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SECTION INDEX
SERVICE MANUAL
FRONT MATTER
0A
KORANDO
GENERAL INFORMATION
0B
ENGINE
1
SUSPENSION
2
FOREWORD
This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval. The right is reserved to make changes at any time without notice.
DRIVE LINE/AXLE
3
BRAKES
4
TRANSMISSION
5
STEERING HVAC (HEATING, VENTILATION, AND AIR CONDITIONING)
6
7
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
RESTRAINTS
8
BODY AND ACCESSORIES
9
PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedure are essential for the safe, reliable operation of all motor vehicles, as well as for the personal safety of the person doing the repair. There are many variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skills of the people doing the work. This manual cannot possibly anticipate all such variations and provide advice or precautions for each. Anyone who deviates from the instructions provided in this manual must ensure their own safety and preserve the safety and integrity of the vehicle. The following list contains general precautions that should always be followed while working on a vehicle.
· · · · · · · ·
Safety stands are required whenever a procedure calls for underbody work. Do not smoke when you work on a vehicle. To prevent serious burns, do not touch any hot metal parts. Set the parking brake when you work on the vehicle. Turn the ignition switch OFF unless a procedure states otherwise. The engine may operate only in a well-ventilated area. Avoid moving parts when the engine is running. Safety glasses must be worn for eye protection.
KORANDO Service Manual
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and removal and installation of components for the KORANDO vehicle. When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice.
Daewoo Motor Company, Limited Overseas Technical Service Department 391-9 Chong Chon-2 Dong, Pu Pyung-Gu, Inchon, Korea Tel : 82-32-509-4161 ~ 4164 Fax : E-mail : 82-32-509-4160 [email protected] [email protected]
Daewoo Motor Company, Limited All rights Reserved No part of this publication may be reproduced, stored in any retrieval system or transmitted, in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Daewoo Motor Company, Limited
TABLE OF CONTENTS
Section 0A Section 0B Section 1 Section 1A1 Section 1B1 Section 1D1 Section 1E1 Section 1F1 Section 1G1 Section 1A2 Section 1B2 Section 1D2 Section 1E2 Section 1F2 Section 1G2 Section 1A3 Section 1B3 Section 1D3 Section 1E3 Section 1F3 Section 1G3 Section 2 Section 2A Section 2B Section 2C Section 2D Section 2E Section 3 Section 3A Section 3C Section 3D Section 4 Section 4A Section 4B Section 4C Section 4D Section 4E Section 4F Section 4G Front Matter General Information Engine M162 General Engine Information M162 Engine Mechanical M162 Engine Cooling M162 Engine Electrical M162 Engine Controls M162 Engine Intake & Exhaust M161 General Engine Information M161 Engine Mechanical M161 Engine Cooling M161 Engine Electrical M161 Engine Controls M161 Engine Intake & Exhaust OM600 General Engine Information OM600 Engine Mechanical OM600 Engine Cooling OM600 Engine Electrical OM600 Engine Controls OM600 Engine Intake & Exhaust Suspension Suspension Diagnosis Wheel Alignment Front Suspension Rear Suspension Tires and Wheels Drive Line / Axle Front Drive Axle Propeller Shaft Rear Drive Axle Brakes Hydraulic Brakes Master Cylinder Power Booster Front Disc Brakes Rear Disc Brakes Antilock Brake System Parking Brakes Section 5 Section 5A Section 5B Section 5C Section 5D1 Section 5D2 Section 6 Section 6A Section 6E Section 7 Section 7B/C Transmission Automatic Transmission Manual Transmission Clutch Transfer Case (Part Time 4480) Transfer Case (TOD) Steering Power Steering System Steering Wheel and Column HVAC (Heating, Ventilation & Air Conditioning) Manual Control/Semiauto Temperature Control Heationg, Ventilation, and Air Conditioning System Full Automatic Temperature Control Heationg, Ventilation, and Air Conditioning System Restraints Seat Belts Supplemental Restraint System (SRS) Body and Accessories Body Wiring System Lighting Systems Wipers/Washer Systems Instrumentation/Driver Information Audio Seats Glass and Mirrors Front and Under Body Bumpers and Fenders Doors Roof Body Front End Remote Keless Entry and Anti-Theft System Control Units and System Switches Immobilizer System
Section 7D
Section 8 Section 8A Section 8B Section 9 Section 9A Section 9B Section 9D Section 9E Section 9F Section 9H Section 9L Section 9N Section 9O Section 9P Section 9Q Section 9R Section 9T Section 9U Section 9V Section 9W
KORANDO SERVICE MANUAL
ISSUED BY OVERSEAS TECH. SERVICE DAEWOO MOTOR CO., LTD. 391-9 CHONG CHON-2DONG, PU PYUNG-GU, INCHON, KOREA TELEPHONE : 82-32-509-4161~4164 FACSIMILE : 82-32-509-4160
ENGINE CONTENTS
SECTION 1A1 M162 GENERAL ENGINE INFORMATION ENGINE MECHANICAL ENGINE COOLING ENGINE ELECTRICAL ENGINE CONTROLS ENGINE INTAKE & EXHAUST GENERAL ENGINE INFORMATION ENGINE MECHANICAL ENGINE COOLING ENGINE ELECTRICAL ENGINE CONTROLS ENGINE INTAKE & EXHAUST
SECTION 1B1 M162 SECTION 1D1 M162 SECTION 1E1 SECTION 1F1 M162 M162
SECTION 1G1 M162 SECTION 1A2 M161
SECTION 1B2 M161 SECTION 1D2 M161 SECTION 1E2 SECTION 1F2 M161 M161
SECTION 1G2 M161 SECTION 1A3
OM600 GENERAL ENGINE INFORMATION
