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Daewoo KORANDO manual available for free PDF download: Service Manual
Daewoo KORANDO Service Manual (1462 pages)
Brand:
Daewoo
| Category:
Automobile
| Size: 21.67 MB
Table of Contents
Section 0B General Information
15
Table of Contents
15
Specifications
18
Vehicle Dimensions and Weights
19
Standard Bolts Specifications
20
Maintenance and Repair
21
Maintenance and Lubrication
21
Explanation of Scheduled Maintenance Services
21
Normal Vehicle Use
21
Scheduled Maintenance Charts (Gasoline Engine)
22
Scheduled Maintenance Charts (Diesel Engine)
24
Owner Inspections and Services
26
While Operating the Vehicle
26
At each Fuel Fill
26
At Least Twice a Month
26
At Least Monthly
26
At Least Twice a Year
26
Each Time the Oil Is Changed
27
At Least Annually
27
Recommended Fluids and Lubricants
28
General Description and System Operation
29
General Repair Instructions
29
Vehicle Identification Number System
30
Vehicle Lifting Procedures
33
Section 2
34
Engine Specifications
35
Component Locator
36
Front View
36
Side View
37
Performance Curve
38
E32 Engine
38
Special Tools
39
Special Tools Table
39
Diagnosis
40
Oil Leak Diagnosis
40
Engine Cranking at the Front of Crankshaft
41
Compression Pressure Test
42
Cylinder Pressure Leakage Test
44
General Information
46
Cleanliness and Care
46
On-Engine Service
46
Section 3
47
Engine Specifications
48
Component Locator
49
Front View
49
Side View
50
Performance Curve
51
E23 Engine
51
E20 Engine
52
Special Tools
53
Special Tools Table
53
Diagnosis
54
Oil Leak Diagnosis
54
Engine Cranking at the Front of Crankshaft
55
Compression Pressure Test
56
Cylinder Pressure Leakage Test
58
General Information
60
Cleanliness and Care
60
On-Engine Service
60
Section 4
61
Specifications
62
Engine Specifications
62
Sectional View
63
OM662LA Engine
63
OM661LA Engine
65
Performance Curve
67
OM662LA Engine
67
OM661LA Engine
68
Special Tools
69
Special Tools Table
69
Diagnosis
70
Oil Leak Diagnosis
70
Compression Pressure Test
71
Cylinder Pressure Leakage Test
73
General Information
75
Cleanliness and Care
75
On-Engine Service
75
Section 1B1 M162 Engine Mechanical
76
Specifications
77
Fastener Tightening Specifications
77
Special Tools
79
Special Tools Table
79
Maintenance and Repair
83
On-Vehicle Service
83
Engine Assembly
83
Crankcase Ventilation System
90
Alternator
92
Power Steering Pump and A/C Bracket
93
Hydraulic Engine Mounting Insulator
96
Poly V-Belt
99
Tensioning Device
101
Poly V-Belt Inspection
103
1B1-30 M162 Engine Mechanical Cylinder Head Cover
105
Cylinder Head Cover
105
Cylinder Head
109
Timing Gear Case Cover
112
Crankshaft Sealing Rear Cover
114
Belt Pulley and Vibration Damper
116
Crankshaft Front Radial Seal
119
Crankshaft Rear Radial Seal
120
Crankshaft
121
Flywheel / Driven Plate
127
Bolt (M6 X 65, 8 Pieces)
128
Camshaft Adjuster
129
Bolt (M6 X 50, 4 Pieces)
130
Camshaft Sprocket Bolt
132
Camshaft
133
Installation Procedure
135
Camshaft Timing Position
138
Valve Spring
141
Thrust Piece
141
Valve Stem Seal
145
Chain Tensioner
146
Timing Chain
149
Tensioning Rail
154
Cylinder Head Guide Rail
155
Crankcase Guide Rail
156
Crankshaft Sprocket
157
Piston
159
Connecting Rod
162
Piston Ring
164
Oil Pan
166
Engine Oil and Oil Filter Element
168
Oil Filter
170
Oil Pump
172
Oil Pressure Relief Valve
174
Oil Non-Return Valve
175
Oil Dipstick Guide Tube
176
Unit Repair
177
Oil Gallery in Crankcase
177
Oil Gallery in Cylinder Head
179
Core Plugs in Crankcase
182
Cylinder Bore
184
