Text preview for : musso.pdf part of DAEWOO MUSSO English
Back to : musso.part01.rar | Home
SECTION INDEX
SERVICE
MANUAL FRONT MATTER 0A
MUSSO GENERAL INFORMATION 0B
ENGINE 1
SUSPENSION 2
FOREWORD DRIVE LINE/AXLE 3
This manual includes procedure for mainte-
nance, adjustment, service operation and re- BRAKES 4
moval and installation of components.
All information, illustrations and specifications
contained in this manual are based on the latest TRANSMISSION 5
product information available at the time of
manual approval.
The right is reserved to make changes at any STEERING 6
time without notice.
HVAC
(HEATING, VENTILATION, 7
AND AIR CONDITIONING)
DAEWOO MOTOR CO., LTD.
RESTRAINTS 8
INCHON, KOREA
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.
MUSSO
Service Manual
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and re-
moval and installation of components for the MUSSO vehicle.
When reference is made in this manual to a brand name, number, or specific tool, an equiva-
lent 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 : 82-32-509-4160
E-mail : [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, Lim-
ited
TABLE OF CONTENTS
Section 0A Front Matter Section 5 Transmission
Section 5A Automatic Transmission
Section 0B General Information
Section 5B Manual Transmission
Section 1 Engine Section 5C Clutch
Section 1A1 M162 General Engine Information Section 5D1 Transfer Case (Part Time 4480)
Section 1B1 M162 Engine Mechanical Section 5D2 Transfer Case (TOD)
Section 1D1 M162 Engine Cooling
Section 1E1 M162 Engine Electrical Section 6 Steering
Section 1F1 M162 Engine Controls Section 6A Power Steering System
Section 1G1 M162 Engine Intake & Exhaust Section 6E Steering Wheel and Column
Section 1A2 M161 General Engine Information Section 7 HVAC (Heating, Ventilation & Air
Section 1B2 M161 Engine Mechanical Conditioning)
Section 1D2 M161 Engine Cooling Section 7B/C Manual Control/Semiauto Tempera-
Section 1E2 M161 Engine Electrical ture Control Heationg, Ventilation,
Section 1F2 M161 Engine Controls and Air Conditioning System
Section 1G2 M161 Engine Intake & Exhaust Section 7D Full Automatic Temperature Control
Heationg, Ventilation, and Air Condi-
Section 1A3 OM600 General Engine Information
tioning System
Section 1B3 OM600 Engine Mechanical
Section 1D3 OM600 Engine Cooling Section 8 Restraints
Section 1E3 OM600 Engine Electrical Section 8A Seat Belts
Section 1F3 OM600 Engine Controls Section 8B Supplemental Restraint System
Section 1G3 OM600 Engine Intake & Exhaust (SRS)
Section 2 Suspension Section 9 Body and Accessories
Section 2A Suspension Diagnosis Section 9A Body Wiring System
Section 2B Wheel Alignment Section 9B Lighting Systems
Section 2C Front Suspension Section 9D Wipers/Washer Systems
Section 2D Rear Suspension Section 9E Instrumentation/Driver Information
Section 2E Tires and Wheels Section 9F Audio
Section 9H Seats
Section 3 Drive Line / Axle
Section 9L Glass and Mirrors
Section 3A Front Drive Axle
Section 9N Front and Under Body
Section 3C Propeller Shaft
Section 9O Bumpers and Fenders
Section 3D Rear Drive Axle
Section 9P Doors
Section 4 Brakes Section 9Q Roof
Section 4A Hydraulic Brakes Section 9R Body Front End
Section 4B Master Cylinder Section 9T Remote Keless Entry and Anti-Theft
