Daewoo Korando User Manual

SECTION 0B

GENE RAL 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 Tw ice A Month 0B--13...................

At Least Monthly 0B--13.........................

At Least Tw ice 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.................

DAEW OO MY_2000

0B --2 GENERAL INFORMATION

SPECIFICATIONS

TECHNICAL DATA

Transaxle Performance

Application 661LA 662NA 662LA

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

2.0L

DOHC

2.3L

DOCH

3.2L

DOCH

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

Engine Type 4Cylinder

DIESEL
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

5Cylinder

DIESEL

5Cylinder

DIESEL

2.0L

DOHC

4Cylinder

GASOLINE

2.3L

DOCH

4Cylinder

GASOLINE

3.2L

DOCH

6Cylinder

GASOLINE

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)

DAEW OO MY_2000

Clutch - Manual Type

GENERAL INFORMATION 0B--3

Application 661LA 662NA 662LA

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

2.0L

DOHC

2.3L

DOCH

3.2L

DOCH

Manual Transmission

Application 661LA 662NA 662LA

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

2.0L

DOHC

2.3L

DOCH

3.2L

DOCH

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

Master Cylinder Diameter (mm) φ 25.4
Booster Ratio 5.6 : 1
Front Brake : Disc Type

Rear Brake : Disc Type

non--ABS 8inch + 9inch
ABS 5.0 7inch + 8inch
ABS 5.3 8inch + 9inch

Ventilated

Solid

DAEW OO MY_2000

0B --4 GENERAL INFORMATION

Tire and Wheel

Application Specifications

Standard Tire Size P235/75 R15, 255/70 R15
Standard Wheel Size 7JJx15
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 T ype RACK & PINION
Wheel Alignment:

Front: Toe--in
Front: Caster
Front: Camber

Oil Capacity 1L

0--4mm

2°30′±30′

0°±30′

Suspension

Application Specifications

Front T ype 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

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

2.0L

DOHC

2.3L

DOCH

Cooling System

3.2L

DOCH

Application 661LA 662NA 662LA

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

2.0L

DOHC

2.3L

DOCH

3.2L

DOCH

DAEW OO MY_2000

Electric System

GENERAL INFORMATION 0B--5

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

DAEW OO MY_2000

0B --6 GENERAL INFORMATION

VEHICLE DIMENSION S 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)

Vehicle Weights

1510
1520

Application 661LA 662NA 662LA

Manual : Curb Weight (kg)

Gross Vehicle
Weight (kg)

Automatic : Curb Weight (kg)

Gross Vehicle
Weight (kg)

Passenger Capacity 5 5 5 5 5 5

1790
2515

1810
2515

1810
2515

1815
2515

1830
2515

1850
2515

2.0L

DOHC

1790
2515

--

--

2.3L

DOCH

1790
2515

1810
2515

3.2L

DOCH

1840
2515

1860
2515

DAEW OO MY_2000

Bolt*

4T 7T 9T 4T 7T 9T

M3 x 0.5 0.5 NSm

(4.5 lb-in)

M4 x 0.7 1.2 NSm

(11 lb-in)

M5 x 0.8 2.4 NSm

(22 lb-in)

M6 x 1.0 4.0 NSm

(36 lb-in)

M8 x 1.25 8.6 NSm

(77 lb-in)

M10 x 1.25 18.6 NSm

(14 lb-in)

M10 x 1.5 18.6 NSm

(14 lb-in)

M12 x 1.25 34.3 NSm

(25lb-in)

M12 x 1.75 32.3 NSm

(24 lb-in)

M14 x 1.5 54.0 NSm

(40 lb-in)

M16 x 1.5 81.3 NSm

(60 lb-in)

M18 x 1.5 117.6 NSm

(87 lb-in)

M20 x 1.5 166.6NSm

(123 lb-in)

M22 x 0.5 225.4NSm

(167 lb-in)

M24 x 1.5 284.2 NSm

(210 lb-in)

M24 x 2.0 274.4 NSm

(203 lb-in)

* Diameter X pitch in millimeters

GENERAL INFORMATION 0B--7

ST ANDARD BOLTS SPECIFICATIONS

Torque (NSm/Ib-in)

Standard Limit

0.9 NSm
(8 lb-in)

2.0 NSm

(18 lb-in)

4.0 NSm

(36 lb-in)

6.7 NSm

(60 lb-in)

15.7 NSm
(12 lb-in)

32.3 NSm
(24 lb-in)

30.4 NSm
(22 lb-in)

56.8 NSm
(42 lb-in)

53.9 NSm
(40 lb-in)

89.2 NSm
(66 lb-in)

107.8 NSm
(80 lb-in)

196.0 NSm

(145 lb-in)

274.4 NSm

(203 lb-in)

372.4 NSm

(276 lb-in)

480.2 NSm

(355 lb-in)

460.6 NSm

(341 lb-in)

1.3 NSm

(12 lb-in)

3.0 NSm

(27 lb-in)

5.6 NSm

(50 lb-in)

9.7 NSm

(87 lb-in)

22.5 NSm
(17 lb-in)

46.0 NSm
(34 lb-in)

44.1 NSm
(33 lb-in)

82.3 NSm
(61 lb-in)

77.4 NSm
(57 lb-in)

127.4 NSm
(94 lb-in)

196.0 NSm

(145 lb-in)

284.2 NSm

(210 lb-in)

392.0 NSm

(290 lb-in)

529.2 NSm

(392 lb-in)

686.0 NSm

(508 lb-in)

666.4 NSm

(493 lb-in)

0.7 NSm

(6.3 lb-in)

1.6 NSm

(14 lb-in)

3.1 NSm

(28 lb-in)

5.4 NSm

(49 lb-in)

12.7 NSm
(9 lb-in)

25.5 NSm

(19 lb-in)

24.5 NSm

(18 lb-in)

45.0 NSm

(33 lb-in)

43.1 NSm

(32 lb-in)

71.6 NSm

(53 lb-in)

107.8 NSm
(80 lb-in)

156.8 NSm

(116 lb-in)

215.6 NSm

(160 lb-in)

294.0 NSm

(218 lb-in)

382.2 NSm

(283 lb-in)

372.4 NSm

(276 lb-in)

1.2 NSm

(11 lb-in)

2.6 NSm

(23 lb-in)

5.2 NSm

(47 lb-in)

9.0 NSm

(81 lb-in)

20.6 NSm

(15.2 lb-in)

42.1 NSm
(31 lb-in)

41.2 NSm
(30 lb-in)

75.5 NSm
(56 lb-in)

71.5 NSm
(53 lb-in)

117.6 NSm
(87 lb-in)

186.2 NSm

(138 lb-in)

264.6 NSm

(196 lb-in)

362.6 NSm

(268 lb-in)

490.0 NSm

(362 lb-in)

637.0 NSm

(471 lb-in)

617.4 NSm

(457 lb-in)

17 NSm

(15 lb-in)

4.0 NSm

(36 lb-in)

7.6 NSm

(68 lb-in)

12.7 NSm

(114 lb-in)

30.4 NSm
(22 lb-in)

60.8 NSm
(31 lb-in)

58.8 NSm
(44 lb-in)

107.8 NSm
(80 lb-in)

98.0 NSm
(73 lb-in)

166.6 NSm
(123 lb-in)

264.6 NSm
(196 lb-in)

372.4 NSm
(276 lb-in)

519.4 NSm

(384 lb-in)

705.6 NSm
(522 lb-in)

921.2 NSm
(682 lb-in)

891.8 NSm
(660 lb-in)

DAEW OO MY_2000

YAA0B010

YAA5A5K0

0B --8 GENERAL INFORMATION

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 Tocarry passengers and cargo within the limitation of

the tire inflation prassure. Refer to “T ire and Wheel” in
section 2E.

