coverage separates circuit layouts, self-diagnosis, fault codes, and hydraulic operation. Brake bleeding procedures distinguish master-cylinder, caliper/hose, and hydraulic-unit replacement.

Chassis procedures cover the double-wishbone front suspension and 5-link rear suspension, plus ECS actuator testing, differential gear-contact checks, and power-steering bleeding. Follow the documented vehicle-lifting and support precautions before underbody work.

Electrical references include diesel and gasoline TCU circuits, ABS/ABD hydraulic circuit diagrams, and Starting & Charging (Diesel) wiring. SRS fault charts and immobilizer no-start flowcharts provide system-specific troubleshooting.

HVAC repair procedures cover manual and semiautomatic controls. Full-automatic air-conditioning wiring is included, but the separate full-automatic HVAC repair chapter listed in the contents is absent.

A Preview of Fluid Capacities and Fastener Data

These examples represent a small selection of the manual's service specifications. The M162 E32 cooling system is listed at 11.3 L, while the T5WC transmission oil capacity is 3.4 L.

The BTRA M74 vehicle specifications list final-drive ratios of 5.38 for 661LA and 4.89 for 662LA applications. For the M162 vibration-damper center bolt, the detailed procedure specifies an initial 200–220 Nm followed by a 90° +10° angle stage.

PDF Search, Diagram Access, and Page Count

Search and diagram access: Body text is searchable, but many diagram labels are not. Two embedded bookmarks lead to the section index and table of contents. Small wiring labels require zooming. The E32 Low Mode shift chart on PDF p. 991 may appear blank in some PDF viewers.

One printable English PDF download contains 1,463 pages, including the 12 opening pages of front matter and section indexes. No separate supplement or additional PDF is included.