Section 4C Power Booster System
Section 4D Front Disc Brakes Section 9U Control Units and System
Section 4E Rear Disc Brakes Section 9W Immobilizer System
Section 4F Antilock Brake System
Section 4G Parking Brakes
MUSSO
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
SECTION 1B1 M162 ENGINE MECHANICAL
SECTION 1D1 M162 ENGINE COOLING
SECTION 1E1 M162 ENGINE ELECTRICAL
SECTION 1F1 M162 ENGINE CONTROLS
SECTION 1G1 M162 ENGINE INTAKE & EXHAUST
SECTION 1A2 M161 GENERAL ENGINE INFORMATION
SECTION 1B2 M161 ENGINE MECHANICAL
SECTION 1D2 M161 ENGINE COOLING
SECTION 1E2 M161 ENGINE ELECTRICAL
SECTION 1F2 M161 ENGINE CONTROLS
SECTION 1G2 M161 ENGINE INTAKE & EXHAUST
SECTION 1A3 OM600 GENERAL ENGINE INFORMATION
SECTION 1B3 OM600 ENGINE MECHANICAL
SECTION 1D3 OM600 ENGINE COOLING
SECTION 1E3 OM600 ENGINE ELECTRICAL
SECTION 1F3 OM600 ENGINE CONTROLS
SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST
SUSPENSION
CONTENTS
SECTION 2A SUSPENSION DIAGNOSIS
SECTION 2B WHEEL ALIGNMENT
SECTION 2C FRONT SUSPENSION
SECTION 2D REAR SUSPENSION
SECTION 2E TIRES AND WHEELS
DRIVE LINE / AXLE
CONTENTS
SECTION 3A FRONT DRIVE AXLE
SECTION 3C PROPELLER SHAFT
SECTION 3D REAR DRIVE AXLE
BRAKE
CONTENTS
SECTION 4A HYDRAULIC BRAKES
SECTION 4B MASTER CYLINDER
SECTION 4C POWER BOOSTER
SECTION 4D FRONT DISC BRAKES
SECTION 4E REAR DISC BRAKES
SECTION 4F ANTILOCK BRAKE SYSTEM
SECTION 4G PARKING BRAKE
TRANSMISSION
CONTENTS
SECTION 5A AUTOMATIC TRANSMISSION
SECTION 5B MANUAL TRANSMISSION
SECTION 5C CLUTCH
SECTION 5D1 TRANSFER CASE (PART TIME 4408)
SECTION 5D2 TRANSFER CASE (TOD)
STEERING
CONTENTS
SECTION 6A POWER STEERING SYSTEM
SECTION 6E STEERING WHEEL AND COLUMN
HVAC (HEATING, VENTILATION &
AIR CONDITIONING)
CONTENTS
SECTION 7B/C MANUAL CONTROL/SEMIAUTO
TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM
SECTION 7D FULL AUTOMATIC
TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM
RESTRAINTS
CONTENTS
SECTION 8A SEAT BELTS
SECTION 8B SUPPLEMENTAL RESTRAINT
SYSTEM (SRS)
BODY AND ACCESSORIES
CONTENTS
SECTION 9A BODY WIRING SYSTEM
SECTION 9B LIGHTING SYSTEM
SECTION 9C HORNS
SECTION 9D WIPERS/WASHER SYSTEM
SECTION 9E INSTRUMENTATION/DRIVER INFORMATION
SECTION 9F AUDIO SYSTEM
SECTION 9H SEATS
SECTION 9L GLASS AND MIRRORS
SECTION 9N FRAME AND UNDERBODY
SECTION 9O BUMPERS AND FASCIAS
SECTION 9P DOORS
SECTION 9Q ROOF
SECTION 9R BODY FRONT END
SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT
SYSTEM
SECTION 9U CONTROL UNITS AND SYSTEM
SECTION 9W IMMOBILIZER SYSTEM
SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 While Operating the Vehicle . . . . . . . . . . . . . 0B-12
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . 0B-12
Vehicle Dimensions and Weights . . . . . . . . . . 0B-5 At Least Twice A Month . . . . . . . . . . . . . . . . 0B-12
Standard Bolt Specifications . . . . . . . . . . . . . . 0B-6 At Least Monthly . . . . . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Repair . . . . . . . . . . . . . . . 0B-7 At Least Twice a Year . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Lubrication . . . . . . . . . . . . . . 0B-7 Each Time the Oil is Changed . . . . . . . . . . . 0B-13
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . 0B-7 At Least Annually . . . . . . . . . . . . . . . . . . . . . 0B-13