D To be driven on reasonable road surfaces and within

legal operating limits.

EXPLAN ATION 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.

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. Usi ng oils of any viscosity
other than those viscosities recommended could result
in engine damage.

D Diesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty condi-

tions.

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. Toequal­ize 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)

Cooling System Service

Drain, flushand refillthe system withnew 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)

DAEW OO MY_2000

GENERAL INFORMATION 0B--9

SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)

Engine

MAINTENANCE ITEM

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 -- Replace or change.

(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condi-

tion. 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”.

MAINTENANCE INTERVAL

DAEW OO MY_2000

0B --10 GENERAL INFORMATION

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
Ti re 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, fre-

quent low -- speed operation in stop--and--go traffic or driving in dusty condition.

(6) Change automatic transaxle fluidand filter every 75,000 km if the vehicle is mainly driven under severe condi-

tions.

-- 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.

DAEW OO MY_2000

GENERAL INFORMATION 0B--11

SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)

Engine

MAINTENANCE ITEM

Kilometers or time in months, whichever comes first
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
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 R I I I I I I I
Air cleaner (2) -- I I I 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 condi-

tion, 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”.

MAINTENANCE INTERVAL

DAEW OO MY_2000

0B --12 GENERAL INFORMATION

Chassis and Body

MAINTENANCE ITEM

MAINTENANCE INTERVAL

Kilometers or time in months, whichever comes first
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
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)
Chassis & underbody bolts & nuts

tight/secure

-- I I I I I I I I I I

I I I I I I I I I I I

Ti re 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, fre-

quent 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.

DAEW OO MY_2000

GENERAL INFORMATION 0B--13

OWNER INSPECTIONS AND SERVICES

WHIL E OPERATING THE VEHICLE

Horn Operation

Blowthe horn occasionallyto make sure it works. Check
all the button locations.

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.

Exhaust System Operation

Be alert to any changes in the sound of the system or
the smellof the fumes. These are signsthat the system
may be leaking or overheating. Have the system in­spected and repaired immediately.

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 ona
straight, level road may show the need for a tire pres­sure adjustment or a wheel alignment.

Steering System Operation

Be alert to changes in the steering action. An inspection
is needed when the steering wheelis 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.

A T 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

Check the oil level and add oil if necessary. The best
time to check the engine oil levelis whenthe 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.

5. Add oil, if needed, to keep the oil levelabove 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.

Windshield Washer Fluid Level

Check the washer fluid level in the reservoir. Add fluid if
necessary.

A T LEAST TWICE A MONTH

Tire And Wheel Inspection and Pressure
Check

Check the tire for abnormal wear or damage. Alsocheck
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.

A T LEAST MONTHL Y

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.

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 younoticefuel leaksor
fumes, find the cause and correct it at once.

A T 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.

Brake Master Cylinder Reservoir Level

Check the fluid and keep it at theproper level. A lowfluid
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.

Weather-Strip Lubrication

Apply a thin film silicone grease using a clean cloth.

DAEW OO MY_2000

0B --14 GENERAL INFORMATION

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 forwear. Inspect the rotors for
surface condition. Inspect other brake parts, theparking
brake, etc., at the same time. Inspect the brakes more
often if habit or conditions result in frequent braking.

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.

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--of--position 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.

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 Drive Belts

Inspect all belts for cracks, fraying, wearand 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.

A T LEAST ANNUALL Y

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.

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.

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.

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.

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.

DAEW OO MY_2000

GENERAL INFORMATION 0B--15

(Changewithfilter

)

ACEA;A2orA3

M

Bsh

g

RECOMMENDED FLUIDS AND LUBRICANTS

Usage Capacity Fluid/Lubricant

Engine Oil
(Change with filter)

Engine Coolant

Brake / Clutch Fluid Approx. 0.5L level must

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

Fuel Door Hinge
Rear Compartment Lid Hinges

Weatherstrips As required Silicone grease

3.2L DOHC 8.2 L

2.3L DOHC 7.5 L

662LA 9.5 L

661LA 8.0 L

3.2L DOHC 11.3 L

2.3L DOHC 10.5 L
662LA 10.5 -- 11.0 L
661LA 9.5 -- 10.0 L

be maintained between

MAX&MINlevel

As required Spray type grease

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

eet ; 228.1, 228.3,

228.5, 229.1

Viscosity -- MB sheet ; 224.1

ALUTEC P--78

DOT--3 & SAE J 1703

DAEW OO MY_2000

0B --16 GENERAL INFORMATION

GENERAL DESCRIPTION AND SYSTEM OPERATION

GENERAL REPAIR INSTRUCTIONS

D If a floor jack is used, the following precautions are

recommended.

D 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.

D Before performing the service operation, disconnect

the negative battery cable in order to reduce the
chance of cable damaged and burning due to short-­cir cuiting.

D Use a cover on the body, the seats and the floor to

protect them against damage and contamination.

D Handle brake fluid and antifreeze solution with care

as they can cause paint damage.

D The use of proper tools, and the recommended es-

sential and available tools where specified, areimpor­tant for efficient and reliable performance of the
service repairs.

D Use genuine DAEWOO parts.

D Discard used cotter pins, gaskets, O--rings, oilseals,

lock washers and self--locking nuts. Prepare new
ones for installation. Normal function of these parts
cannot be maintained if these parts are reused.

D Keep the disassembled parts neatly ingroups to facil-

itate proper and smooth reassembly.

D Keep attaching bolts and nuts separated, as they

vary in hardness and design depending on the posi­tion of the installation.

D Clean the parts before inspection or reassembly.
D Also clean the oil parts, etc. Use compressed air to

make certain they are free of restrictions.

D Lubricate rotating and slidi ngfaces of parts with oil or

grease before installation.

D When necessary, use a sealer on gaskets to prevent

leakage.

D Carefully observe all specifications for bolt and nut

torques.

D When service operation is completed, make a final

check to be sure service was done properly and the
problem was corrected.

DAEW OO MY_2000

GENERAL INFORMATION 0B--17

VEHICLE IDENTIFICATION NUMBER SYSTEM

DAEW OO MY_2000

0B --18 GENERAL INFORMATION

Manufacturer’s Plate

1 Type Approval No.
2 ehicle Identification Number.

Manufacturer’s Plate Location

Diesel Engine Gasoline Engine

DAEW OO MY_2000

GENERAL INFORMATION 0B--19

Gasolind Engine Number Diesel Engine Number

Engine Number Location

Diesel Engine

The engine number is stamped on the cylinder block in
front of injection pump.

IL6 3200 Gasolind Engine

The engine number is stamped on the lower rear side of
the alternator.

DAEW OO MY_2000

0B --20 GENERAL INFORMATION

2300 DOHC Gasolind Engine

The engine number is stamped on the upper rear left-­hand side of the cylinder block.

VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the lifting 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, take special care to avoid damag­ing the fuel tank, the filter neck, the exhaust system, or
the underbody.

Vehicle Lifting Points

Using Jack

(Rearward of Front Tire)

Using Jack

(Forward of Rear Tire)

DAEW OO MY_2000

SECTION 1

ENGINE

SECTION 1A1 (M162 ENGINE)

GENERAL ENGINE INFORMA TION

TABLE OF CONTENTS

Specifications 1A1--2............................

Engine Specifications 1A1--2.....................

Component Locator 1A1--3.......................

Front View 1A1--3...............................

Side View 1A1--4...............................

Performance Curve 1A1--5........................

E32 Engine 1A1--5..............................