SECTION 1B3 OM600 ENGINE MECHANICAL SECTION 1D3 OM600 ENGINE COOLING SECTION 1E3 SECTION 1F3 OM600 ENGINE ELECTRICAL OM600 ENGINE CONTROLS
SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST
SUSPENSION CONTENTS
SECTION 2A SECTION 2B SECTION 2C SECTION 2D SECTION 2E
SUSPENSION DIAGNOSIS WHEEL ALIGNMENT FRONT SUSPENSION REAR SUSPENSION TIRES AND WHEELS
DRIVE LINE / AXLE CONTENTS
SECTION 3A SECTION 3C SECTION 3D
FRONT DRIVE AXLE PROPELLER SHAFT REAR DRIVE AXLE
BRAKE CONTENTS
SECTION 4A SECTION 4B SECTION 4C SECTION 4D SECTION 4E SECTION 4F SECTION 4G
HYDRAULIC BRAKES MASTER CYLINDER POWER BOOSTER FRONT DISC BRAKES REAR DISC BRAKES ANTILOCK BRAKE SYSTEM PARKING BRAKE
TRANSMISSION CONTENTS
SECTION 5A SECTION 5B SECTION 5C
AUTOMATIC TRANSMISSION MANUAL TRANSMISSION CLUTCH
SECTION 5D1 TRANSFER CASE (PART TIME 4408) SECTION 5D2 TRANSFER CASE (TOD)
STEERING CONTENTS
SECTION 6A SECTION 6E
POWER STEERING SYSTEM STEERING WHEEL AND COLUMN
HVAC (HEATING, VENTILATION & AIR CONDITIONING) CONTENTS
SECTION 7B/C
MANUAL CONTROL/SEMIAUTO TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM FULL AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
SECTION 7D
RESTRAINTS CONTENTS
SECTION 8A SECTION 8B
SEAT BELTS SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
BODY AND ACCESSORIES CONTENTS
SECTION 9A SECTION 9B SECTION 9C SECTION 9D SECTION 9E SECTION 9F SECTION 9G SECTION 9H SECTION 9L SECTION 9M SECTION 9N SECTION 9O SECTION 9P SECTION 9Q SECTION 9R SECTION 9T
BODY WIRING SYSTEM LIGHTING SYSTEM HORNS WIPERS/WASHER SYSTEM INSTRUMENTATION/DRIVER INFORMATION AUDIO SYSTEM INTERIOR TRIM SEATS GLASS AND MIRRORS EXTERIOR TRIM FRAME AND UNDERBODY BUMPERS AND FASCIAS DOORS ROOF BODY FRONT END REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM SECTION 9U CONTROL UNITS AND SYSTEM SECTION 9V SWITCHES SECTION 9W IMMOBILIZER SYSTEM
SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 Vehicle Dimensions and Weights . . . . . . . . . . 0B-5 Standard Bolts Specifications . . . . . . . . . . . . . 0B-6 Maintenance and Repair . . . . . . . . . . . . . . . 0B-7 Maintenance and Lubrication . . . . . . . . . . . . . 0B-7 Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . 0B-7 Explanation of Scheduled Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-7 Scheduled Maintenance Charts (Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . 0B-8 Scheduled Maintenance Charts (Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . 0B-10 Owner Inspections and Services . . . . . . . 0B-12
While Operating the Vehicle . . . . . . . . . . . . . At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . At Least Twice A Month . . . . . . . . . . . . . . . . At Least Monthly . . . . . . . . . . . . . . . . . . . . . . At Least Twice a Year . . . . . . . . . . . . . . . . . . Each Time The Oil is Changed . . . . . . . . . . . At Least Annually . . . . . . . . . . . . . . . . . . . . . Recommended Fluids and Lubricants . . . . . General Description and System Operation . . . . . . . . . . . . . . . . . . . . . . . . General Repair Instructions . . . . . . . . . . . . . Vehicle Identification Number System . . . . . . Vehicle Lifting Procedures . . . . . . . . . . . . . . 0B-12 0B-12 0B-12 0B-12 0B-12 0B-13 0B-13 0B-14
0B-15 0B-15 0B-16 0B-19
SPECIFICATIONS
TECHNICAL DATA
Performance-Manual Transaxle
Application Maximum Speed (Km/h) Minimum Turning Radius (m) 661LA 140 5.8 662NA 137 5.8 662LA 148 5.8 2.0L DOCH 2.3L DOCH 3.2L DOCH 154 5.8 165 5.8 176 5.8
Performance-Autumatic Transaxle
Application Maximum Speed (Km/h) Minimum Turning Radius (m) 661LA 140 5.8 662NA 137 5.8 662LA 140 5.8 2.3L DOCH 160 5.8 3.2L DOCH 170 5.8
0B-2 GENERAL INFORMATION
Engine
Application Engine Type Bore (mm) Stroke (mm) Total Displacement (cc) Compression Ratio Maximum Power (ps/rpm) Maximum Torque (kg.m/rpm) 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH 6Cylinder GASOLINE 89.9 84 3199 10:1 222/5500 31.6/3750 4Cylinder 5Cylinder 5Cylinder 4Cylinder 4Cylinder DIESEL GASOLINE GASOLINE DIESEL DIESEL 90.9 89.9 89 89 89 88.4 78.7 92.4 92.4 92.4 2295 1998 2874 2874 2299 10.4:1 9.6:1 22:1 22:1 22:1 95/4000 120/4000 135/5500 149/5500 101/4000 21.5/2400 19.6/2400 25.5/2400 19.3/4000 22.4/4000
Ignition System
Application Ignition Type Ignition Timing (BOTH) Ignition Sequence Spark Plug Gap (mm) Spark Plug Maker Spark Plug Type 2.0L DOHC 6°± 2° 1-3-4-2 0.8 ± 0.1 2.3L DOHC Distributorless ignition 6°± 2° 1-3-4-2 0.8 ± 0.1 Bosch, Chapion, Beru F8DC4(BOSCH) C11YCC(CHAMPION) 14F8DU4(BERU) 3.2L DOHC 8°± 2° 1-5-3-6-2-4 0.8 ± 0.1
Clutch - Manual Type
Application Type Outside Diameter (mm) Inside Diameter (mm) Thickness Fluid 661LA 225 150 9.2 662NA 225 150 9.2 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC Single Dry Diaphram 240 150 9.2 225 150 9.2 225 150 9.2 240 155 9.3
Common use :Brake Fluid
Manual Transmission
Application Maker Type or Model Gear Ratio : 1st 2nd 3rd 4th 5th Reverse Final Drive Ratio Oil Capacity (L) 661LA TREMEC T5 3.969 2.341 1.457 1.000 0.851 3.705 4.55 3.4 662NA TREMEC T5 3.969 2.341 1.457 1.000 0.851 3.705 4.55 3.4 662LA TREMEC T5 3.969 2.341 1.457 1.000 0.851 3.705 4.27 3.4 2.0L DOHC 2.3L DOHC 3.2L DOHC TREMEC T5 3.969 2.341 1.457 1.000 0.851 3.705 4.89 3.4 TREMEC T5 3.969 2.341 1.457 1.000 0.851 3.705 4.55 3.4 TREMEC T5 3.969 2.341 1.457 1.000 0.851 3.705 3.73 3.4
