1998 Ssangyong Korando Service & Repair Manual

DAEWOO MY_2000 SECTION 0B GENERAL INFORMATION TABLE OF CONTENTS Specifications 0B--2 ............................. Technical Data 0B--2 ............................ Vehicle Dimensions and Weights 0B--6 ............ Standard Bolts Specifications 0B--7 ............... Maintenance and Repair 0B--8 .................... Maintenance and Lubrication 0B--8 ............... Normal Vehicle Use 0B--8 ........................ Explanation of Scheduled Maintenance Services 0B--8 ............................... Scheduled Maintenance Charts (Gasoline Engine) 0B--9 ....................... Scheduled Maintenance Charts (Diesel Engine) 0B--11 ......................... Owner Inspections and Services 0B--13 ........... While Operating the Vehicle 0B--13 ............... At Each Fuel Fill 0B--13 .......................... At Least Twice A Month 0B--13 ................... At Least Monthly 0B--13 ......................... At Least Twice a Year 0B--13 ..................... Each Time The Oil is Changed 0B--14 ............. At Least Annually 0B--14 ......................... Recommended Fluids and Lubricants 0B--15 ....... General Description and System Operation 0B--16 ................................ General Repair Instructions 0B--16 ................ Vehicle Identification Number System 0B--17 ....... Vehicle Lifting Procedures 0B--20 .................

0B -- 2 GENERAL INFORMATION DAEWOO MY_2000 SPECIFICATIONS TECHNICAL DATA Transaxle Performance Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH Maximum Speed (Km/h) 140 134 148 154 165 176 Minimum Turning Radius (m) 5.8 5.8 5.8 5.8 5.8 5.8 Performance- Autumatic Transaxle Application 661LA 662NA 662LA 2.3L DOCH 3.2L DOCH Maximum Speed (Km/h) 140 137 140 160 170 Minimum Turning Radius (m) 5.8 5.8 5.8 5.8 5.8 Engine Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH Engine Type 4Cylinder DIESEL 5Cylinder DIESEL 5Cylinder DIESEL 4Cylinder GASOLINE 4Cylinder GASOLINE 6Cylinder 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)

GENERAL INFORMATION 0B -- 3 DAEWOO MY_2000 Clutch - Manual Type Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH 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 DOCH 3.2L DOCH 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 4.55 4.89 4.55 3.73 Oil Capacity (L) 3.4 3.4 3.4 3.4 3.4 3.4 Auto Transmission Application 661LA 662LA 2.3L DOCH 3.2L DOCH 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 5.380 4.890 5.860 4.890 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) φ 25.4 Booster Ratio 5.6 : 1 Front Brake : Disc Type Rear Brake : Disc Type Ventilated Solid

0B -- 4 GENERAL INFORMATION DAEWOO MY_2000 Tire and Wheel Application Specifications Standard Tire Size P235/75 R15, 255/70 R15 Standard Wheel Size 7JJ x 15 Inflation Pressure At Full Lode P235 / 75 : Front Rear P255 / 75 : Front Rear 30 Psi 30 Psi 30 Psi 30 Psi Steering System Application Specifications Gear Type RACK & PINION Wheel Alignment: Front: Toe--in Front: Caster Front: Camber 0 -- 4mm 2°30′± 30′ 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 Capacity 70 L Lubricating System Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH 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 Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH 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

GENERAL INFORMATION 0B -- 5 DAEWOO MY_2000 Electric System Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH Battery (MF) 12V -- 90AH Generator 75A 75A 75A 75A 115A 115A Starter 2.2kw 2.2kw 2.2kw 1.2kw 1.2kw 1.7kw

0B -- 6 GENERAL INFORMATION DAEWOO MY_2000 VEHICLE DIMENSIONS AND WEIGHTS Vehicle Dimensions Application Specifications Overall Length (mm) 4330 Overall Width (mm) 1841 Overall Height (mm) 1840 Wheel Base (mm) 2840 Tread: Front (mm) Rear (mm) 1510 1520 Vehicle Weights Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOCH 3.2L DOCH Manual : Curb Weight (kg) Gross Vehicle Weight (kg) 1790 2515 1810 2515 1830 2515 1790 2515 1790 2515 1840 2515 Automatic : Curb Weight (kg) Gross Vehicle Weight (kg) 1810 2515 1815 2515 1850 2515 -- -- 1810 2515 1860 2515 Passenger Capacity 5 5 5 5 5 5