Diagnosis 1A1--6.................................

Oil Leak Diagnosis 1A1--6........................

Engine Cranking at The

FrontofCrankshaft 1A1--7.....................

Compression Pressure Test 1A1--8...............

Cylinder Pressure Leakage Test 1A1--10...........

General Information 1A1--12......................

Cleanliness and Care 1A1--12....................

On--Engine Service 1A1--12......................

DAEW OO MY_2000

1A1 --2 GENERAL ENGINE INFORMATION

g

SPECIFICATIONS

ENGINE SPECIFICATIONS

Application E32 Engine

Engine Model M162.990
Displacement (CC) 3199
Cylinder (Bore x Stroke) (mm) 89.9 x 84.0
Fuel Injection / Ignition System MSE 3.62S
Compression Ratio 10 : 1
Number of Cylinders 6
Camshaft Valve Arrangement DOHC
Camshaft Drive Type Chain--Driven
Max. Output (ps/rpm) 222 / 5500
Max. Torque (kgSm/rpm) 31.6 / 3750
Firing Order 1--5--3-- 6--2-- 4
Ignition Type Distributorless Double Ignition
Ignition Timing BTDC 8°±2°
Valve Timing

Valve Clearance Adjustment Automatic Control
Idle Speed (rpm) 700 ± 50
Fuel Injection Pressure (kg/cm@) 3--4
Oil Capacity (liter) 8.2
Lubrication Type Forced by Gear Pump
Oil Filter Type Full Flow with Paper Filter
Fuel Unleaded Gasoline

Intake Open/Close ATDC 11° / ABDC 34°
Exhaust Open/Close BBDC 31° /BTDC14°

MSE 3.62S/3.53S (Motorsteuer Elektronik : German)

MSE : Engine Control Electronic

3.62S : 6 Cylinder Version

3.53S : 4 Cylinder Version

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A1--3

COMPONENT LOCATOR

FRONT VIEW

1 HFM Sensor
2 Intake Air Duct
3 Resonance Flap
4 Cylinder Head Cover
5 Exhaust Camshaft
6 Intake Camshaft
7 Cylinder Head
8 Spark Plug Connector

9 Valve Tappet
10 Injector
11 Exhaust Valve

DAEW OO MY_2000

12 Intake Manifold
13 Connecting Rod
14 Exhaust Manifold
15 Crankshaft
16 Engine Mounting Bracket
17 Starter
18 Crankcase
19 Oil Pump Sprocket
20 Oil Strainer
21 Oil Pan
22 Drain Plug

1A1 --4 GENERAL ENGINE INFORMATION

SIDE VIEW

23 Camshaft Adjuster
24 Cooling Fan and Viscous Clutch
25 Piston
26 Flywheel of Drive Plate

27 Oil Pump Drive Chain
28 Oil Return Pipe
29 Timing Chain
30 Oil Pump

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A1--5

PERFORMANCE CURVE

E32 ENGINE

DAEW OO MY_2000

1A1 --6 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. Onsome occasions a fluid leak may be
difficult to locate or repair. Thefollowingproceduresmay
help you in locating and repairing most leaks.

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.

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.

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 theengine 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.

Repairing the Leak

Once the origin of the leak has been pinpoi nted and
traced back to its source, the cause of the leak must be
determinednorder for it to berepaired 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

D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The fasteners are tightened improperlyor the threads

are dirty or damaged.

D The flanges or the sealing surface is warped.
D There are scratches, burrs or other damage to the

sealing surface.

D The gasket is damaged or worn.
D There is cracking or porosity of the component.
D An improper seal was used (where applicable).

Seals

D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The seal bore is damaged (scratched, burred or

nicked).

D The seal is damaged or worn.
D Improper installation is evident.
D There are cracks in the components.
D The shaft surface is scratched, nicked or damaged.
D A loose or worn bearing is causing excess seal wear.

DAEW OO MY_2000

ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

Preceding Work: Removal of cooling fan

GENERAL ENGINE INFORMATION 1A1--7

1 Vibration Damper Assembly
2 Crankshaft Pulley

Notice

D Remove the negative ground cable before proceed-

ing the work.

D Rotate the pulley in normal engine rotating direction

when cranking.

3Bolt 8.6±0.9 NSm..........................

DAEW OO MY_2000

1A1 --8 GENERAL ENGINE INFORMATION

p

COMPR ESSION PRESSUR E TEST

1 Compression Pressure Tester
2 Diagram Sheet

3 Adaptor
4 Sealing Cone

Standard Service Data

Compression Ratio 10 : 1
Normal Engine Temperature 80°C
Normal Compression Pressure

Permissible Pressure Difference Between Individual
Cylinders

General Min. 10 bar, Max. 14 bar
Fuel Optimization Min. 6 bar, Max. 10 bar

Max. 1.5 bar

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A1--9

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 compressionpressure of the other cylin­ders in the same way.

8. If measured value is not within the specifications,per­form the cylinder pressure leakage test.

Notice

D Discharge the combustion residues in the cylinders

before testing the compression pressure.

D Apply the parking brake before cranking the engine.

DAEW OO MY_2000

1A1 --10 GENERAL ENGINE INFORMATION

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 Max. 10 %
At Piston and Piston Ring Max. 20 %

Max. 25 %

Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark OT (TDC) a(120°) b (240°)

Cylinder Number 1, 6 2, 5 3, 4

Cylinder Pressure Leakage Tester

Universal T ool

Bosch, EFAW 210A

Sun, CLT 228

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A1--11

Leakage Test

1. Warm the engine up to normal operating tempera­ture.

2. Disconnect the negative battery cable.

3. Remove the spark plugs.

4. 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 airpressure lineand adjustthe
scale of tester.

7. Install the connecting hose to spark plug hole.

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 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:

FiringOrder:1--5--3--6--2--4

11. Compare the leakage pressure with the specifica­tions.

DAEW OO MY_2000

1A1 --12 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-thousandths of an
inch. When any internal engine parts are serviced, care
and cleanlinessare important. A liberal coating of enigne
oil should beapplied tofriction areas during assembly ,to
protect and lubricate the surfaces on initial operation.
Propercleaningandprotection of machinedsurfacesand
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
installedinthe samelocations, and withthe samemating
surfaces, as when they were removed.

Battery cables should be disconnectedbefore any major
work is performed on the engine. Failure to disconnect

cables may result in damage to wire harness or other
electrical parts.

ON-EN GINE SERVIC E

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.

DAEW OO MY_2000

1A2 --2 GENERAL ENGINE INFORMATION

SPECIFICATIONS

ENGINE SPECIFICATIONS

Application E23 Engine E20 Engine

Engine Model M161.970 M161.940
Displacement (CC) 2295 1998
Cylinder (Bore x Stroke) (mm) 90.9 x 88.4 89.9 x 78.7
Fuel Injection / Ignition System MSE 3.53S ←
Compression Ratio 10.4:1 9.6:1
Number of Cylinders 4 ←
Camshaft Valve Arrangement DOHC ←
Camshaft Drive Type Chain--Driven ←
Max. Output (ps/rpm) 149 / 5500 135 / 5500
Max. Torque (kgSm/rpm) 22.4 / 4000 19.3 / 4000
Firing Order 1-- 3--4-- 2 ←
Ignition Type Distributorless ←
Ignition Timing BTDC 6°± 2° ←
Valve

Timing
Valve Clearance Adjustment Automatic Control ←

Idle Speed (rpm) 750 ± 50 ←
Fuel Injection Pressure (kg/cm@) 3.2 -- 4.2 ←
Oil Capacity (liter) 7.5 ←
Lubrication Type Forced by Gear Pump ←
Oil Filter Type Full Flow with Paper Filter ←
Fuel Unleaded Gasoline ←