Crankcase Mating Surface
186
Cylinder Head Mating Surface
188
Section 1B2 M161 Engine Mechanical
190
Specifications
193
Special Tools
193
Special Tools Table
193
Maintenance and Repair
198
On-Vehicle Service
198
Engine Assembly
198
Crankcase Ventilation System
205
Alternator
209
Power Steering Pump and A/C Bracket
210
Hydraulic Engine Mounting Insulator
213
Poly V-Belt
216
Tensioning Deivce
218
Tensioning Device Shock Absorber
219
Poly V-Belt Inspection
220
Cylinder Head Cover
223
Cylinder Head
227
Gasket
230
Timing Gear Case Cover
232
Crankshaft Sealing Rear Cover
235
Belt Pulley and Vibration Damper
237
Crankshaft Front Radial Seal
240
Crankshaft Rear Radial Seal
241
Crankshaft
242
Flywheel/Driven Plate
248
Camshaft Adjuster
250
Camshaft Sprocket Bolt
253
Camshaft
254
Camshaft Timing Position
257
Inspection Procedure
258
Valve Spring
260
Valve Stem Seal
264
Chain Tensioner
265
Timing Chain
268
Tensioning Rail
273
Cylinder Head Guide Rail
274
Crankcase Guide Rail
275
Crankshaft Sprocket
276
Piston
278
Connecting Rod
281
Piston Ring
283
Oil Pan
285
Oil Pump
286
Replacement Procedure
288
Oil Pressure Relief Valve
291
Oil Non-Return Valve
292
Oil Dipstick Guide Tube
293
Core Plugs in Crankcase
294
Unit Repair
294
Cylinder Bore
296
Crankcase Mating Surface
298
Cylinder Head Mating Surface
300
Section 1B3 Om600 Engine Mechanical
302
Fastener Tightening Specifications
303
Specifications
303
Special Tools
305
Special Tools Table
306
Specifications
305
Maintenance and Repair
313
On-Vehicle Service
313
Engine Assembly
313
Poly V-Belt
322
Tensioning Device
324
Poly V-Belt Alignment & Inspection
327
Prechamber
330
Milling of Prechamber Sealing Surface
333
TDC (TDC Sensor Bracket) Setting
336
Om600 Engine Mechanical 1B3-37 Cylinder Head
338
Cylinder Head
362
Timing Case Cover
364
Crankshaft End Cover
372
Vibration Damper and Hub
375
Crankshaft Front Radial Seal
381
Crankshaft Ball Bearing
383
Crankshaft
384
Flywheel
394
Machining of Flywheel
398
Flywheel Ring Gear
399
Hydraulic Valve Clearance Compensation Element Check
402
Valve Tappets
404
Valve Springs Check
406
Valve Springs (Cylinder Head Installed)
410
Valve Stem Seals
413
Check and Replacement of Valve Guides
417
Checking Procedure
419
Valve Seat Rings
423
Check and Machining of Valves
428
Exhaust Valve
429
Machining of Valve Seat
433
Camshaft Timing Test
438
Camshaft
440
Chain Tensioner
446
Timing Chain
448
Tensioning Rail
452
Cylinder Head Guide Rail
453
Timing Case Cover Guide Rail
457
Crankshaft Sprocket
459
Piston
464
Oil Filter
470
Gasket
470
Oil Pan
472
Oil Spray Nozzle
475
Oil Pump
476
Unit Repair
478
Cylinder Head Pressure Leakage Test
478
Bolt
478
Facing Cylinder Head Mating Surface
479
Replacement of Crankcase Core Plug
481
Facing Crankcase Contacting Surface
483
Oil Gallery Steel Ball
484
Cylinder Bore Measurement
488
Section 1D1 M162 Engine Cooling
489
Special Tools
491
Special Tools Table
491
Diagnosis
492
System Leakage Test
492
Coolant Drain and Fill up
493
Clamp
494
Maintenance and Repair
493
On-Vehicle Service
493
Coolant Connection Fitting
495
Bolt
496
Water Pump
496
Thermostat
498
Oil Cooler Pipe Line
499
Cooling Fan and Viscous Clutch
500
Cooling Fan Shroud
502
Radiator
502
Section 1D2 M161 Engine Cooling
505
Special Tools
507
Special Tools Table
507
Diagnosis
508
System Leakage Test
508
Maintenance and Repair
509
On-Vehicle Service
509
Cooling Fan and Viscous Clutch
511
Coolant Pump
513
Thermostat
515
Thermostat Housing Assembly
516
Removal and Installation of Cooling Fan Shroud
518