Explanation of Scheduled Maintenance Recommended Fluids and Lubricants . . . . . 0B-14
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-7 General Description and System
Scheduled Maintenance Charts Operation . . . . . . . . . . . . . . . . . . . . . . . . 0B-15
(Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . 0B-8 General Repair Instructions . . . . . . . . . . . . . 0B-15
Scheduled Maintenance Charts Vehicle Identification Number System . . . . . . 0B-16
(Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . 0B-10
Vehicle Lifting Procedures . . . . . . . . . . . . . . 0B-19
Owner Inspections and Services . . . . . . . 0B-12
SPECIFICATIONS
TECHNICAL DATA
Transaxle Performance
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 143 145 156 168 176 190
Minimum Turning Radius (m) 5.7 5.7 5.7 5.7 5.7 5.7
Performance-Autumatic Transaxle (MB)
Application 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 171 190
Minimum Turning Radius (m) 5.7 5.7
Performance-Autumatic Transaxle (BTRA)
Application 661LA 662NA 662LA 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 143 138 156 171 188
Minimum Turning Radius (m) 5.7 5.7 5.7 5.7 5.7
0B-2 GENERAL INFORMATION
Engine
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Engine Type 4Cylinder 5Cylinder 5Cylinder 4Cylinder 4Cylinder 6Cylinder
DIESEL DIESEL DIESEL GASOLINE GASOLINE GASOLINE
Bore (mm) 89 89 89 89.9 90.9 89.9
Stroke (mm) 92.4 92.4 92.4 78.7 88.4 84
Total Displacement (cc) 2299 2874 2874 1998 2295 3199
Compression Ratio 22:1 22:1 22:1 9.6:1 10.4:1 10:1
Maximum Power (ps/rpm) 101/4000 95/4000 120/4000 135/5500 149/5500 222/5500
Maximum Torque (kg.m/rpm) 21.5/2400 19.6/2400 25.5/2400 19.3/4000 22.4/4000 31.6/3750
Ignition System
Application 2.0L DOHC 2.3L DOHC 2.0L DOHC
Ignition Type Distributorless Ignition
Ignition Timing (BOTH) 6°± 2° 6°± 2° 8°± 2°
Ignition Sequence 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Spark Plug Gap (mm) 0.8 ± 0.1 0.8 ± 0.1 0.8 ± 0.1
Spark Plug Maker Bosch, Chapion, Beru
Spark Plug Type F8DC4(BOSCH)
C11YCC(CHAMPION)
14F8DU4(BERU)
Clutch - Manual Type
Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Type Single Dry Diaphram
Outside Diameter (mm) 225 225 240 225 225 240
Inside Diameter (mm) 150 150 150 150 150 155
Thickness 9.2 9.2 9.2 9.2 9.2 9.3
Fluid Common use :Brake Fluid
Manual Transmission
Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Maker TREMEC TREMEC TREMEC TREMEC TREMEC TREMEC
Type or Model T5 T5 T5 T5 T5 T5
Gear Ratio : 1st 3.969 3.969 3.969 3.969 3.969 3.969
2nd 2.341 2.341 2.341 2.341 2.341 2.341
3rd 1.457 1.457 1.457 1.457 1.457 1.457
4th 1.000 1.000 1.000 1.000 1.000 1.000
5th 0.851 0.851 0.851 0.851 0.851 0.851
Reverse 3.705 3.705 3.705 3.705 3.705 3.705
Final Drive Ratio 4.55 4.55 4.27 4.55 4.55 3.73
Oil Capacity (L) 3.4 3.4 3.4 3.4 3.4 3.4
GENERAL INFORMATION 0B-3
Auto Transmission (MB)
Application 662LA 2.3L DOHC 3.2L DOHC
Maker MB MB MB
Type or Model W4A040 W4A040 W4A040
Gear Ratio : 1st 3.871 3.871 3.871
2nd 2.247 2.247 2.247
3rd 1.436 1.436 1.436
4th 1.000 1.000 1.000
Reverse 5.586 5.586 5.586
Final Drive Ratio 5.38 4.27 3.73
Oil Capacity (L) 9 - 9.5 9 - 9.5 9 - 9.5
Auto Transmission (BTRA)
Application 661LA 662LA 2.3L DOHC 3.2L DOHC
Maker BTRA BTRA BTRA BTRA