GENERAL INFORMATION 0B-3
Auto Transmission
Application Maker Type or Model Gear Ratio : 1st 2nd 3rd 4th Reverse Final Drive Ratio Oil Capacity (L) 661LA BTRA M74 4WD 2.741 1.508 1.000 0.708 2.429 5.38 9 662LA BTRA M74 4WD 2.741 1.508 1.000 0.708 2.429 4.89 9 2.3L DOHC BTRA M74 4WD 2.741 1.508 1.000 0.708 2.429 5.86 9 3.2L DOHC BTRA M74 4WD 2.741 1.508 1.000 0.708 2.429 4.89 9
Brake
Application non-ABS Booster Size ABS 5.0 ABS 5.3 Master Cylinder Diameter (mm) Booster Ratio Front Brake : Disc Type Rear Brake : Disc Type Specifications 8inch + 9inch 7inch + 8inch 8inch + 9inch f 25.4 5.6 : 1 Ventilated Solid
Tire and Wheel
Application Standard Tire Size Standard Wheel Size Inflation Pressure At Full Lode P235 / 75 : Front Rear P255 / 75 : Front Rear Specifications P235/75 R15, 255/70 R15 7JJ ´ 15 30 Psi 30 Psi 30 Psi 30 Psi
Steering System
Application Gear Type Wheel Alignment: Front : Toe-in Front : Caster Front : Camber Oil Capacity Specifications RACK & PINION 0 - 4 mm 2 °30' ± 30' 0 ± 30' ° 1L
0B-4 GENERAL INFORMATION
Suspension
Application Front Type Rear Type Specifications Double Wishbone 5 - Link
Fuel System
Application Fuel Pump Type Fuel Capacity Specifications Electric Motor Pump 70 L
Lubricating System
Lubricating Type Oil Pump Type Oil Filter Type Oil Capacity (L) (Including Oil Filter) 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC External Gear pump Full Flow 7.2 7.5 8.2 9.5
Combination(Full & Part) 8.0 9.0
Cooling System
Cooling Type Coolant Capacity (L) Radiator Type Water Pump Type 661LA 9.5-10 662NA 10.5 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC 10.5 11.3 10.5 - 11 10.5 Forced Circulation Centrifugal
Electric System
Application Battery (MF) Generator Starter 661LA 75A 2.2kw 662NA 75A 2.2kw 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC 12V - 90AH 75A 2.2kw 75A 1.2kw 115A 1.2kw 115A 1.7kw
GENERAL INFORMATION 0B-5
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application Overall Length (mm) Overall Width (mm) Overall Height (mm) Wheel Base (mm) Tread : Front (mm) Rear (mm) Application 4330 1841 1840 2840 1510 1520
Vehicle Weights
Application Manual : Curb Weight (kg) Gross Vehicle Weight (kg) Automatic : Curb Weight (kg) Gross Vehicle Weight (kg) Passenger Capacity 661LA 1790 2515 1810 2515 5 662NA 1810 2515 1815 2515 5 662LA 1830 2515 1850 2515 5 2.0L DOHC 2.3L DOHC 3.2L DOHC 1790 2515 5 1790 2515 1810 2515 5 1840 2515 1860 2515 5
0B-6 GENERAL INFORMATION
STANDARD BOLTS SPECIFICATIONS
Torque (N·m / Ib-in) Bolt* M3 ´ 0.5 M4 ´ 0.7 M5 ´ 0.8 M6 ´ 1.0 M8 ´ 1.25 M10 ´ 1.25 M10 ´ 1.5 M12 ´ 1.25 M12 ´ 1.75 M14 ´ 1.5 M16 ´ 1.5 M18 ´ 1.5 M20 ´ 1.5 M22 ´ 0.5 M24 ´ 1.5 M24 ´ 2.0 4T · 0.5 N·m (4.5 lb-in) 1.2 N·m · (11 lb-in) 2.4 N·m · (22 lb-in) 4.0 N·m · (36 lb-in) 8.6 N·m · (77 lb-in) · 18.6 N·m (14 lb-in) 18.6 N·m · (14 lb-in) 34.3 N·m · (25lb-in) 32.3 N·m · (24 lb-in) 54.0 N·m · (40 lb-in) 81.3 N·m · (60 lb-in) 117.6 N·m · (87 lb-in) 166.6N·m · (123 lb-in) 225.4N·m · (167 lb-in) 284.2 N·m · (210 lb-in) 274.4 N·m · (203 lb-in) Standard 7T 0.9 N·m · (8 lb-in) 2.0 N·m · (18 lb-in) 4.0 N·m · (36 lb-in) 6.7 N·m · (60 lb-in) 15.7 N·m · (12 lb-in) 32.3 N·m · (24 lb-in) 30.4 N·m · (22 lb-in) 56.8 N·m · (42 lb-in) 53.9 N·m · (40 lb-in) 89.2 N·m · (66 lb-in) 107.8 N·m · (80 lb-in) 196.0 N·m · (145 lb-in) 274.4 N·m · (203 lb-in) 372.4 N·m · (276 lb-in) 480.2 N·m · (355 lb-in) 460.6 N·m · (341 lb-in) 9T 1.3 N·m · (12 lb-in) 3.0 N·m · (27 lb-in) 5.6 N·m · (50 lb-in) 9.7 N·m · (87 lb-in) 22.5 N·m · (17 lb-in) 46.0 N·m · (34 lb-in) 44.1 N·m · (33 lb-in) 82.3 N·m · (61 lb-in) 77.4 N·m · (57 lb-in) 127.4 N·m · (94 lb-in) 196.0 N·m · (145 lb-in) 284.2 N·m · (210 lb-in) 392.0 N·m · (290 lb-in) 529.2 N·m · (392 lb-in) 686.0 N·m · (508 lb-in) 666.4 N·m · (493 lb-in) 4T 0.7 N·m · (6.3 lb-in) 1.6 N·m · (14 lb-in) 3.1 N·m · (28 lb-in) 5.4 N·m · (49 lb-in) 12.7 N·m · (9 lb-in) 25.5 N·m · (19 lb-in) 24.5 N·m · (18 lb-in) 45.0 N·m · (33 lb-in) 43.1 N·m · (32 lb-in) 71.6 N·m · (53 lb-in) 107.8 N·m · (80 lb-in) 156.8 N·m · (116 lb-in) 215.6 N·m · (160 lb-in) 294.0 N·m · (218 lb-in) 382.2 N·m · (283 lb-in) 372.4 N·m · (276 lb-in) Limit 7T 1.2 N·m · (11 lb-in) 2.6 N·m · (23 lb-in) 5.2 N·m · (47 lb-in) 9.0 N·m · (81 lb-in) 20.6 N·m · (15.2 lb-in) 42.1 N·m · (31 lb-in) 41.2 N·m · (30 lb-in) 75.5 N·m · (56 lb-in) 71.5 N·m · (53 lb-in) 117.6 N·m · (87 lb-in) 186.2 N·m · (138 lb-in) 264.6 N·m · (196 lb-in) 362.6 N·m · (268 lb-in) 490.0 N·m · (362 lb-in) 637.0 N·m · (471 lb-in) 617.4 N·m · (457 lb-in) 9T 17 N·m · (15 lb-in) 4.0 N·m · (36 lb-in) 7.6 N·m · (68 lb-in) 12.7 N·m · (114 lb-in) 30.4 N·m · (22 lb-in) 60.8 N·m · (31 lb-in) 58.8 N·m · (44 lb-in) 107.8 N·m · (80 lb-in) 98.0 N·m · (73 lb-in) 166.6 N·m · (123 lb-in) 264.6 N·m · (196 lb-in) 372.4 N·m · (276 lb-in) 519.4 N·m · (384 lb-in) 705.6 N·m · (522 lb-in) 921.2 N·m · (682 lb-in) 891.8 N·m · (660 lb-in)
*Diameter ´ pitch in millimeters
GENERAL INFORMATION 0B-7
MAINTENANCE AND REPAIR MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE
The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: l To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to "Tire and Wheel" in section 2E. l To be driven on reasonable road surfaces and within legal operating limits.