Intake Open/Close ATDC 19.25° / ABDC 28.76° ATDC 13.15° / ABDC 13.57°
Exhaust Open/Close BBDC 20.62° / BTDC 15.08° BBDC 16.58° / BTDC 17.05°

MSE 3.62S/3.53S (Motorsteuer Elektronik : German)

MSE : Engine Control Electronic

3.62S : 6 cylinder version

3.53S : 4 cylinder version

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A2--3

COMPONENT LOCATOR

FRONT VIEW

1 HFM Sensor
2 Intake Air Duct
3 Cylinder Head Cover
4 Ignition Coil
5 Spark Plug Connector
6 Fuel Distributor
7 Injector
8 Exhaust Camshaft

9 Intake Camshaft
10 Valve Tappet
11 Intake Valve

DAEW OO MY_2000

12 Intake Manifold
13 Cylinder Head
14 Exhaust Manifold
15 Dipstick Guide Tube and Gauge
16 Connecting Rod
17 Crankshaft
18 Engine Mounting Bracket
19 Starter
20 Crankcase
21 Oil Pump Sprocket
22 Oil Pan

1A2 --4 GENERAL ENGINE INFORMATION

SIDE VIEW

23 Camshaft Adjuster
24 Oil Filler Cap
25 Engine Hanger Bracket
26 Cooling Fan and Viscous Clutch
27 Oil Filter
28 Timing Chain

29 Oil Pump Drive Chain
30 Oil Strainer
31 Oil Pump
32 Ring Gear and Flywheel of Drive Plate
33 Piston

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A2--5

PERFORMANCE CURVE

E32 ENGINE

DAEW OO MY_2000

1A2 --6 GENERAL ENGINE INFORMATION

E20 ENGINE

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A2--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. Onsome occasions a fluid leak may be
difficult to locate or repair. Thefollowingproceduresmay
help you in locating and repairing most leaks.

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.

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.

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 theengine 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.

Repairing the Leak

Once the origin of the leak has been pinpoi nted and
traced back to its source, the cause of the leak must be
determinednorder for it to berepaired 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

D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The fasteners are tightened improperlyor the threads

are dirty or damaged.

D The flanges or the sealing surface is warped.
D There are scratches, burrs or other damage to the

sealing surface.

D The gasket is damaged or worn.
D There is cracking or porosity of the component.
D An improper seal was used (where applicable).

Seals

D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The seal bore is damaged (scratched, burred or

nicked).

D The seal is damaged or worn.
D Improper installation is evident.
D There are cracks in the components.
D The shaft surface is scratched, nicked or damaged.
D A loose or worn bearing is causing excess seal wear.

DAEW OO MY_2000

1A2 --8 GENERAL ENGINE INFORMATION

ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

Preceding Work: Removal of cooling fan

1 Vibration Damper Assembly
2 Crankshaft Pulley

Notice

D Remove the negative ground cable before proceed-

ing the work.

D Rotate the pulley in normal engine rotating direction

when cranking.

3Bolt 8.6±0.9 NSm..........................

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A2--9

p

COMPR ESSION PRESSUR E TEST

1 Compression Pressure Tester
2 Diagram Sheet

3 Adaptor
4 Sealing Cone

Standard Service Data

Compression Ratio 10.4, 9.6
Normal Engine Temperature 80°C
Normal Compression

Pressure
Permissible Pressure Difference Between Individual

Cylinders

E23 Engine(e = 10.4) Min. 11 bar, Max. 15 bar
E20 Engine(e = 9.6) Min. 10.5 bar, Max. 14 bar

Max. 1.5 bar

DAEW OO MY_2000

1A2 --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 compressionpressure of the other cylin­ders in the same way.

8. If measured value is not within the specifications,per­form the cylinder pressure leakage test.

Notice

D Discharge the combustion residues in the cylinders

before testing the compression pressure.

D Apply the parking brake before cranking the engine.

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A2--11

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 Max. 10 %
At Piston and Piston Ring Max. 20 %

Max. 25 %

Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark OT (TDC) UT (BDC : 180°)

Cylinder Number 1, 4 2, 3

Cylinder Pressure Leakage Tester

DAEW OO MY_2000

Universal T ool

Bosch, EFAW 210A

Sun, CLT 228

1A2 --12 GENERAL ENGINE INFORMATION

Leakage Test

1. Warm the engine up to normal operating tempera­ture.

2. Disconnect the negative battery cable.

3. Remove the spark plugs.

4. 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 airpressure lineand adjustthe
scale of tester.

7. Install the connecting hose to spark plug hole.

8. Position the piston of No.1 cylinder at TDC by rotat­ing the crankshaft.

YAA1A2080

9. Connect the connecting hose to tester and measure
the leakage volume after blowing up 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.

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A2--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-thousandths of an
inch. When any internal engine parts are serviced, care
and cleanlinessare important. A liberal coating of enigne
oil should beapplied tofriction areas during assembly ,to
protect and lubricate the surfaces on initial operation.
Propercleaningandprotection of machinedsurfacesand
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
installedinthe samelocations, and withthe samemating
surfaces, as when they were removed.

Battery cables should be disconnectedbefore any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.

ON-EN GINE SERVIC E

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.

DAEW OO MY_2000

1A3--2 GENERAL ENGINE INFORMATION

ENGINE SPECIFICATIONS (Con t’d )

Application OM662LA OM661LA

Idle Speed (rpm) 720 -- 820 750 -- 850
Fuel Injection Pressure (bar) 135 -- 143 135 -- 143
Oil Capacity (liter) 8.0 -- 9.5 6.5 -- 8.0
Lubrication Type Forced by Gear Pump Forced by Gear Pump
Oil Filter Type Combined Full--Flow and Partial

Flow Filter

Fuel Diesel Diesel

Combined Full--Flow and Partial

Flow Filter

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A3--3

SECTIONAL VIEW

OM662L A ENGIN E

Front View

DAEW OO MY_2000

1A3--4 GENERAL ENGINE INFORMATION

Side View

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A3--5

OM661L A ENGIN E

Front View

DAEW OO MY_2000

1A3--6 GENERAL ENGINE INFORMATION

Side View

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A3--7

PERFORMANCE CURVE

OM662L A ENGIN E

DAEW OO MY_2000

1A3--8 GENERAL ENGINE INFORMATION

OM661L A ENGIN E

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A3--9

SPECIAL TOOLS

SPECIAL TOOL S T AB LE

000 589 10 99 01

Torque Wrench

001 589 76 21 00

Compression Pressure

Tester

601 589 65 09 00

Socket

001 589 73 21 00

Hand Vacuum Pump

DAEW OO MY_2000

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. Onsome occasions a fluid leak may be
difficult to locate or repair. Thefollowingproceduresmay
help you in locating and repairing most leaks.

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 Wai t a few minutes.

2.3 You should be able to find the approximate loca-

tion 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.

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 condi­tions.

4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.

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 theengine 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.

Repairing the Leak

Once the origin of the leak has been pinpoi nted and
traced back to its source, the cause of the leak must be
determinednorder for it to berepaired 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

D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The fasteners are tightened improperlyor the threads

are dirty or damaged.

D The flanges or the sealing surface is warped.
D There are scratches, burrs or other damage to the

sealing surface.

D The gasket is damaged or worn.
D There is cracking or porosity of the component.
D An improper seal was used (where applicable).

Seals

D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The seal bore is damaged (scratched, burred or

nicked).

D The seal is damaged or worn.
D Improper installation is evident.
D There are cracks in the components.
D The shaft surface is scratched, nicked or damaged.
D A loose or worn bearing is causing excess seal wear.