Removal and Installation of Radiator
519
Section 1D3 Om600 Engine Cooling
521
Diagnosis
522
Cooling Circulation
522
Thermostat Operation
523
Cooling System Leakage Test
524
Drain and Filling of Coolant
525
Maintenance and Repair
525
On-Vehicle Service
525
Coolant Pump
526
Coolant Pump Housing
528
Cooling Fan Clutch
530
Radiator
532
Cooling Sub-System
534
Thermostat
536
Section 1E1 M162 Engine Electrical
538
Specifications
539
Battery Specifications
539
Fastener Tightening Specifications
539
Special Tools
540
Special Tools Table
540
Maintenance and Repair
541
On-Vehicle Service
541
Alternator
541
Starting Motor
542
Battery
543
Spark Plug
544
Ignition Cable
546
Unit Repair
549
Battery
549
Section 1E2 M161 Engine Electrical
550
Specifications
551
Starting Motor Specifications
551
Battery Specifications
551
Fastener Tightening Specifications
551
Special Tools
552
Special Tools Table
552
Maintenance and Repair
553
On-Vehicle Service
553
Alternator
553
Starting Motor
554
Battery
555
Spark Plug
556
Ignition Cable
558
Unit Repair
561
Battery
561
Section 1E3 Om600 Engine Electrical
562
Specifications
563
Maintenance and Repair
563
On-Vehicle Service
563
Glow Plug
563
Alternator
567
Washer
569
Starter Motor
569
Section 1F1 M162 Engine Controls
570
Special Tools
572
Special Tools Table
572
Schematic and Routing Diagrams
573
Diagnosis
574
Self Diagnosis Socket Pin Numbers and Descriptions
574
Self Diagnosis Failure Code
575
Test Box Connection
578
Fuel Injection System Test (Mse3.62)
579
Ignition System Test
589
Idling Control and Electronic Pedal System Test
594
Air Conditioner Control System Test
596
Fuel Pressure and Internal Leakage Test
597
Fuel Pump Test
599
Injector Test
601
Maintenance and Repair
603
On-Vehicle Service
603
Ecu
603
Fuel Pressure Regulator
614
Bolt
618
Fuel Distributor
618
Injector
622
Fuel Filter
625
Fuel Pump
626
Purge Switchover Valve
630
Vacuum System
632
Crankshaft Position Sensor
633
Camshaft Position Sensor
635
Hot Film Air Mass (HFM) Sensor
637
Oxygen Sensor
640
Knock Sensor
642
Coolant Temperature Sensor
643
Accelerator Pedal Module
646
Section 1F2 M161 Engine Controls
648
Special Tools
650
Special Tools Table
650
Schematic and Routing Diagrams
651
Diagnosis
653
Self Diagnosis Socket Pin Numbers and Descriptions
653
Self Diagnosis Failure Code (for E23 Eng)
654
Test Box Connection
657
Fuel Injection System Test
658
Ignition System Test
667
Idling Control and Electronic Pedal System Test
672
Air Conditioner Control System Test
674
Fuel Pressure and Internal Leakage Test
675
Fuel Pump Test
677
Injector Test
679
Maintenance and Repair
681
On-Vehicle Service
681
Ecu
681
Fuel Pressure Regulator
692
Fuel Distributor
696
Injector
701
Fuel Filter
704
Fuel Pump
705
Purge Switchover Valve
709
Vacuum System
711
Crankshaft Position Sensor
713
Camshaft Position Sensor
715
Hot Film Air Mass (HFM) Sensor
717
Oxygen Sensor
720
Knock Sensor
722
Coolant Temperature Sensor
723
Accelerator Pedal Module
726
Section 1F3 Om600 Engine Controls
728
Specifications
729
Maintenance and Repair
729
On-Vehicle Service
729
Fuel System
729
Fuel Injection Pump Coding
730
Fuel Tank
731
Vacuum Control System Test
732
Vacuum Pump(Sectional View)
737
Vacuum Pump Test
738
Vacuum Pump
740
Vacuum Unit Replacement
742
Idle Speed Adjustment
743
Fuel Pump Test
745
Fuel Pump
748
Injection Nozzle Test
749
Fuel Injection Nozzle
752
Injection Nozzles
752
Nozzle Washer
752
Injection Nozzle Repair
754
Repair Procedure
755
Camshaft Drive Sprocket
757
Cylinder Head Bolt
757
Cylinder Head Cover