Fuel Filter Replacement
Replace the engine fuel filter every. l Gasoline Engine : 60,000km (36,000 miles) l Diesel Engine : 45,000km (24,000 miles)
Spark Plug Replacement
Replace spark plugs with same type. l Type : BOSCH : F8DC4 BERU : 14F-8DU4 Champion : C11YCC l Gap : 0.8 ± 0.1 mm
EXPLANATION OF SCHEDULED MAINTENANCE SERVICES
The services listed in the maintenance schedule are further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants.
Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed.
Brake System Service
Check the disc brake pads or the drum brake linings. Check the pad and the lining thickness carefully.
Engine Oil and Oil Filter Change
Always use above the API SH grade or recommended engine oil.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type)
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section.
Air Cleaner Element Replacement
Clean the air cleaner element every. l Gasoline Engine : 15,000km (10,000 miles) l Diesel Engine : 10,000km (6,000 miles) Replace the air cleaner element every . l Gasoline Engine : 60,000km (36,000 miles) l Diesel Engine : 30,000km (18,000 miles) Replace the air cleaner more often under dusty conditions
0B-8 GENERAL INFORMATION
SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)
Engine
MAINTENANCE INTERVAL MAINTENANCE ITEM Drive belt Engine oil & filter Cooling system hose & connections Engine coolant Fuel filter Fuel line & connections Air cleaner Ignition timing Spark plugs Charcoal canister & vapor lines (1) (3) (3) (2) (2) x1,000 km Months Kilometers or time in months, whichever comes first 1 15 12 30 24 45 36 60 48 75 60 90 72 105 84 120 96
I I I I I
-
I R I I I I I I -
I R I I I I I R -
I R I I I I I I I
I R I R R I R I R -
I R I I I I I -
I R I I I I I R I
I R I I I I I I -
I R I R R I R I R -
Chart Symbols: I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R - Replace or change. (1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition. Change engine oil and the filter every 7,500 km or 6 months, whichever comes first. (2) More frequent maintenance is required if under dusty driving condition. (3) Refer to "Recommended fluids and lubricants".
GENERAL INFORMATION 0B-9
Chassis and Body
MAINTENANCE INTERVAL x1,000 km MAINTENANCE Months ITEM Exhaust pipes & mountings Brake/Clutch fluid (3)(4) Parking brake/Brake pads F & R (5) Brake line & connections (including booster) Manual transmission oil (3) Clutch & brake pedal free play Front & Rear Differential Fluid (3) Transfer case fluid Automatic transmission fluid (MB W4A040) (6) Automatic transmission fluid (BTRA M74) Chassis & underbody bolts & nuts tight/secure Tyre condition & inflation pressure Wheel alignment (7) Steering wheel & linkage Power steering fluid & lines* (3) Drive shaft boots Seat belts, buckles & anchors Lubricate locks, hinges & bonnet latch Kilometers or time in months, whichever comes first 1 15 12 30 24 45 36 60 48 75 60 90 72 105 84 120 96
I I I
I
I I I I
I I I I I I I I I I I I I I I I I
I R I I I I I I I I I I I I I I I
I I I I R I R R R I I I I I I I I
I R I I I I I
I
I I I I I I I I I
I I I I I I I I I I I I I I I I I
I R I I R I R R R I I I I I I I I
I I I I I I I
I
I R I I I I I
I
I I I I I I I I I
I I I I I I I I
Inspect & ADJUST when abnormal condition is noted
I
Chart Symbols : I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R - Replace or change. (3) Refer to "Recommended fluids and lubricants". (4) Change the brake / clutch fluid every 15,000 km if the vehicle is mainly driven under severe conditions: - Driving in hilly or mountainous terrain, or - Towing a trailer frequently (5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low speed operation in stop-and-go traffic or driving in dusty condition. (6) Change automatic transaxle fluid and filter every 75,000 km if the vehicle is mainly driven under severe conditions. - In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or - In hilly or mountainous terrain, or - When doing frequent trailer towing, or - Uses such as found in taxi, police or delivery service. (7) If necessary, rotate and balance wheels.
0B-10 GENERAL INFORMATION
SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)
Engine
MAINTENANCE INTERVAL MAINTENANCE ITEM
Drive belt Engine oil & fillter (1) Cooling system hose & connections Engine coolant Fuel filter Fuel line & connections Glow plug Pre - fuel filter Air cleaner Ignition timing (see NOTE 1) x1,000 km Months (3) (3) (2) 1 10 6 20 12 30 18 40 24 50 30 60 36 70 42 80 48 90 54 100 60
I
R
I
R
I R I I I I I I I
I R I
I R I R I I I I I
I R I
I R I R I I I R I
I R I
I R I
I R I R I I R I
I R I I I I I I I
I
I I I I
I I R I
I I I I
I I I I
(2)
I R I I I
NOTE 1 : Injection Timing : Adjust as required : - When excessive smoke is visible (black or white) - Poor performance/economy Chart Symbols: I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R - Replace or change. (1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition, change engine oil every 5,000km or 3 months, whichever comes first. (2) More frequent maintenance is required if under dusty driving conditing. (3) Refer to "Recommended fluids and lubricants".
GENERAL INFORMATION 0B-11
Chassis and Body
MAINTENANCE INTERVAL MAINTENANCE ITEM
x1,000 km 1 Months Exhaust pipes & mountings Brake/clutch fluid (3) (4) Parking brake/Brake pads (F & R) (5) Brake line & connections (including booster) Manual transmission fluid (3) Clutch & brake pedal free play F & R Differential fluid (3) Transfer case fluid (3) Automatic transmission fluid (BTRA M74) (6) Chassis & underbody bolts & nuts tight/secure Tyre condition & inflation pressure Wheel alignment (7) Steering wheel & linkage Power steering fluid & lines* (3) Drive shaft boots Seat belts, buckles & anchors Lubricate locks, hinges & bonnet latch Kilometers or time in months, whichever comes first 10 6 20 12 30 18 40 24 50 30 60 36 70 42 80 48 90 54 100 60
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Inspect & ADJUST when abnormal condition is noted
I I I
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Chart Symbols : I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R - Replace or change. (3) Refer to "Recommended fluids and lubricants". (4) Change the brake / clutch fluid more regularly if the vehicle is mainly driven under severe conditions : - Driving in hilly or mountainous terrain, or - Towing a trailer frequently (5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low speed operation in stop-and-go traffic or driving in dusty condition. (6) Change automatic transmission fluid every 70,000 km if the vehicle is mainly driven under severe conditions. - In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or - In hilly or mountainous terrain, or - When doing frequent trailer towing, or - Uses such as found in taxi, police or delivery service. (7) If necessary, rotate and balance wheels.