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A3--11

COMPR ESSION PRESSUR E TEST

1 Test Adapter
2 Flexible Connector
3 Compression Pressure Recorder

Service Data

Normal Compression Pressure
Minimum Compression Pressure Approx.18bar
Permissible Pressure Difference Between Individual Cylinders Max. 3bar

DEngine at normal operating temperature of 80_C

Tools Required

000 589 65 09 00 Socket
001 589 73 21 00 Hand Vacuum Pump

28bar

DAEW OO MY_2000

1A3--12 GENERAL ENGINE INFORMATION

Compression Pressure Measurement

Notice

Ensure that no gear is engaged and that the vehicle
is protected from rolling.

1. Run the engine to be the coolant temperature80_C.

2. Remove the fuel injection nozzle.

Socket Wrench Insert 001 589 65 09 00

3. Install the test adapter (1) and connect the flexible

connector (2) tothe compression pressure recorder.

Compression Pressure Recorder 001 589 76 21 00

4. Disconnect the vacuum line from the stop unit and

connect the hand vacuum pump to the stop unit.

5. Pump the hand vacuum pump and make the fuel in-

jection pump in stop position.

Operating Pressure Approx. 500bar

Hand Vacuum Pump 001 589 73 21 00

6. Using a starter motor, crank the engine 8 revolu-

tions.

7. Measure the remaining cylinder compression pres-

sure in the same manner and compare it with ser­vice data.

Notice

If out of standard, do cylinderpressure leakage test.

8. Remove the compression pressure recorder.

9. Install the fuel injection nozzle.

DAEW OO MY_2000

GENERAL ENGINE INFORMATION 1A3--13

CYLINDER PRESSURE LEAKAGE TEST

1 Connector
2 Connection Piece
3 Connection Hose

Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80_C)

At Whole Engine
At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %

Max. 25 %

Commercial T ools

Cylinder Pressure Leakage tester
Connection Piece BOSCH order no. 1 687 010 016

BOSCH, EFAW 210 A or SUN CLT 228

DAEW OO MY_2000

1A3--14 GENERAL ENGINE INFORMATION

Leakage Test

1. Run the engine to be the coolant temperature80_C.

2. Remove the fuel injection nozzle.

3. Open the coolant subtank cap.

4. Check the coolant level and replenish if necessary.

5. Open the oil filler cap.

6. Remove the air cleaner cover and element.

7. Position the piston at TDC.

8. Install the connector (1) and connection piece (2).

9. Calibrate the tester and connect the connection

hose (3)

10. Pressurize with compressed air and compare the

pressure changes with permissible pressure leak­age.

11. If permissible pressure leakage is out of standard,

check followings :

-- Intake and exhaust lines.

-- Sounds in oil filler area.

-- Air bubbles in radiator coolant.

12. Do pressure leakage test for the remainingcylinders

according to the firing order.

D OM 662LA Engine : 1--2--4--5--3
D OM 661LA Engine : 1--3--4--2

13. Remove the tester.

14. Close the coolant pressure cap and oil filler cap.

15. Install the air cleaner element and cover.

16. Install the fuel injection nozzle.

DAEW OO MY_2000

SECTION 1B1

M16 2 ENGINE MECHANICAL

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.

TABLE OF CONTENTS

Specifications 1B1--2............................

Fastener Tightening Specifications 1B1--2..........

Special T ools 1B1--4.............................

Special Tools Table 1B1--4.......................

Maintenance and Repair 1B1--7...................

On--Vehicle Service 1B1--7.........................

Engine Assembly 1B1--7.........................

Crankcase Ventilation System 1B1--14.............

Generator 1B1--16..............................

Engine Mount 1B1--17...........................

Poly V--Belt 1B1--18.............................

Tensioning Device 1B1--20.......................

Poly V--Belt Inspection 1B1--21...................

Cylinder Head Cover 1B1--24.....................

Cylinder Head Front Cover 1B1--26...............

Cylinder Head 1B1--28...........................

Ti ming Gear Case Cover 1B1--31.................

Crankshaft Sealing Rear Cover 1B1--33...........

Belt Pulley and Vibration Damper 1B1--35..........

Crankshaft Front Radial Seal 1B 1--38.............

Crankshaft Rear Radial Seal 1B1--40..............

Crankshaft 1B 1--41.............................

Flywheel / Driven Plate 1B1--47...................

Camshaft Adjuster 1B1--50.......................

Camshaft Sprocket Bolt 1B1--52..................

Camshaft 1B1--54..............................

Camshaft Timing Position 1B1--59................

Valve Spring 1B1--62............................

Valve Stem Seal 1B1--66........................

Chain Tensioner 1B1--67.........................

Ti ming Chain 1B1--70............................

Tensioning Rail 1B1--75..........................

Cylinder Head Guide Rail 1B1--76.................

Crankcase Guide Rail 1B1--77....................

Crankshaft Sprocket 1B1--78.....................

Piston 1B1--80..................................

Connecting Rod 1B1--83.........................

Piston Ring 1B1--85.............................

Engine Oil Specification 1B1--87..................

Oil Pan 1B1--88.................................

Engine Oil and Oil Filter Element 1B1--90..........

Oil Filter 1B1--92................................

Oil Pump 1B1--94...............................

Oil Pressure Relief Valve 1B1--96.................

Oil Non-Return V alve 1B1--97....................

Oil Dipstick Guide Tube 1B1--98..................

Unit Repair 1B1--99..............................

Oil Gallery in Crankcase 1B1--99..................

Oil Gallery in Cylinder Head 1B1--101..............

Core Plugs in Crankcase 1B1--104................

Cylinder Bore 1B1--106..........................

Crankcase Mating Surface 1B1--108..............

Cylinder Head Mating Surface 1B1--1 10...........

DAEW OO MY_2000

1B1 --2 M162 ENGINE MECHANICAL

g

SPECIFICATIONS

FASTEN ER TIGHTEN ING SPECIFICATIONS

Application NSm Lb-Ft Lb-In

Fuel Feed and Return Line 21 -- 25 15 -- 18 -­Exhaust Manifold and Pipe 30 22 -­Propeller Shaft to Transmission 81 -- 89 60 -- 66 -­Engine Mounting Nuts 70 52 -­Generator Carrier Bolts 25 18 -­Tensioning Pulley Bolt 40.5 -- 49.5 29.9 -- 36.5 -­Steering Pump Bolts 22.5 -- 27.5 16.6 -- 20.3 -­A/C Bracket Bolts 22.5 -- 27.5 16.6 -- 20.3 -­Intake Air Duct Mounting Nuts 9--11 -- 80 -- 97
Spark Plug Cover Bolts 9--11 -- 80 -- 97
Cylinder Head Cover Bolts 9--11 -- 80 -- 97
Magnetic Assembly Bolt 9--11 -- 80 -- 97
Cylinder Head Front Cover Bolt 22.5 -- 27.5 16.6 -- 20.3 -­Cylinder Head Bolts 55

+90°
+90°

Ti ming Gear Case Cover Bolts

Crankshaft Sealing Rear Cover Mounting Bolts 9--11 -- 80 -- 97
Vibration Damper Center Bolt 200 + 20