Type or Model M74 4WD M74 4WD M74 4WD M74 4WD
Gear Ratio : 1st 2.741 2.741 2.741 2.741
2nd 1.508 1.508 1.508 1.508
3rd 1.000 1.000 1.000 1.000
4th 0.708 0.708 0.708 0.708
Reverse 2.429 2.429 2.429 2.429
Final Drive Ratio 5.38 4.89 5.86 4.89
Oil Capacity (L) 9 9 9 9
Brake
Application Specifications
Booster Size non-ABS 8inch + 9inch
ABS 5.0 7inch + 8inch
ABS 5.3 8inch + 9inch
Master Cylinder Diameter (mm) f 25.4
Booster Ratio 5.6 : 1
Front Brake : Disc Type Ventilated
Rear Brake : Disc Type Solid
Tire and Wheel
Application Specifications
Standard Tire Size P235/75 R15, 255/70 R15
Standard Wheel Size 7JJ ´ 15
Inflation Pressure At Full Lode
P235 / 75 : Front 30 Psi
Rear 30 Psi
P255 / 75 : Front 30 Psi
Rear 30 Psi
0B-4 GENERAL INFORMATION
Steering System
Application Specifications
Gear Type RACK & PINION
Wheel Alignment:
Front Toe-in 0 - 4 mm
Front Caster 2°30'± 30'
Front Camber 0 ± 30'
°
Oil Capacity 1L
Suspension
Application Specifications
Front Type Double Wishbone
Rear Type 5 - Link
Fuel System
Application Specifications
Fuel Pump Type Electric Motor Pump
Fuel Filter Type Cartridge
Fuel Capacity 70 L
Lubricating System
Lubricating Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Oil Pump Type External Gear pump
Oil Filter Type Combination(Full & Part) Full Flow
Oil Capacity (L) (Including Oil Filter) 8.0 9.0 9.5 7.2 7.5 8.2
Cooling System
Cooling Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Coolant Capacity (L) 9.5-10 10.5 10.5-11 10.5 10.5 11.3
Radiator Type Forced Circulation
Water Pump Type Centrifugal
Electric System
Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Battery (MF) 12V - 90AH 12V - 75AH
Generator 75A 75A 75A 115A 115A 115A
Starter 2.2kw 2.2kw 2.2kw 1.2kw 1.2kw 1.7kw
GENERAL INFORMATION 0B-5
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application Application
Overall Length (mm) 4656
Overall Width (mm) 1864
Overall Height (mm) 1735
Wheel Base (mm) 2630
Tread : Front (mm) 1510
Rear (mm) 1520
Vehicle Weights
Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Manual : Curb Weight (kg) 1860 1968 1890 1937 1850 1930
Gross Vehicle Weight (kg) 2520 2520 2520 2520 2520 2520
Automatic : Curb Weight (kg) 1916 1989 2005 - 1942 2025
Gross Vehicle Weight (kg) 2520 2520 2520 - 2520 2520
Passenger Capacity 5 5 5 5 5 5
0B-6 GENERAL INFORMATION
STANDARD BOLTS SPECIFICATIONS
Torque (N·m / Ib-in)
Bolt* Standard Limit
4T 7T 9T 4T 7T 9T
M3 ´ 0.5 0.5 N·m
· 0.9 N·m
· 1.3 N·m
· 0.7 N·m
· 1.2 N·m
· 17 N·m
·
(4.5 lb-in) (8 lb-in) (12 lb-in) (6.3 lb-in) (11 lb-in) (15 lb-in)
M4 ´ 0.7 1.2 N·m
· 2.0 N·m
· 3.0 N·m
· 1.6 N·m
· 2.6 N·m
· 4.0 N·m
·
(11 lb-in) (18 lb-in) (27 lb-in) (14 lb-in) (23 lb-in) (36 lb-in)
M5 ´ 0.8 2.4 N·m
· 4.0 N·m
· 5.6 N·m
· 3.1 N·m
· 5.2 N·m
· 7.6 N·m
·
(22 lb-in) (36 lb-in) (50 lb-in) (28 lb-in) (47 lb-in) (68 lb-in)
M6 ´ 1.0 4.0 N·m
· 6.7 N·m
· 9.7 N·m
· 5.4 N·m
· 9.0 N·m
· 12.7 N·m·
(36 lb-in) (60 lb-in) (87 lb-in) (49 lb-in) (81 lb-in) (114 lb-in)
M8 ´ 1.25 8.6 N·m
· 15.7 N·m· 22.5 N·m
· 12.7 N·m· 20.6 N·m
· 30.4 N·m·
(77 lb-in) (12 lb-in) (17 lb-in) (9 lb-in) (15.2 lb-in) (22 lb-in)
M10 ´ 1.25 18.6 N·m
· 32.3 N·m· 46.0 N·m
· 25.5 N·m· 42.1 N·m
· 60.8 N·m·
(14 lb-in) (24 lb-in) (34 lb-in) (19 lb-in) (31 lb-in) (31 lb-in)
M10 ´ 1.5 18.6 N·m
· 30.4 N·m· 44.1 N·m