757
Gasket
757
Removal and Installation of Injection Timing Device
757
Injection Timing Device
762
Start of Delivery Test (Position Sensor, RIV Method)
764
Test Procedure
765
Bolt
773
Fuel Injection Pump
773
Section 1G1 M162 Engine Intake & Exhaust
779
Specifications
780
Maintenance and Repair
780
On-Vehicle Service
780
Air Cleaner
780
Intake Air Duct
782
Nut
782
Intake Manifold
783
Resonance Flap
785
Exhaust Manifold
787
Section 1G2 M161 Engine Intake & Exhaust
790
Specifications
791
Maintenance and Repair
791
On-Vehicle Service
791
Air Cleaner
791
Air Intake Shield
793
Intake Air Duct
794
Intake Manifold
796
Exhaust Manifold
798
Section 1G3 Om600 Engine Intake & Exhaust
801
Specifications
802
Maintenance and Repair
802
Air Cleaner and Inlet Duct & Hose
802
On-Vehicle Service
802
Intake and Exhaust Manifold
804
Charge Air System Diagram
807
Turbocharger
807
Intercooler
808
Turbocharger Assembly
810
Section 2A Suspension Diagnosis
813
Specifications
814
General Specifications
814
Diagnosis
815
General Diagnosis
815
Input & Output Devices and Damping
817
System Layout
817
Damping Force Control Logic
818
Normal Control
818
Self-Diagnosis
819
Actuator Inspection
820
Schematic and Routing Diagrams
821
Diagnosis Test
823
Self Diagnosis Test
823
Section 2B Wheel Alignment
825
Diagnosis
826
Tire Diagnosis
826
Radial Tire Lead/Pull
827
Vibration Diagnosis
829
2B-6 Wheel Alignment
830
Specifications
826
Maintenance and Repair
830
On-Vehicle Service
830
Camber
833
Caster
833
Four Wheel Alignment
833
General Description and System Operation
833
Toe
833
Section 2C Front Suspension
834
Component Locator
836
Front Suspension
836
Maintenance and Repair
837
On-Vehicle Service
837
Front Stabilizer Bar
837
Torsion Bar
839
Front Lower and Upper Arm
841
Front Shock Absorber
843
Axle Vertical Acceleration Sensor (Wheel G Sensor)
845
Vertical and Lateral Sensor
846
Ecs (Ecu)
847
Rear Shock Absorber
856
Section 2E Tires and Wheels
858
Diagnosis
859
Radial Tire
860
Wheel Disc
860
Component Locator
861
Wheel and Tire
861
Maintenance and Repair
862
Wheels and Tires
862
Component Locator
867
Front Axle
867
On-Vehicle Service
870
Sectiond Rear Drive Axle
894
Specifications
895
General Specifications
895
Diagnosis
896
Heating
896
Oil Leakage
896
Vibration
897
Noise
897
Component Locator
898
Gasket
899
Maintenance and Repair
899
On-Vehicle Service
899
Axle Shaft
899
Axle
902
Unit Repair
904
Axle Housing
904
Section 4A Hydraulic Brakes
911
Diagnosis
912
Poor Braking
912
Increasing Pedal Stroke
913
Poor Braking of Parking Brake
913
Specifications
912
Component Locator
914
Abs
914
Abs / Abd
915
Non-Abs/Abd
916
Maintenance and Repair
917
On-Vehicle Service
917
Bleeding the Brakes
917
Brake Pedal
919
LCRV (Load Conscious Reducing Valve)
922
Front Disc Brake
935
Rear Disc Brake
940
Section 4F Antilock Brake System
943
Specifications
944
Schematic and Routing Diagrams
944
Component Locator
946
ABD System Description
947
Self Diagnosis
949
Defect Codes
951
Maintenance and Repair
957
On-Vehicle Service
957
Wheel Speed Sensor
957
Hydraulic Circuit
959
Section 4G Parking Brake
965
Specifications
965
Fastener Tightening Specifications
965
Component Locator
966
4G-2 Parking Brake
966
Maintenance and Repair
967
On-Vehicle Service
967
Parking Brake
967
Section 5A Automatic Transmission
969
Specifications
970
Model Part Numbers and Applications
970
Model Specifications
970
Clutch Pack Details
971
Special Tools
972
Special Tools Table
972
Schematic and Routing Diagrams
973
Shift Pattern Diagram
975