Connecting Rod Bearing Cap Bolts 40

Flywheel Mounting Bolt 45 + 5

Amarture Bolt 35 26 -­Camshaft Adjuster Flange Bolts 18 -- 22

Intake Flange Shaft Bolts 18 -- 22

Exhaust Camshaft Sprocket Bolts 18 -- 22

Camshaft Bearing Cap Bolts 22.5 -- 27.5 16.6 -- 20.3 -­Chain Tensioner Screw Plug 40 30 -­Chain Tensioner Assembly 72 -- 88 53 -- 65 -­Oil Pump Sprocket Bolt 29 -- 35 21 -- 26 -­Tensioning Device Bolts 26 -- 32 19 -- 24 -­Water Pump Pulley Bolts 22.5 -- 27.5 16.6 -- 20.3 -­Upper Intake Manifold Bolt 22.5 -- 27.5 16.6 -- 20.3 -­Lower Intake Mainfold Bolt 22.5 -- 27.5 16.6 -- 20.3 -­Flange Bolt to Exhaust Mainfold 30 22 --

M8 22.5 -- 27.5 16.6 -- 20.3 -­M6 9--11 -- 80 -- 97

+90° +10°

+90°

+90° +10°

60°±5°

60°±5°

60°±5°

41
+90°
+90°

148 + 15

+90° +10°

30
+90°

33 + 3.7

+90° +10°

13 -- 16
60°±5°

13 -- 16
60°±5°

13 -- 16
60°±5°

--

--

--

--

--

--

--

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 3

g

FASTEN ER TIGHTEN ING SPECIFICATIONS (Cont’d )

Application NSm Lb-Ft Lb-In

Exhaust Mainfold Nut to Stud Bolt 26 -- 34 19 -- 25 -­OilDrain Plug 25 18 -­Oil Filter Cover 25 18 -­Oil Filter Bolt 25 18 -­Oil Pump Drive Sprocket Bolt 29 -- 35 21 -- 26 -­Oil Pump Mounting Bolt 22.5 -- 27.5 16.6 -- 20.3 -­Oil Strainer Bracket Bolt 9--11 -- 89 -- 97
Oil Pressure Relief Valve Screw Plug 50 37 -­Oil Dipstick Guide Tube Bolt 9--11 -- 89 -- 97
Oil Gallery Screw Plug 15 11 -­Torque Converter Mounting Bolts 42 31 -­Crankshaft Bearing Cap Bolts 55/+90° 41/+90° -­Oil Pan Mounting Bolts

M8 25 18 -­M6 10 -- 89

DAEW OO MY_2000

1B1 --4 M162 ENGINE MECHANICAL

SPECIAL TOOLS

SPECIAL TOOL S T AB LE

000 589 58 43 00
Chain Assembly

111 589 01 59 00

Supporting Bar

111 589 18 61 00

Lever Pusher

103 589 02 09 00

Oil Filter Remover

DW110--120
Holding Pin

111 589 25 63 00

Thrust Piece

116 589 01 34 00

Threaded Pin

116 589 20 33 00
Sliding Hammer

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 5

Special Tools Table (Cont’d)

119 589 00 43 00

Drift

601 589 03 14 00

Crankshaft Front Seal

Installer

603 589 00 40 00

Fan Clutch Holder

601 589 03 43 00

Crankshaft Rear Seal

Installer

602 589 00 40 00

Engine Lock

617 589 00 10 00

Allen Wrench Socket

DAEW OO MY_2000

615 589 01 33 00

Crankshaft Sprocket

Puller

DW110 -- 090

Connecting Hose

1B1 --6 M162 ENGINE MECHANICAL

Special Tools Table (Cont’d)

DW110 -- 100

Valve Tappet Remover

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 7

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

ENGINE ASSEMBLY

DAEW OO MY_2000

1B1 --8 M162 ENGINE MECHANICAL

Removal & Installation Procedure

1. Disconnect the negative terminal of battery.

2. Remove the hood.

3. Remove the under cover.

Installation Notice

Ti ghtening Torque 28 -- 47 NSm (21 -- 35 lb-ft)

4. Disconnect the mass air flow sensor meter connec­tor.

5. Disconnect the mass air flow sensor meter from the
air filter housing.

6. Remove the intake air duct mounting nuts.

Installation Notice

Ti ghtening Torque 9--11NSm (80 -- 97 lb-in)

7. Remove the air cleaner cover. Remove the mounting
bolts and air cleaner housing and element assembly.

8. Loosen the radiator drain cock and drain the coolant.

Notice: Open the coolant reservoir cap.

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 9

9. Loosen the cylinder block drain plug and then drain
the coolant completely.

Installation Notice

Ti ghtening Torque 30 NSm (22 lb-ft)

Notice: Replace the seal before installation of the drain
plug.

10. Remove the cooling fan shroud. Refer to Section

1D1, Engine Cooling.

11. Disconnect the each hose from radiator.

12. Remove the upper mounting bolts of radiator and
then remove the radiator.

DAEW OO MY_2000

1B1 --10 M162 ENGINE MECHANICAL

13. Remove the hydraulic pipe of power steering.

Notice: Completely drain the oil.

14. Discharge the refrigerant from A/C system, and dis­connect the discharge pipe and suction pipe from
the compressor. Refer to Section 7B, Manual Con-

trol Heating, Ventilation, and Air Conditioning Sys­tem.

15. Remove the fuel feed and return line.

Notice: Beforeremoving the fuel lines, release thepres­sure in the fuel system.

Installation Notice

Ti ghtening Torque 21 -- 25 NSm (15 -- 18 lb-ft)

16. Disconnect the terminals from the generator.

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 11

17. Disconnect the terminals from starter motor and re­move the starter motor.

18. Disconnect the engine main harness ground.

19. Disconnect the engine ground wire.

20. Disconnect following sensors connector.

D HFM sensor.
D Coolant temperature sensor.
D 2 knock sensors.
D Camshaft and crankshaft sensors.

21. After removing the ignition coil cover, disconnect the
ignition coil connector.

22. Remove the harness cover and disconnect the 6 in­jection valve connectors. Disconnect the main har­ness.

DAEW OO MY_2000

1B1 --12 M162 ENGINE MECHANICAL

23. Separate the hose toward engine from canister
purge solenoid valve.

24. Remove the canister. Refer to Section 1F1, Engine

Control.

25. Remove the automatic transmission oil cooler line
retaining bolts from the automatic transmission side
and oil pan side

26. Remove the automatic transmission oil cooler line
retaining bolts from engine side and oil pan side.

27. Separate the vacuum hose for brake booster.

28. Separate the other vacuum hoses.

29. By rotating the crankshaft from the front of engine,
remove the 6 torque converter mounting bolts from
the engine ring gear plate.

Installation Notice

Ti ghtening Torque 42 NSm (31 lb-ft)

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 13

30. Remove the exhaust manifold and exhaust pipe.

Installation Notice

Ti ghtening Torque 30 NSm (22 lb-ft)

31. Remove the t ransmission. Refer to Section 5A, Au-

tomatic Transmission.

32. Install a chain to the bracket of engine, by using a
hoist or crane.

33. Remove the engine mount nuts.

Installation Notice

Ti ghtening Torque 70 NSm (52 lb-ft)

34. Carefullyseparate theengine assemblyfrom theve­hicle.

35. Installation should follow the removal procedure in
the reverse order.

DAEW OO MY_2000

1B1 --14 M162 ENGINE MECHANICAL

CRANKCASE VENTILATION SYSTEM

1 Crankcase
2 Air Admission Port in Crankcase
3 Oil Drain Port
4 Filter
5 Gasket
6 A/C Bracket
7 Oil Drain Pipe
8OilPan

9 Air Admission Line
10 Vent Line
11 Restriction Hole (Diameter = 2 mm)
12 Intake Manifold

13 Intake Air Duct (Cross Pipe)
14 Cylinder Head Cover
15 Oil Separator
16 Oil Separator
17 Air Admission and Vent Connection
18 Air Admission and Vent Connection
19 Throttle Valve
20 Vent Line

A Fresh Air
B Blowby Gas in Partial Load
C Blowby Gas in Full Load

DAEW OO MY_2000

Operation at Idling and Mid-Load

D It show that the throttle valve (19) is closed or very

partially opened and the vacuum pressure in intake
manifold is high.
The blowby gas in the crankcase in partial load flows
into the intake manifold through the vent line (20) af­ter passing the air conditioner bracket (6) and the fil­ter (4). The air reentered into the intake manifold will
be dilluted on the flowthrough the restriction hole(11)
in the vent line (10).
The circulated engine oil is separated at the air condi­tioner bracket (6) and then returns into the oil pan
through the drain pipe (7).
The vacuum pressure generated at the crankcase
sucks fresh air from intake air line (13) through the air
admission and vent connection (17,18).
The fresh air prevents engine oil from being contami­nated and the air admission and vent connection
(17,18) is designed to control the rapid pressure
changes in intake air line (13).