· 24.5 N·m· 41.2 N·m
· 58.8 N·m·
(14 lb-in) (22 lb-in) (33 lb-in) (18 lb-in) (30 lb-in) (44 lb-in)
M12 ´ 1.25 34.3 N·m
· 56.8 N·m· 82.3 N·m
· 45.0 N·m· 75.5 N·m
· 107.8 N·m ·
(25lb-in) (42 lb-in) (61 lb-in) (33 lb-in) (56 lb-in) (80 lb-in)
M12 ´ 1.75 32.3 N·m
· 53.9 N·m· 77.4 N·m
· 43.1 N·m· 71.5 N·m
· 98.0 N·m·
(24 lb-in) (40 lb-in) (57 lb-in) (32 lb-in) (53 lb-in) (73 lb-in)
M14 ´ 1.5 54.0 N·m
· 89.2 N·m· 127.4 N·m· 71.6 N·m· 117.6 N·m· 166.6 N·m ·
(40 lb-in) (66 lb-in) (94 lb-in) (53 lb-in) (87 lb-in) (123 lb-in)
M16 ´ 1.5 81.3 N·m
· 107.8 N·m· 196.0 N·m· 107.8 N·m· 186.2 N·m· 264.6 N·m ·
(60 lb-in) (80 lb-in) (145 lb-in) (80 lb-in) (138 lb-in) (196 lb-in)
M18 ´ 1.5 117.6 N·m· 196.0 N·m· 284.2 N·m· 156.8 N·m· 264.6 N·m· 372.4 N·m ·
(87 lb-in) (145 lb-in) (210 lb-in) (116 lb-in) (196 lb-in) (276 lb-in)
M20 ´ 1.5 166.6N·m· 274.4 N·m· 392.0 N·m· 215.6 N·m· 362.6 N·m· 519.4 N·m ·
(123 lb-in) (203 lb-in) (290 lb-in) (160 lb-in) (268 lb-in) (384 lb-in)
M22 ´ 0.5 225.4N·m· 372.4 N·m· 529.2 N·m· 294.0 N·m· 490.0 N·m· 705.6 N·m ·
(167 lb-in) (276 lb-in) (392 lb-in) (218 lb-in) (362 lb-in) (522 lb-in)
M24 ´ 1.5 284.2 N·m· 480.2 N·m· 686.0 N·m· 382.2 N·m· 637.0 N·m· 921.2 N·m ·
(210 lb-in) (355 lb-in) (508 lb-in) (283 lb-in) (471 lb-in) (682 lb-in)
M24 ´ 2.0 274.4 N·m· 460.6 N·m· 666.4 N·m· 372.4 N·m· 617.4 N·m· 891.8 N·m ·
(203 lb-in) (341 lb-in) (493 lb-in) (276 lb-in) (457 lb-in) (660 lb-in)
*Diameter ´ pitch in millimeters
GENERAL INFORMATION 0B-7
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE Fuel Filter Replacement
The maintenance instructions contained in the Replace the engine fuel filter every.
maintenance schedule are based on the assumption l Gasoline Engine : 60,000km (36,000 miles)
that the vehicle will be used for the following reasons: l Diesel Engine : 45,000km (24,000 miles)
l To carry passengers and cargo within the limitation
Spark Plug Replacement
of the tire inflation prassure. Refer to "Tire and Wheel"
in section 2E. Replace spark plugs with same type.
l To be driven on reasonable road surfaces and within l Type : BOSCH : F8DC4
legal operating limits. BERU : 14F-8DU4
Champion : C11YCC
EXPLANATION OF SCHEDULED l Gap : 0.8 ± 0.1 mm
MAINTENANCE SERVICES Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other
The services listed in the maintenance schedule are
damage. Check the wire boot fit at the Distributor and at
further explained below. When the following maintenance
the spark plugs. Replace the wires as needed.
services are performed, make sure all the parts are
replaced and all the necessary repairs are done before Brake System Service
driving the vehicle. Always use the proper fluid and Check the disc brake pads or the drum brake linings.
lubricants. Check the pad and the lining thickness carefully.
Engine Oil and Oil Filter Change Tire and Wheel Inspection and Rotation
Always use above the API SH grade or recommended Check the tires for abnormal wear or damage. To
engine oil. equalize wear and obtain maximum tire life, rotate the
Engine Oil Viscosity tires. If irregular or premature wear exists, check the
wheel alignment and check for damaged wheels. While
Engine oil viscosity (thickness) has an effect on fuel
the tires and wheels are removed, inspect the brakes.