0B-12 GENERAL INFORMATION
OWNER INSPECTIONS AND SERVICES
WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check all the button locations.
5. Add oil, if needed, to keep the oil level above the lower mark. Avoid overfilling the engine, since this may cause engine damage. 6. Push the indicator all the way back down into the engine after taking the reading. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking. Also, if the brake warning light goes on, or flashes, something may be wrong with part of the brake system.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if necessary.
Exhaust System Operation
Be alert to any changes in the sound of the system or the smell of the fumes. These are signs that the system may be leaking or overheating. Have the system inspected and repaired immediately.
AT LEAST TWICE A MONTH
Tire And Wheel Inspection and Pressure Check
Check the tire for abnormal wear or damage. Also check for damaged wheels. Check the tire pressure when the tires are cold (check the spare also, unless it is a stowaway). Maintain the recommended pressures. Refer to "Tire and Wheel" is in section 0B.
Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats at normal highway speeds. This may mean a wheel needs to be balanced. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or a wheel alignment.
AT LEAST MONTHLY
Light Operation
Check the operation of the license plate light, the headlights (including the high beams), the parking lights, the fog lights, the taillight, the brake lights, the turn signals, the backup lights and the hazard warning flasher.
Steering System Operation
Be alert to changes in the steering action. An inspection is needed when the steering wheel is hard to turn or has too much free play, or is unusual sounds are noticed when turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately.
Engine Oil Level
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 6A, Power Steering System.
Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm. 1. After stopping the engine, wait a few minutes for the oil to drain back to the oil pan. 2. Pull out the oil level indicator (dip stick). 3. Wipe it clean, and push the oil level indicator back down all the way. 4. Pull out the oil level indicator and look at the oil level on it.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced. Check the breather hole in the reservoir cover to be free from dirt and check for an open passage.
GENERAL INFORMATION 0B-13
Weather-Strip Lubrication
Apply a thin film silicone grease using a clean cloth.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and Operation
Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors.
EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect the disc brake pads for wear. Inspect the rotors for surface condition. Inspect other brake parts, the parking brake, etc., at the same time. Inspect the brakes more often if habit or conditions result in frequent braking.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire, all the jacking equipment, and the tools must be securely stowed at all times. Oil the jack ratchet or the screw mechanism after each use.
Steering, Suspension and Front Drive Axle Boot And Seal Inspection
Inspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears or leakage. Replace the seals if necessary.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood, the fuel door, the rear compartment hinges and the latches, the glove box and the console doors, and any folding seat hardware.
Exhaust System Inspection
Inspect the complete system (including the catalytic converter if equipped). Inspect the body near the exhaust system. Look for broken, damaged, missing, or out-ofposition parts as well as open seams, holes, loose connections, or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment.
Underbody Flushing
Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control. At least every spring clean the underbody. First, loosen the sediment packed in closed areas of the vehicle. Then flush the underbody with plain water.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding, damaged, or missing parts. Lubricate all linkage joints and throttle cable joints, the intermediate throttle shaft bearing, the return spring at throttle valve assembly, and the accelerator pedal sliding face with suitable grease. Check the throttle cable for free movements.
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the fluid is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the proper mixture in order to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper tension. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly.
0B-14 GENERAL INFORMATION
RECOMMENDED FLUIDS AND LUBRICANTS
Usage Engine Oil (Change with filter) 3.2L DOHC 2.3L DOHC 662LA 661LA Capacity 8.2 L 7.5 L 9.5 L 8.0 L Fluid/Lubricant Quality class - API ; SH grade or above ACEA ; A2 or A3 MB sheet ; 229.1 Viscosity - MB sheet ; 224.1 Quality class - API ; CG grade or above ACEA ; B2 or B3 MB sheet ; 228.1, 228.3, 228.5, 229.1 Viscosity - MB sheet ; 224.1 ALUTEC P-78
Engine Coolant
3.2L DOHC 2.3L DOHC 662LA 661LA
Brake / Clutch Fluid
Power Steering System Parking Brake Cable Hood Latch Assembly Hood and Door Hinges Fuel Door Hinge Rear Compartment Lid Hinges Weatherstrips
11.3 L 10.5 L 10.5 - 11.0 L 9.5 - 10.0 L Approx. 0.5L level must be maintained between MAX & MIN level 1.0 L As required As required As required
DOT-3 & SAE J 1703
ATF DEXRON-II Grease Grease Spray type grease
As required
Silicone grease
GENERAL INFORMATION 0B-15
GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
l If a floor jack is used, the following precautions are recommended. l Park the vehicle on level ground, "block" the front or rear wheels, set the jack against the frame, raise the vehicle and support it with chassis stands and then perform the service operation. l Before performing the service operation, disconnect the negative battery cable in order to reduce the chance of cable damaged and burning due to shortcir cuiting. l Use a cover on the body, the seats and the floor to protect them against damage and contamination. l Handle brake fluid and antifreeze solution with care as they can cause paint damage. l The use of proper tools, and the recommended essential and available tools where specified, are important for efficient and reliable performance of the service repairs.
l Use genuine DAEWOO parts. l Discard used cotter pins, gaskets, O-rings, oil seals, lock washers and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused. l Keep the disassembled parts neatly in groups to facilitate proper and smooth reassembly. l Keep attaching bolts and nuts separated, as they vary in hardness and design depending on the position of the installation. l Clean the parts before inspection or reassembly. l Also clean the oil parts, etc. Use compressed air to make certain they are free of restrictions. l Lubricate rotating and sliding faces of parts with oil or grease before installation. l When necessary, use a sealer on gaskets to prevent leakage. l Carefully observe all specifications for bolt and nut torques. l When service operation is completed, make a final check to be sure service was done properly and the problem was corrected.
0B-16 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER SYSTEM
* K P T L 4 B 1 B S V P 000000 *
12~17.Production Serial Number : 000001- 999999 11.Plant Code P : PyongTaek Plant 10.Model Year V : 1997 W : 1998 X : 1999 Y : 2000 9. Check Digit S : All area except North America 8. Engine Type 6 : 2295cc, In-line 4Cylinder, Gasoline (E23) 8 : 1998cc, In-line 4Cylinder, Gasoline (E20) 9 : 3199cc, In-line 6Cylinder, Gasoline (E32) A : 2299cc, In-line 4Cylinder, Diesel (OM661) B : 2874cc, In-line 5Cylinder, Diesel (OM662) 7. Restraint System 1 : 3-Point Safety Belt, 2 : 2-Point Safety Belt 6. Trim Level A : Standard, B : Deluxe, C : Super Deluxe 5. Body Type 2: 3-Door, 4: 3-Door Soft Top 4. Line Models L : Korando, LHD, R : Korando, RHD 3. Vehicle Type T : Passenger Car, A : Truck 2. Maker ldentification : P 1. Nation : K *. Symbol according to No.