Operation at Full-Load

D The throttle valve (19) is fully opened.

All the blowby gases flow into the intake air duct (13)
after passing through the oil separator (15,16) of the
cylinder head cover (14) when fully loaded. This dil­luted air will be supplied to the combustion chamber
through the intake manifold (12).

M162 ENGINE MECHANICAL 1B1-- 15

DAEW OO MY_2000

1B1 --16 M162 ENGINE MECHANICAL

GENERA T OR

1 Nut (M8) 22.5--27.5 NSm (16.6--20.3 lb-ft).....

2 Bolt (M8 x 30, 3 pieces)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

3 Bolt (M8 x 40, 1 piece)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

4 Bolt (M8 x 70, 1 piece)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

5 Bolt (M8 x 75, 1 piece)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

Removal & Installation Procedure

1. Remove the drive belt.

2. Remove the generator.

3. Unscrew the generator carrier bolts and remove the
carrier.

Installation Notice

Ti ghtening Torque 25 NSm (18 lb-ft)

4. Installation should follow the removal procedure in
the reverse order.

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 17

ENGINE MOUNT

Removal & Installation Procedure

1. Unscrew the upper engine mount nuts and remove
the engine.

Installation Notice

Ti ghtening Torque 70 NSm (52 lb-ft)

2. Unscrew the lower nuts.

Installation Notice

Ti ghtening Torque 38 NSm (28 lb-ft)

3. Remove the hydraulic engine mounting insulator.

4. Installation should follow the removal procedure in
the reverse order.

DAEW OO MY_2000

1B1 --18 M162 ENGINE MECHANICAL

Preceding Work: Removal of cooling fan

POLY V -- BELT

1 Poly V--belt 2 Belt Tensioning Pulley

Removal & Installation Procedure

1. Release the belt tension by turning the belt tensioning
pulley nut clockwise.

2. Remove the poly v--belt.

Notice: Check the belt for damage and tensioning
pulley bearing point for wear and replace them if neces­sary.

3. Install the belt by turning the nut of tensioning pulley
clockwise.

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 19

Poly V- Belt Arrangement

1 Belt Tensioning Pulley
2 Crankshaft Belt Pulley
3 A/C Compressor Pulley
4 Cooling Fan Pulley

5 Generator Pulley
6 Idler
7 Power Steering Pump Pulley
8 Cooling Fan and Water Pump Pulley

DAEW OO MY_2000

1B1 --20 M162 ENGINE MECHANICAL

TENSIONIN G DEVICE

Preceding Work: Removal of poly v--belt

1 Belt (L = 2245)
2 Bolt Combi (M8 x 14, 3 pieces) + Washer

22.5--27.5 NSm (16.6--20.3 lb-ft).............

3 Water Pump Pulley
4Nut
5 Tensioning Pulley

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 21

Removal & Installation Procedure

1. Remove the poly v--belt.

2. Remove the tensioning pulley by turning its mounting
nut counter clockwise as shown in figure.

Installation Notice

Ti ghtening Torque

3. Remove the 3 bolts (2) and remove the water pump
pulley (arrow).

Installation Notice

Ti ghtening Torque

4. Remove the mounting bolts (M8 x30, 3 pieces) at the
tensioning device, and remove the tensioning device
(arrow).

Installation Notice

Ti ghtening Torque 26 -- 32 NSm (19 -- 24 lb-ft)

5. Installation should follow the removal procedure in
the reverse order.

40.5 -- 49.5 NSm

(29.9 -- 36.5 lb-ft)

22.5 -- 27.5 NSm

(16.6 -- 20.3 lb-ft)

DAEW OO MY_2000

POLY V -- BELT INSPECTION

D Make marks on the belt with chalk.
D Rotate the engine and check the belt for damage.

Notice: If one of the following types of damages is
found, replace the belt.

1B1 --22 M162 ENGINE MECHANICAL

1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.

3. Pointed rib.

4. Belt cord visible in the base of rib.

5. Cord torn out at the side.

6. Outer cords frayed.

7. Rib detached from the base of belt.

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 23

8. Splits across the rib.

9. Sections of rib torn out.

10. Splits across several ribs.

11. Splits across the back of the belt.

DAEW OO MY_2000

1B1 --24 M162 ENGINE MECHANICAL

CYLINDER HEAD COVER

1 Ignition Cable Dust Cover
2 Bolt (M6 x 65, 8 pieces)

3 Bolt (M6 x 50, 4 pieces)
4 Spacer Sleeve

5 Thrust Piece

6 Cylinder Head Cover

7 Gasket Replace...........................

9--11 NSm (80--97 lb-in).....................

9--11 NSm (80--97 lb-in).....................

8 Spart Plug Hole Seal Replace...............

9 Camshaft Seal Repl ace.....................

Composition of The Cylinder Head Cover
Bolts

A. M6 x 50, 4 Pieces -- Bolts + Washers
B. M6 x 65, 8 Pieces -- Bolts + Washers

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 25

Removal & Installation Procedure

1. Remove the intake air duct.

Installation Notice

Ti ghtening Torque 9--11NSm (80 -- 97 lb-in)

2. Remove the spark plug cover.

Installation Notice

Ti ghtening Torque 9--11NSm (80 -- 97 lb-in)

Notice: Unscrew the seven (M6 x 60) bolts and remove
the spark plug cover.

3. Remove the spark plug connector and ignition cable.

4. Unscrew allthe bolts (2,3) and remove the head cov­er and the gasket.

Installation Notice

Ti ghtening Torque 9--11NSm (80 -- 97 lb-in)

Notice: Replace the gasket witha newone if necessary.

5. Installation should follow the removal procedure in
the reverse order.

6. Check for oil leaks by operating the engine.

DAEW OO MY_2000

1B1 --26 M162 ENGINE MECHANICAL

CYLINDER HEAD FRONT COVER

Preceding Work: Removal of cylinder head cover

Removal of coolant connection fitting

1 Camshaft Position Sensor
2 Magnet Assembly
3 Upper Guide Rail
4 Bolt (M6 x 60, 3 pieces)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

5 Bolt (M8 x 80, 3 pieces)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

6 Front Cover

7 Rubber Gasket Replace....................

8 Bolt (M6 x 16, 3 pieces)

9--11 NSm (80--97 lb-in).....................

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 27

Removal & Installation Procedure

1. Remove the magnet assembly.

Installation Notice

Ti ghtening Torque 9--11NSm (80 -- 97 lb-in)

2. Remove the cylinder head front cover (6).

Installation Notice

Ti ghtening Torque

22.5 -- 27.5 NSm

(16.6 -- 20.3 lb-ft)

Apply the sealant at the mating surface of the cylinder
head and the front cover.