economy and cold weather operation. Lower viscosity
engine oils can provide better fuel economy and cold
weather performance; however, higher temperature Tire Rotation (Left - Hand Drive Type)
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 Kilometers or time in months, whichever comes first
x1,000 km 1 15 30 45 60 75 90 105 120
MAINTENANCE
ITEM Months - 12 24 36 48 60 72 84 96
Drive belt I I I I I I I I I
Engine oil & filter (1) (3) I R R R R R R R R
Cooling system hose & connections I I I I I I I I I
Engine coolant (3) I I I I R I I I R
Fuel filter (2) - - - - R - - - R
Fuel line & connections I I I I I I I I I
Air cleaner (2) I I I R I I R
Ignition timing I I I I I I I I
Spark plugs - I R I R I R I R
Charcoal canister & vapor lines - - - I - - I - -
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 Kilometers or time in months, whichever comes first
x1,000 km 1 15 30 45 60 75 90 105 120
MAINTENANCE
ITEM Months - 12 24 36 48 60 72 84 96
Exhaust pipes & mountings - I I I I I I I I
Brake/Clutch fluid (3)(4) - I R I R I R I R
Parking brake/Brake pads F & R (5) - I I I I I I I I
Brake line & connections (including booster) I I I I I I I I I
Manual transmission oil (3) I I I R I I R I I
Clutch & brake pedal free play - I I I I I I I I
Front & Rear Differential Fluid (3) I I I R I I R I I
Transfer case fluid I I I R I I R I I
Automatic transmission fluid (MB W4A040) (6) I I I R I I R I
Automatic transmission fluid (BTRA M74) I I I I I I I I I
Chassis & underbody bolts & nuts tight/secure I I I I I I I I I
Tire condition & inflation pressure I I I I I I I I I
Wheel alignment (7) Inspect & ADJUST when abnormal condition is noted
Steering wheel & linkage I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I
Drive shaft boots I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I
Lubricate locks, hinges & bonnet latch I I I I I I I 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 Kilometers or time in months, whichever comes first
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
MAINTENANCE
ITEM Months - 6 12 18 24 30 36 42 48 54 60
Drive belt I I I I I I I I I I I
Engine oil & fillter (1) (3) R R R R R R R R R R R
Cooling system hose & connections I I I I I I I I I
Engine coolant (3) I R I
Fuel filter (2) R R
Fuel line & connections I I I I I I I I I I I
Glow plug I I I R I
Pre - fuel filter I I I I I I I I I I
Air cleaner (2) I I R I I R I I R I
Ignition timing (see NOTE 1) I I I I I I I 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 Kilometers or time in months, whichever comes first
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
MAINTENANCE
ITEM Months - 6 12 18 24 30 36 42 48 54 60
Exhaust pipes & mountings I I I I I I I I I I
Brake/clutch fluid (3) (4) I I I R I I R I I R I
Parking brake/Brake pads (F & R) (5) I I I I I I I I I I
Brake line & connections (including booster) I I I I I I I I I I
Manual transmission fluid (3) I I I I R I I I I R
Clutch & brake pedal free play I I I I I I I I I I
F & R Differential fluid (3) I I I I I R I I I I R
Transfer case fluid (3) I I I I R I I I I R
Automatic transmission fluid (BTRA M74) (6) I I I I I I I I I I
Chassis & underbody bolts & nuts tight/secure I I I I I I I I I I I
Tire condition & inflation pressure I I I I I I I I I I I
Wheel alignment (7) Inspect & ADJUST when abnormal condition is noted
Steering wheel & linkage I I I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I I I
Drive shaft boots I I I I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I I I
Lubricate locks, hinges & bonnet latch I I I I I I I I I I 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 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
5. Add oil, if needed, to keep the oil level above the
OWNER INSPECTIONS lower mark. Avoid overfilling the engine, since this
AND SERVICES may cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.
WHILE OPERATING THE VEHICLE 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
Horn Operation pan fast enough to give a true oil level reading.
Blow the horn occasionally to make sure it works. Check Engine Coolant Level and Condition
all the button locations.
Check the coolant level in the coolant reservoir tank
Brake System Operation and add coolant if necessary. Inspect the coolant.
Be alert for abnormal sounds, increased brake pedal Replace dirty or rusty coolant.
travel or repeated puling to one side when braking. Also, Windshield Washer Fluid Level
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system. 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 AT LEAST TWICE A MONTH
the smell of the fumes. These are signs that the system Tire And Wheel Inspection and Pressure
may be leaking or overheating. Have the system
inspected and repaired immediately.