GENERAL INFORMATION 0B -- 7 DAEWOO MY_2000 STANDARD BOLTS SPECIFICATIONS Torque (NSm / Ib-in) Bolt* Standard Limit 4T 7T 9T 4T 7T 9T M3 x 0.5 0.5 NSm (4.5 lb-in) 0.9 NSm (8 lb-in) 1.3 NSm (12 lb-in) 0.7 NSm (6.3 lb-in) 1.2 NSm (11 lb-in) 17 NSm (15 lb-in) M4 x 0.7 1.2 NSm (11 lb-in) 2.0 NSm (18 lb-in) 3.0 NSm (27 lb-in) 1.6 NSm (14 lb-in) 2.6 NSm (23 lb-in) 4.0 NSm (36 lb-in) M5 x 0.8 2.4 NSm (22 lb-in) 4.0 NSm (36 lb-in) 5.6 NSm (50 lb-in) 3.1 NSm (28 lb-in) 5.2 NSm (47 lb-in) 7.6 NSm (68 lb-in) M6 x 1.0 4.0 NSm (36 lb-in) 6.7 NSm (60 lb-in) 9.7 NSm (87 lb-in) 5.4 NSm (49 lb-in) 9.0 NSm (81 lb-in) 12.7 NSm (114 lb-in) M8 x 1.25 8.6 NSm (77 lb-in) 15.7 NSm (12 lb-in) 22.5 NSm (17 lb-in) 12.7 NSm (9 lb-in) 20.6 NSm (15.2 lb-in) 30.4 NSm (22 lb-in) M10 x 1.25 18.6 NSm (14 lb-in) 32.3 NSm (24 lb-in) 46.0 NSm (34 lb-in) 25.5 NSm (19 lb-in) 42.1 NSm (31 lb-in) 60.8 NSm (31 lb-in) M10 x 1.5 18.6 NSm (14 lb-in) 30.4 NSm (22 lb-in) 44.1 NSm (33 lb-in) 24.5 NSm (18 lb-in) 41.2 NSm (30 lb-in) 58.8 NSm (44 lb-in) M12 x 1.25 34.3 NSm (25lb-in) 56.8 NSm (42 lb-in) 82.3 NSm (61 lb-in) 45.0 NSm (33 lb-in) 75.5 NSm (56 lb-in) 107.8 NSm (80 lb-in) M12 x 1.75 32.3 NSm (24 lb-in) 53.9 NSm (40 lb-in) 77.4 NSm (57 lb-in) 43.1 NSm (32 lb-in) 71.5 NSm (53 lb-in) 98.0 NSm (73 lb-in) M14 x 1.5 54.0 NSm (40 lb-in) 89.2 NSm (66 lb-in) 127.4 NSm (94 lb-in) 71.6 NSm (53 lb-in) 117.6 NSm (87 lb-in) 166.6 NSm (123 lb-in) M16 x 1.5 81.3 NSm (60 lb-in) 107.8 NSm (80 lb-in) 196.0 NSm (145 lb-in) 107.8 NSm (80 lb-in) 186.2 NSm (138 lb-in) 264.6 NSm (196 lb-in) M18 x 1.5 117.6 NSm (87 lb-in) 196.0 NSm (145 lb-in) 284.2 NSm (210 lb-in) 156.8 NSm (116 lb-in) 264.6 NSm (196 lb-in) 372.4 NSm (276 lb-in) M20 x 1.5 166.6NSm (123 lb-in) 274.4 NSm (203 lb-in) 392.0 NSm (290 lb-in) 215.6 NSm (160 lb-in) 362.6 NSm (268 lb-in) 519.4 NSm (384 lb-in) M22 x 0.5 225.4NSm (167 lb-in) 372.4 NSm (276 lb-in) 529.2 NSm (392 lb-in) 294.0 NSm (218 lb-in) 490.0 NSm (362 lb-in) 705.6 NSm (522 lb-in) M24 x 1.5 284.2 NSm (210 lb-in) 480.2 NSm (355 lb-in) 686.0 NSm (508 lb-in) 382.2 NSm (283 lb-in) 637.0 NSm (471 lb-in) 921.2 NSm (682 lb-in) M24 x 2.0 274.4 NSm (203 lb-in) 460.6 NSm (341 lb-in) 666.4 NSm (493 lb-in) 372.4 NSm (276 lb-in) 617.4 NSm (457 lb-in) 891.8 NSm (660 lb-in) * Diameter X pitch in millimeters YAA5A5K0 YAA0B010

0B -- 8 GENERAL INFORMATION DAEWOO MY_2000 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: D To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to “Tire and Wheel” in section 2E. D To be driven on reasonable road surfaces and within legal operating limits. EXPLANATION OF SCHEDULED MAINTENANCE SERVICES The services listed in the maintenance schedule are fur- ther explained below. When the following maintenance services are performed, make sure all the parts are re- placed and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants. Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil. 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. D Gasoline Engine : 15,000km (10,000 miles) D Diesel Engine : 10,000km (6,000 miles) Replace the air cleaner element every . D Gasoline Engine : 60,000km (36,000 miles) D Diesel Engine : 30,000km (18,000 miles) Replace the air cleaner more often under dusty conditions. Fuel Filter Replacement Replace the engine fuel filter every. D Gasoline Engine : 60,000km (36,000 miles) D Diesel Engine : 45,000km (24,000 miles) Spark Plug Replacement Replace spark plugs with same type. D Type : BOSCH : F8DC4 BERU : 14F--8DU4 Champion : C11YCC D Gap : 0.8 ± 0.1 mm 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. Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage. To equal- ize 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)

GENERAL INFORMATION 0B -- 9 DAEWOO MY_2000 SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE) Engine MAINTENANCE ITEM MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first x1,000 km 1 15 30 45 60 75 90 105 120 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 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 -- Replaceor 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”.

0B -- 10 GENERAL INFORMATION DAEWOO MY_2000 Chassis and Body MAINTENANCE ITEM MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first x1,000 km 1 15 30 45 60 75 90 105 120 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 I I 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 -- Replaceor 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.

1998 Ssangyong Korando Service & Repair Manual

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