661LA Power Mode
976
662LA Normal Mode
977
662LA Power Mode
978
662LA Low Mode
979
E32 Power Mode
980
E32 Normal Mode
981
E32 Low Mode
982
E23 Power Mode
983
E23 Normal Mode
984
E23 Low Mode
985
Introduction
986
Operator Interfaces
988
Gear Select Lever Operation
988
Driving Mode Selector
989
Control Systems
990
General
990
Electronic Control System
990
Hydraulic Control System
999
Power Train System
1010
Torque Converter
1011
Clutch Packs
1012
Bands
1013
One Way Clutches
1013
Planetary Gear Set
1013
Parking Mechanism
1014
Power Flows
1015
Introduction
1015
Power Flow - Park and Neutral
1016
Power Flow - Reverse
1017
Power Flow - Drive 4 (Overdrive)
1025
Diagnosis
1028
Diagnostic System
1028
Mechanical Tests
1037
Self Diagnosis Test
1043
Adjustments
1047
Hydraulic System
1047
Electronic Adjustments
1048
Maintenance and Repair
1050
On-Vehicle Service
1050
Unit Repair
1053
Rebuild Warnings
1053
Disassembly Procedure
1053
Assembly Procedure
1062
Front and Rear Band Adjustment
1096
Section 5B Manual Transmission
1099
Specifications
1099
General Specifications
1099
External View
1101
Gear Train
1101
Power Flow
1102
Diagnosis
1103
Transmission Jumps out
1104
Transmission Locked in One Gear
1104
Transmission Noise
1104
Transmission Leakage
1105
Diagnosis Table
1106
Component Locator
1107
Maintenance and Repair
1109
On-Vehicle Service
1109
Transmission
1112
Unit Repair
1115
Major Unit
1115
Main Shaft
1125
Input Shaft
1130
Counter Shaft
1132
Extension Housing
1133
Shift Cover
1134
Inspection of Components
1138
Pre-Installation Checks
1143
Section 5C Clutch
1145
Specifications
1145
General Specifications
1145
Special Tools
1147
Diagnosis
1148
Clutch Slips
1148
Poor Disengagement
1148
Difficult Pedal Operation
1149
Clutch Noisy
1149
Clutch Assembly
1150
Pedal and Master Cylinder
1151
Component Locator
1150
Maintenance and Repair
1152
On-Vehicle Service
1152
Clutch Disc
1153
Master Cylinder
1157
Clutch Pedal
1159
Clutch Oil Chamber
1161
Section 5D1 Transfer Case (Part Time 4408)
1162
Specifications
1162
General Specifications
1162
Schematic and Routing Diagram
1163
Diagnosis
1164
Self- Diagnosis
1165
System Description
1165
Self-Diagnosis Test
1169
Diagnostic Diagram
1170
Maintenance and Repair
1171
On-Vehicle Service
1171
Maintenance of Transfer Case Lubricant
1171
Transfer Case
1172
Unit Repair
1175
Transfer Case
1176
Transfer Case Control Unit (TCCU)
1197
Section 5D2 Transfer Case (Tod)
1199
Specifications
1199
General Specifications
1199
Function Description
1200
TOD Control Unit
1208
Schematic and Routing Diagrams
1210
Diagnosis
1211
Diagnostic Tests
1211
Diagnostic Trouble Codes (Dtc's)
1213
Coding
1214
Eliminate the Memorized Fault Code
1216
Maintenance and Repair
1229
On-Vehicle Service
1229
Transfer Case (TOD)
1230
Propeller Shaft
1234
Speed Sensor in Front and Rear
1234
Replacement of Oil
1236
Unit Repair
1237
Transfer Case
1237
Steering System
1253
Steering Column
1260
Heater Unit
1266
Air Conditioner System
1271
Gasoline Engine
1272
Defrost Switch
1291
Auto Switch
1291
Blower Switch (Up/Down)
1291
Off Switch
1291
Temperature Up/Down Switch
1291
Maintenance and Repair
1295
Troubleshooting
1299
Front Seat Belt
1306
Rear Seat Belt
1307
Air Bag Module
1325
Air Conditioner
1343
Rear Wiper and Washer
1366
Combination Meter
1371
Console Box
1378
Front Bumper
1398
Rear Bumper
1400
Front Door
1404
Operating Characteristics
1433
Combination Switch
1442
Other Switches
1446
Diesel Engine
1457
Immobilizer Antenna
1461
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