Check
Check the tire for abnormal wear or damage. Also check
Tires, Wheels and Alignment Operation for damaged wheels. Check the tire pressure when the
Be alert to any vibration of the steering wheel or the tires are cold ( check the spare also, unless it is a
seats at normal highway speeds. This may mean a wheel stowaway). Maintain the recommended pressures. Refer
needs to be balanced. Also, a pull right or left on a to "Tire and Wheel" is in section 0B.
straight, level road may show the need for a tire pressure
adjustment or a wheel alignment. AT LEAST MONTHLY
Steering System Operation Light Operation
Be alert to changes in the steering action. An inspection Check the operation of the license plate light, the
is needed when the steering wheel is hard to turn or headlights (including the high beams), the parking lights,
has too much free play, or is unusual sounds are noticed the fog lights, the taillight, the brake lights, the turn
when turning or parking. signals, the backup lights and the hazard warning flasher.
Headlight Aim Fluid Leak Check
Take note of the light pattern occasionally. Adjust the Periodically inspect the surface beneath the vehicle for
headlights if the beams seem improperly aimed. water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air
AT EACH FUEL FILL conditioning system after use is normal. If you notice
A fluid loss in any (except windshield washer) system fuel leaks or fumes, find the cause and correct it at once.
may indicate a problem. Have the system inspected and
repaired immediately. AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Engine Oil Level
Check the power steering fluid level. Keep the power
Check the oil level and add oil if necessary. The best
steering fluid at the proper level. Refer to Section 6A,
time to check the engine oil level is when the oil is warm.
Power Steering System.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan. Brake Master Cylinder Reservoir Level
2. Pull out the oil level indicator (dip stick). Check the fluid and keep it at the proper level. A low
3. Wipe it clean, and push the oil level indicator back fluid level can indicate worn disc brake pads which may
down all the way. need to be serviced. Check the breather hole in the
reservoir cover to be free from dirt and check for an
4. Pull out the oil level indicator and look at the oil level open passage.
on it.
GENERAL INFORMATION 0B-13
Weather-Strip Lubrication AT LEAST ANNUALLY
Apply a thin film silicone grease using a clean cloth.
Lap and Shoulder Belts Condition and
EACH TIME THE OIL IS CHANGED Operation
Inspect the belt system including: the webbing, the
Brake System Inspection buckles, the latch plates, the retractor, the guide loops
This inspection should be done when the wheels are and the anchors.
removed for rotation. Inspect the lines and the hoses
for proper hookup, binding, leaks, cracks, chafing, etc. Movable Head Restraint Operation
Inspect the disc brake pads for wear. Inspect the rotors On vehicles with movable head restraints, the restraints
for surface condition. Inspect other brake parts, the must stay in the desired position.
parking brake, etc., at the same time. Inspect the brakes
Spare Tire and Jack Storage
more often if habit or conditions result in frequent braking.
Be alert to rattles in the rear of the vehicle. The spare
Steering, Suspension and Front Drive Axle tire, all the jacking equipment, and the tools must be
Boot And Seal Inspection securely stowed at all times. Oil the jack ratchet or the
Inspect the front and rear suspension and the steering screw mechanism after each use.
system for damaged, loose or missing parts, signs of Key Lock Service
wear or lack of lubrication. Inspect the power steering
Lubricate the key lock cylinder.
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle Body Lubrication Service
boot and seals for damage, tears or leakage. Replace Lubricate all the body door hinges including the hood,
the seals if necessary. the fuel door, the rear compartment hinges and the
Exhaust System Inspection latches, the glove box and the console doors, and any
folding seat hardware.
Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the exhaust Underbody Flushing
system. Look for broken, damaged, missing, or out-of- Flushing the underbody will remove any corrosive
position parts as well as open seams, holes, loose materials used for ice and snow removal and dust control.
connections, or other conditions which could cause heat At least every spring clean the underbody. First, loosen
buildup in the floor pan or could let exhaust fumes seep the sediment packed in closed areas of the vehicle. Then
into the trunk or passenger compartment. flush the underbody with plain water.
Throttle Linkage Inspection Engine Cooling System
Inspect the throttle linkage for interference or binding, Inspect the coolant and freeze protection fluid. If the fluid
damaged, or missing parts. Lubricate all linkage joints is dirty or rusty, drain, flush and refill the engine cooling
and throttle cable joints, the intermediate throttle shaft system with new coolant. Keep the coolant at the proper
bearing, the return spring at throttle valve assembly, and mixture in order to ensure proper freeze protection,
the accelerator pedal sliding face with suitable grease. corrosion protection and engine operating temperature.