GENERAL INFORMATION 0B-17
Manufacturer's Plate
1.Type Approval No.
2.Vehicle Identification No.
Manufacturer's Plate Location
Diesel Engine
Gasoline Engine
0B-18 GENERAL INFORMATION
Gasolind Engine Number Diesel Engine Number
162 993 1 0 012345
662 920 1 0 012345
Serial Number 0 : Manual T/M 1 : Hydr - Auto Coupling 2 : Automatic T/M 0 : Common 1 : Left - Hand Drive 2 : Right - Hand Drive 3 : KORANDO 99 : 3.2L 97 : 2.3L 94 : 2.0L ENGINE TYPE
Serial Number 0 : Manual T/M 1 : Hydr - Auto Coupling 2 : Automatic T/M 0 : Common 1 : Left - Hand Drive 2 : Right - Hand Drive
910 :Non-Intercooler Engine 920 : Intercooler Engine
661 : 2299cc 662 : 2874cc
Engine Number Location
IL6 3200
The engine number is stamped on the lower rear side of the alternator.
2300 DOHC
The engine number is stamped on the upper rear lefthand side of the cylinder block.
GENERAL INFORMATION 0B-19
VEHICLE LIFTING PROCEDURES
To raise the vehicle, place the liffting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle. If any other hoist method is used, use special care to avoid damaging the fuel tank, the filter neck, the exhaust system, or the underbody.
Vehicle Lifting Points Diesel Engine
The engine number is stamped on the cylinder block in front of injection pump.
Using Jack (Rearward of Front Tire)
Using Jack (Forward of Rear Tire)
SECTION 1
ENGINE
SECTION 1A1(M162 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . Front View . . . . . . . . . . . . . . . . . . . . . . . . . . Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Curve . . . . . . . . . . . . . . . . . . E32 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A1-1 1A1-1 1A1-3 1A1-3 1A1-4 1A1-5 1A1-5 1A1-6 1A1-6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-7 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A1-7 Engine Cranking at The Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A1-8 Compression Pressure Test . . . . . . . . . . . . . 1A1-9 Cylinder Pressure Leakage Test. . . . . . . . . 1A1-11 General Information . . . . . . . . . . . . . . . . . 1A1-13 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A1-13 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A1-13
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Engine Model Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max. Output (ps/rpm) Max. Torque (kg·m/rpm) Firing Order Ignition Type Ignition Timing Valve Timing Intake Open/Close Exhaust Open/Close Valve Clearance Adjustment E32 Engine M162.993 3199 89.9 x 84.0 MSE 3.62S 10 : 1 6 DOHC Chain-Driven 222 / 5500 31.6 / 3750 1-5-3-6-2-4 Distributorless Double Ignition BTDC 8° ± 2° ATDC 11° / ABDC 34° BBDC 31° / BTDC 14° Automatic Control
1A1-2 GENERAL ENGINE INFORMATION
ENGINE SPECIFICATIONS (Cont'd)
Application Idle Speed (rpm) Fuel Injection Pressure (kg/cm²) Oil Capacity (liter) Lubrication Type Oil Filter Type Fuel MSE 3.62S/3.53S (Motorsteuer Elektronik : German) MSE : Engine Control Electronic 3.62S : 6 Cylinder Version 3.53S : 4 Cylinder Version E32 Engine 700 ± 50 3-4 8.2 Forced by Gear Pump Full Flow with Paper Filter Unleaded Gasoline
GENERAL ENGINE INFORMATION 1A1-3
COMPONENT LOCATOR
FRONT VIEW
1 2 3 4 5 6 7 8 9 10 11
HFM Sensor Intake Air Duct Resonance Flap Cylinder Head Cover Exhaust Camshaft Intake Camshaft Cylinder Head Spark Plug Connector Valve Tappet Injector Exhaust Valve
12 13 14 15 16 17 18 19 20 21 22
Intake Manifold Connecting Rod Exhaust Manifold Crankshaft Engine Mounting Bracket Starter Crankcase Oil Pump Sprocket Oil Strainer Oil Pan Drain Plug
1A1-4 GENERAL ENGINE INFORMATION
SIDE VIEW
23 24 25 26
Camshaft Adjuster Cooling Fan and Viscous Clutch Piston Flywheel of Drive Plate
27 28 29 30
Oil Pump Drive Chain Oil Return Pipe Timing Chain Oil Pump
GENERAL ENGINE INFORMATION 1A1-5
PERFORMANCE CURVE
E32 ENGINE
1A1-6 GENERAL ENGINE INFORMATION
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 Torque Wrench
001 589 65 09 00 Socket
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench
GENERAL ENGINE INFORMATION 1A1-7
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit. 1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle normal operating conditions as directed in the kit. 3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc. 2. Identify where the fluid is leaking from. 2.1 After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2.2 Wait a few minutes. 2.3 You should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. 4.1 Clean the area well. 4.2 Dry the area. 4.3 Operate the vehicle for several miles at normal operating temperature and varying speeds. 4.4 After operating the vehicle, visually check the suspected component. 4.5 If you still cannot locate the leak, try using the powder or black light and dye method.
Repairing the Leak
Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined n order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.
Gaskets
l The fluid level/pressure is too high. l The crankcase ventilation system is malfunctioning. l The fasteners are tightened improperly or the threads l l l l l
are dirty or damaged. The flanges or the sealing surface is warped. There are scratches, burrs or other damage to the sealing surface. The gasket is damaged or worn. There is cracking or porosity of the component. An improper seal was used (where applicable).
Seals
l The fluid level/pressure is too high. l The crankcase ventilation system is malfunctioning. l The seal bore is damaged (scratched, burred or l l l l l
Powder Method
1. Clean the suspected area. 2. Apply an aerosol-type powder (such as foot powder) to the suspected area. 3. Operate the vehicle under normal operating conditoins. 4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.
nicked). The seal is damaged or worn. Improper installation is evident. There are cracks in the components. The shaft surface is scratched, nicked or damaged. A loose or worn bearing is causing excess seal wear.
1A1-8 GENERAL ENGINE INFORMATION
ENGINE CRANKING AT THE FRONT OF CRANKSHAFT
Preceding Work : Removal of cooling fan
1 Vibration Damper Assembly 2 Crankshaft Pulley
3 Bolt ................................................. 8.6 ± 0.9 Nm
Notice l Remove the negative ground cable before proceeding the work. l Rotate the pulley in normal engine rotating direction when cranking.