Check the throttle cable for free movements. Inspect the hoses. Replace the cracked, swollen, or
Engine Drive Belts deteriorated hoses. Tighten the clamps. Clean the
outside of the radiator and the air conditioning
Inspect all belts for cracks, fraying, wear and proper
condenser. Wash the filler cap and the neck. Pressure
tension. Adjust or replace the belts as needed.
test the cooling system and the cap in order to help
Hood Latch Operation ensure proper 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 Capacity Fluid/Lubricant
Engine Oil 3.2L DOHC 8.2 L Quality class - API ; SH grade or above
(Change with filter) ACEA ; A2 or A3
2.3L DOHC 7.5 L MB sheet ; 229.1
Viscosity - MB sheet ; 224.1
662LA 9.5 L Quality class - API ; CG grade or above
ACEA ; B2 or B3
661LA 8.0 L MB sheet ; 228.1, 228.3,
228.5, 229.1
Viscosity - MB sheet ; 224.1
Engine Coolant 3.2L DOHC 11.3 L ALUTEC P-78
2.3L DOHC 10.5 L
662LA 10.5 - 11.0 L
661LA 9.5 - 10.0 L
Brake / Clutch Fluid Approx. 0.5L level must DOT-3 & SAE J 1703
be maintained between
MAX & MIN level
Power Steering System 1.0 L ATF DEXRON-II
Parking Brake Cable As required Grease
Hood Latch Assembly As required Grease
Hood and Door Hinges As required Spray type grease
Fuel Door Hinge
Rear Compartment Lid Hinges
Weatherstrips As required Silicone grease
GENERAL INFORMATION 0B-15
l Use genuine DAEWOO parts.
GENERAL DESCRIPTION l Discard used cotter pins, gaskets, O-rings, oil seals,
AND SYSTEM OPERATION lock washers and self-locking nuts. Prepare new ones
for installation. Normal function of these parts cannot
be maintained if these parts are reused.
GENERAL REPAIR INSTRUCTIONS
l Keep the disassembled parts neatly in groups to
l If a floor jack is used, the following precautions are facilitate proper and smooth reassembly.
recommended.
l Keep attaching bolts and nuts separated, as they
l Park the vehicle on level ground, "block" the front or vary in hardness and design depending on the
rear wheels, set the jack against the frame, raise the position of the installation.
vehicle and support it with chassis stands and then
perform the service operation. l Clean the parts before inspection or reassembly.
l Before performing the service operation, disconnect l Also clean the oil parts, etc. Use compressed air to
the negative battery cable in order to reduce the make certain they are free of restrictions.
chance of cable damaged and burning due to short- l Lubricate rotating and sliding faces of parts with oil
cir cuiting. or grease before installation.
l Use a cover on the body, the seats and the floor to l When necessary, use a sealer on gaskets to prevent
protect them against damage and contamination. leakage.
l Handle brake fluid and antifreeze solution with care l Carefully observe all specifications for bolt and nut
as they can cause paint damage. torques.
l The use of proper tools, and the recommended l When service operation is completed, make a final
essential and available tools where specified, are check to be sure service was done properly and the
important for efficient and reliable performance of problem was corrected.
the service repairs.
0B-16 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER SYSTEM
K P T P 0 A 1 9 S W P 122357
12~17.Production Serial Number
: 000001- 999999
11.Plant Code
P : PyongTaek Plant
10.Model Year
M : 1991
N : 1992
P : 1993
R : 1994
S : 1995
T : 1996
V : 1997
W : 1998
X : 1999
Y : 2000
9. Check Digit
Constant "S"
8. Engine Type
3 : 2299cc, In-line 4Cylinder, Diesel (OM601)
4 : 2874cc, In-line 5Cylinder, Diesel (OM602)
8 : 1998cc, In-line 4Cylinder, Gasoline (E20)
6 : 2295cc, In-line 4Cylinder, Gasoline (E23)
9 : 3199cc, In-line 6Cylinder, Gasoline (E32)
A : 2299cc, In-line 4Cylinder, Diesel (OM601)
B : 2874cc, In-line 5Cylinder, Diesel (OM602)
C : 2299cc, In-line 4Cylinder, Diesel (SY662LA)
D : 2874cc, In-line 5Cylinder, Diesel (SY662LA)
7. Restraint System
0 : NO Seat Belt,
1 : 3-Point Seat Belts, 2 : 2-Point Seat Belts
6. Trim Level
A : Standard, B : Deluxe, C : Super Deluxe
5. Body Type