Tools Required 000 589 10 99 01 Torque wrench 001 589 65 09 00 Socket
GENERAL ENGINE INFORMATION 1A1-9
COMPRESSION PRESSURE TEST
1 Compression Pressure Tester 2 Diagram Sheet
3 Adaptor 4 Sealing Cone
Tools Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench
Standard Service Data
Compression Ratio Normal Engine Temperature Normal Compression Pressure 10 : 1 80°C Min. 10 bar, Max. 14 bar Min. 6 bar, Max. 10 bar Max. 1.5 bar
General Fuel Optimization Permissible Pressure Difference Between Individual Cylinders
1A1-10 GENERAL ENGINE INFORMATION
Measuring Procedure
1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5. Crank the engine approx. eight revolutions by using the start motor. 6. Compare the measurements of compression pressure tester with the specifications. 7. Measure the compression pressure of the other cylinders in the same way. 8. If measured value is not within the specifications, perform the cylinder pressure leakage test. Notice l Discharge the combustion residues in the cylinders before testing the compression pressure. l Apply the parking brake before cranking the engine.
GENERAL ENGINE INFORMATION 1A1-11
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap 4 Vibration Damper
6 Cylinder Pressure Leakage Tester with Connecting Hose
Permissible Pressure Leakage
At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max. 25 % Max. 10 % Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC Mark Cylinder Number OT (TDC) 1, 6 a (120°) 2, 5 b (240°) 3, 4
Universal Tool
Cylinder Pressure Leakage Tester Bosch, EFAW 210A Sun, CLT 228
1A1-12 GENERAL ENGINE INFORMATION
Leakage Test
Warm the engine up to normal operating temperature. Disconnect the negative battery cable. Remove the spark plugs. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5. Open the engine oil filler cap. 6. Connect the tester to air pressure line and adjust the scale of tester. 7. Install the connecting hose to spark plug hole. 1. 2. 3. 4.
8. Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
9. Connect the connecting hose to tester and measure the leakage volume after blowing up 5bar of compressed air. Notice Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable. 10. Perform the pressure test according to the firing order. Notice Firing Order : 1 - 5 - 3 - 6 - 2 - 4 11. Compare the leakage pressure with the specifications.
GENERAL ENGINE INFORMATION 1A1-13
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.
SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . Front View . . . . . . . . . . . . . . . . . . . . . . . . . . Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Curve . . . . . . . . . . . . . . . . . . E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-1 1A2-1 1A2-3 1A2-3 1A2-4 1A2-5 1A2-5 1A2-6 1A2-7 1A2-7 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-8 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8 Engine Cranking At The Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9 Compression Pressure Test . . . . . . . . . . . . 1A2-10 Cylinder Pressure Leakage Test. . . . . . . . . 1A2-12 General Information . . . . . . . . . . . . . . . . . 1A2-14 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Engine Model Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max. Output (ps/rpm) Max. Torque (kg·m/rpm) Firing Order Ignition Type Ignition Timing Valve Timing Intake Open/Close Exhaust Open/Close Valve Clearance Adjustment E23 Engine M161.973 2295 90.9 x 88.4 MSE 3.53S 10.4:1 4 DOHC Chain-Driven 149 / 5500 22.4 / 4000 1-3-4-2 Distributorless BTDC 6° ± 2° ATDC 19.25° / ABDC 28.76° BBDC 20.62° / BTDC 15.08° Automatic Control E20 Engine M161.943 1998 89.9 x 78.7 ¬ 9.6:1 ¬ ¬ ¬ 135 / 5500 19.3 / 4000 ¬ ¬ ¬ ATDC 13.15° / ABDC 13.57° BBDC 16.58° / BTDC 17.05° ¬
1A2-2 GENERAL ENGINE INFORMATION
ENGINE SPECIFICATIONS (Cont'd)
Application Idle Speed (rpm) Fuel Injection Pressure (kg/cm²) Oil Capacity (liter) Lubrication Type Oil Filter Type Fuel E23 Engine 750 ± 50 3.2 - 4.2 7.5 Forced by Gear Pump Full Flow with Paper Filter Unleaded Gasoline E20 Engine ¬ ¬ ¬ ¬ ¬ ¬
MSE 3.62S/3.53S (Motorsteuer Elektronik : German) MSE : Engine Control Electronic 3.62S : 6 cylinder version 3.53S : 4 cylinder version
GENERAL ENGINE INFORMATION 1A2-3
COMPONENT LOCATOR
FRONT VIEW
1 2 3 4 5 6 7 8 9 10 11
HFM Sensor Intake Air Duct Cylinder Head Cover Ignition Coil Spark Plug Connector Fuel Distributor Injector Exhaust Camshaft Intake Camshaft Valve Tappet Intake Valve
12 13 14 15 16 17 18 19 20 21 22
Intake Manifold Cylinder Head Exhaust Manifold Dipstick Guide Tube and Gauge Connecting Rod Crankshaft Engine Mounting Bracket Starter Crankcase Oil Pump Sprocket Oil Pan
1A2-4 GENERAL ENGINE INFORMATION
SIDE VIEW
23 24 25 26 27 28
Camshaft Adjuster Oil Filler Cap Engine Hanger Bracket Cooling Fan and Viscous Clutch Oil Filter Timing Chain
29 30 31 32 33
Oil Pump Drive Chain Oil Strainer Oil Pump Ring Gear and Flywheel of Drive Plate Piston
GENERAL ENGINE INFORMATION 1A2-5
PERFORMANCE CURVE
E23 ENGINE
1A2-6 GENERAL ENGINE INFORMATION
E20 ENGINE
GENERAL ENGINE INFORMATION 1A2-7
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 Torque Wrench
001 589 65 09 00 Socket
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench
1A2-8 GENERAL ENGINE INFORMATION
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit. 1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle normal operating conditions as directed in the kit. 3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc. 2. Identify where the fluid is leaking from. 2.1 After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2.2 Wait a few minutes. 2.3 You should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. 4.1 Clean the area well. 4.2 Dry the area. 4.3 Operate the vehicle for several miles at normal operating temperature and varying speeds. 4.4 After operating the vehicle, visually check the suspected component. 4.5 If you still cannot locate the leak, try using the powder or black light and dye method.
Repairing the Leak
Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined n order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.
Gaskets
l The fluid level/pressure is too high. l The crankcase ventilation system is malfunctioning. l The fasteners are tightened improperly or the threads l l l l l
are dirty or damaged. The flanges or the sealing surface is warped. There are scratches, burrs or other damage to the sealing surface. The gasket is damaged or worn. There is cracking or porosity of the component. An improper seal was used (where applicable).
Seals
l The fluid level/pressure is too high. l The crankcase ventilation system is malfunctioning. l The seal bore is damaged (scratched, burred or l l l l l
Powder Method
1. Clean the suspected area. 2. Apply an aerosol-type powder (such as foot powder) to the suspected area. 3. Operate the vehicle under normal operating conditoins. 4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.
nicked). The seal is damaged or worn. Improper installation is evident. There are cracks in the components. The shaft surface is scratched, nicked or damaged. A loose or worn bearing is causing excess seal wear.
GENERAL ENGINE INFORMATION 1A2-9
ENGINE CRANKING AT THE FRONT OF CRANKSHAFT
Preceding Work : Removal of cooling fan
1 Vibration Damper Assembly 2 Crankshaft Pulley
3 Bolt ................................................. 8.6 ± 0.9 Nm
Notice
l Remove the negative ground cable before proceeding the work. l Rotate the pulley in normal engine rotating direction when cranking.
Tools Required 000 589 10 99 01 Torque wrench 001 589 65 09 00 Socket
1A2-10 GENERAL ENGINE INFORMATION
COMPRESSION PRESSURE TEST
1 Compression Pressure Tester 2 Diagram Sheet
3 Adaptor 4 Sealing Cone
Tools Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench
Standard Service Data
Compression Ratio Normal Engine Temperature Normal Compression Pressure 10.4, 9.6 80°C Min. 11 bar, Max. 15 bar Min. 10.5 bar, Max. 14 bar Max. 1.5 bar
E23 Engine(e = 10.4) E20 Engine(e = 9.6) Permissible Pressure Difference Between Individual Cylinders
GENERAL ENGINE INFORMATION 1A2-11
Measuring Procedure
1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5. Crank the engine approx. eight revolutions by using the start motor. 6. Compare the measurements of compression pressure tester with the specifications. 7. Measure the compression pressure of the other cylinders in the same way. 8. If measured value is not within the specifications, perform the cylinder pressure leakage test. Notice l Discharge the combustion residues in the cylinders before testing the compression pressure. l Apply the parking brake before cranking the engine.
1A2-12 GENERAL ENGINE INFORMATION
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap 5 Vibration Damper
6 Cylinder Pressure Leakage Tester with Connecting Hose
Permissible Pressure Leakage
At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max. 25 % Max. 10 % Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC Mark Cylinder Number OT (TDC) 1, 4 UT (BDC : 180°) 2, 3
Universal Tool
Cylinder Pressure Leakage Tester Bosch EF AW 210A Sun, CLT 228
GENERAL ENGINE INFORMATION 1A2-13
Leakage Test
Warm the engine up to normal operating temperature. Disconnect the negative battery cable. Remove the spark plugs. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5. Open the engine oil filler cap. 6. Connect the tester to air pressure line and adjust the scale of tester. 7. Install the connecting hose to spark plug hole. 1. 2. 3. 4.
8. Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
9. Connect the connecting hose to tester and measure the leakage volume after blowing up 5bar of compressed air. Notice Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable. 10. Perform the pressure test according to the firing order. Notice Firing Order : 1 - 3 - 4 - 2 11. Compare the leakage pressure with the specifications.
1A2-14 GENERAL ENGINE INFORMATION
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.
SECTION 1
ENGINE
SECTION 1A3(OM600 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . . . Sectional View . . . . . . . . . . . . . . . . . . . . . . OM662LA Engine . . . . . . . . . . . . . . . . . . . . . OM661LA Engine . . . . . . . . . . . . . . . . . . . . . Performance Curve . . . . . . . . . . . . . . . . . . OM662LA Engine . . . . . . . . . . . . . . . . . . . . . OM661LA Engine . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A3-1 1A3-1 1A3-3 1A3-3 1A3-5 1A3-7 1A3-7 1A3-8 1A3-9
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A3-9 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A3-10 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . 1A3-10 Compression Pressure Test . . . . . . . . . . . . 1A3-11 Cylinder Pressure Leakage Test . . . . . . . . . 1A3-13 General Information . . . . . . . . . . . . . . . . . 1A3-15 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A3-15 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A3-15
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Engine Type Displacement (CC) Cylinder (Bore x Stroke) (mm) Fuel Injection / Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max. Output (ps/rpm) Max. Torque (kg·m/rpm) Firing Order Injection Timing Valve Timing Intake Open/Close (at 2mm lift) Exhaust Open/Close Valve Clearance Adjustment OM662LA Four-Stroke Diesel 2874 89 x 92.4 PES 5 M55 C320 RS 168 22:1 5 SOHC Chain-Drive 120 / 4000 25.5 / 4000 1-2-4-5-3 BTDC 18°± 10° ATDC 11.33° / ABDC 17° BBDC 28° / BTDC 15.25° Automatic Control OM661LA Four-Stroke Diesel 2299 89 x 92.4 PES 5 M55 C320 RS 167 22:1 4 SOHC Chain-Drive 101 / 4000 21.5 / 2400 1-3-4-2 BTDC 18°± 10° ATDC 11.33° / ABDC 17° BBDC 28° / BTDC 15.25° Automatic Control
1A3-2 GENERAL ENGINE INFORMATION
ENGINE SPECIFICATIONS (Cont'd)
Application Idle Speed (rpm) Fuel Injection Pressure (bar) Oil Capacity (liter) Lubrication Type Oil Filter Type Fuel OM 662 LA OM 661 LA 720 - 820 750 - 850 135 - 143 135 - 143 8.0 - 9.5 6.5 - 8.0 Forced by Gear Pump Forced by Gear Pump Combined Full-Flow and Partial Flow Combined Full-Flow and Partial Flow Filter Filter Diesel Diesel
GENERAL ENGINE INFORMATION 1A3-3
SECTIONAL VIEW
OM662LA ENGINE
Front View
1A3-4 GENERAL ENGINE INFORMATION
Side View
GENERAL ENGINE INFORMATION 1A3-5
OM661LA ENGINE
Front View
1A3-6 GENERAL ENGINE INFORMATION
Side View
GENERAL ENGINE INFORMATION 1A3-7
PERFORMANCE CURVE
OM662LA ENGINE
rpm
1A3-8 GENERAL ENGINE INFORMATION
OM661LA ENGINE
rpm
GENERAL ENGINE INFORMATION 1A3-9
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 Torque Wrench
001 589 65 09 00 Socket
001 589 76 21 00 Compression Pressure Tester
001 589 73 21 00 Hand Vacuum Pump
1A3-10 GENERAL ENGINE INFORMATION
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks. 1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle normal operating conditions as directed in the kit. 3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc. 2. Identify where the fluid is leaking from. 2.1 After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2.2 Wait a few minutes. 2.3 You should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. 4.1 Clean the area well. 4.2 Dry the area. 4.3 Operate the vehicle for several miles at normal operating temperature and varying speeds. 4.4 After operating the vehicle