3. Remove the upper guide rail pinand theguide rail(3).

Installation Notice

Install it while the chain tensioner is loose.

4. Remove the gasket (arrow).

Installation Notice

Replace the gasket with new one and apply the sea­lant.

5. Installation should follow the removal procedure in
the reverse order.

DAEW OO MY_2000

1B1 --28 M162 ENGINE MECHANICAL

CYLINDER HEAD

Preceding Work: Removal of cylinder head cover

Removal of cylinder head front cover
Removal of upper intake manifold

1 Cylinder Head Bolt (14 pieces)

1st step 55 NSm (41lb-ft)...................

2nd step 90°

3rdstep90°
2 Washers (14 pieces)
3 Flange Bolts (3 pieces)

1ststep18--22NSm (13--16 lb-ft)............

2nd step 60°±5°

4 Exhaust Camshaft Sprocket
5 Cylinder Head

6 Gasket Replace...........................

7 Dowel Sleeve

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 29

TighteningTorqu

e

Tools Required

617589001000 AllenWrenchSocket
116 589 01 34 00 Threaded Pin
116 589 20 33 00 Sliding Hammer

Removal & Installation Procedure

1. Rotate the crankshaft so that the piston of number 1
cylinder is at TDC.

Notice: Rotate the crankshaft in the normal engine di­rection.

2. Put the alignment marks (arrows) on the timing chain
and camshaft sprocket.

3. Drain the coolant from the crankcase.

4. Remove the three flange bolts in the exhaust cam­shaft sprocket.

Installation Notice

1st step: 18 -- 22 NSm

TighteningTorque

2nd step:60°±5°

(13 -- 16 lb-ft)

Do not reuse the removed bolts.

5. Separate the chain from the camshaft sprocket.

Notice: Be careful not to drop the chain into the timing
case.

6. Remove the guide rail fixing pin using threaded pin
116 589 01 34 00 (1) and sliding hammer 116 589 33
00 (2).

DAEW OO MY_2000

1B1 --30 M162 ENGINE MECHANICAL

L

th(L)

7. Remove the cylinder head bolts in numerical order
usingallenwrenchsocket617589001000.

Installation Notice

1st step: 55 NSm

(41 lb-ft)

Ti ghtening Torque

2nd step:90°
3rd step: 90°

8. Check the length of the cylinder head bolt.

Installation Notice

eng

New 160 ± 0.8 mm

Max. 162 ± 0.7 mm

D Replace the bolt if the measured length exceed

the max. length.

D Apply the oil to the thread surface of bolt.

9. Carefully remove the cylinder head and check the
mating surface.

10. Installation should follow the removal procedure in
the reverse order.

DAEW OO MY_2000

TIMING GEAR CASE COVER

Preceding Work: Removal of cylinder head front cover

Removal of generator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper

M162 ENGINE MECHANICAL 1B1-- 31

1 Bolt (M8 x 60, 3 pieces)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

2 A/C Bracket
3 Bolt (M8 x 65, 3 pieces)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

4 Bolt (M8 x 40, 1 piece)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

DAEW OO MY_2000

5 Bolt (M8 x 60, 1 piece)

22.5--27.5 NSm (16.6--20.3 lb-ft).............

6Seal
7 Timing Gear Case Cover
8RollPin
9 Bolt (M6 x 22, 6 pieces)

9--11 NSm (80--97 lb-in).....................

1B1 --32 M162 ENGINE MECHANICAL

T

igh

teningT

Removal & Installation Procedure

1. Put the alignment marks (arrows) on the timing chain
and camshaft sprocket.

2. Unscrew the A/C bracket bolts (1) and remove the
bracket.

Installation Notice

Ti ghtening Torque

22.5 -- 27.5 NSm

(16.6 -- 20.3 lb-ft)

3. Remove the cooling fan and the viscous clutch. Un­screw the threebolts from the coolingfan bracket and
remove the bracket (arrows).

Installation Notice

Ti ghtening Torque

22.5 -- 27.5 NSm

(16.6 -- 20.3 lb-ft)

4. Remove the timing gear case cover after unscrewing
the bolts (3) and (4) from the timing gear case cover
and the bolt (9) from the oil pan.

Notice: Be careful not to damage the oil pan gasket.

Installation Notice

Bolt (3, 4):22.5 -- 27.5 NSm

(16.6 -- 20.3 lb-ft)

orque

Bolt (9): 9 -- 11 NSm

(80 -- 97 lb-in)

D Apply the sealant after cleaning the timing gear

case cover surface.

D Be careful not to stain the oil chamber of chain

tensioner with the sealant.

5. Installation should follow the removal procedure in
the reverse order.

6. Warm up the engine and check for oil leaks.

DAEW OO MY_2000

CRANKSHAFT SEALING REAR COVER

Preceding Work: Removal of the automatic transmission drive plate

M162 ENGINE MECHANICAL 1B1-- 33

1 Bolt (M6 x 20, 6 pieces)
2 Radial Shaft Seal

3 Rear Cover

4 Sleeve

9--11 NSm (80--97 lb-in).....................

5 Bolt (M6 x 85, 2 pieces)

9--11 NSm (80--97 lb-in).....................

6Washer

DAEW OO MY_2000

1B1 --34 M162 ENGINE MECHANICAL

Tools Required

601 589 03 43 00 Crankshaft Rear Seal Installer

Removal & Installation Procedure

1. Unscrew the bolts (1) and (5) and remove the closing
cover by pulling the rear cover lug (arrows).

Notice: Be careful not to damage the oil pan gasket.

2. Clean the sealing surface of the crankcase and the
rear sealing cover.

3. Checkthe radialshaft seal and replace it if necessary.

4. Apply the Loctite 573 to the rear cover sealing sur­face.

5. Apply the engine oil to the dust lip of the radial shaft
seal.

Notice: Do not use the grease.

6. Install the crankshaft rear radial seal and the crank­shaft sealingrear cover, usingcrankshaft rear sealin­staller 601 589 03 43 00.

7. Install the crankshaft sealing rear cover mounting
bolts and remove the crankshaft rear seal installer
601 589 03 43 00.

Installation Notice

Ti ghtening Torque 9--11NSm (80 -- 97 lb-in)

8. Installation should follow the removal procedure in
the reverse order.

DAEW OO MY_2000

BEL T PULLEY AND VIBRA TION DAMPER

Preceding Work: Removal of cooling fan and viscous clutch

Removal of fan shroud
Removal of drive belt

M162 ENGINE MECHANICAL 1B1-- 35

1 Vibration Damper Center Bolt (M18 x 50)

1st step 200+20 NSm (148+15 lb-ft)..........

2nd step 90°+10°
2 Vibration Damper Disk
3 Bolt (M6 x 20, 6 pieces)

7.7--9.5 NSm (68.1--84.1 lb-in)...............

DAEW OO MY_2000

4 Vibration Damper Assembly
5 Woodruff Key
6 Bolt (M6 x 12, 4 pieces)

9--11 NSm (80--97 lb-in).....................

7 Cooling Fan Pulley

1B1 --36 M162 ENGINE MECHANICAL

p

Components

1 Center Bolt (M18 x 50)
2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover

ServiceDataStandard

Permissble Deviation of The Vibration Damper

7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)

9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

Radial Runout 0.6 mm

Axial Runout 0.6 mm

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 37

TighteningTorqu

e

Tools Required

602589004000 EngineLock

Removal & Installation Procedure

1. Adjust the piston of number 1 cylinder to the TDC.

2. Remove the start motor and install the engine lock
602 589 00 40 00 to the flywheel ring gear.

3. Remove the vibration damper center bolt.

Installation Notice

1st step: 200 + 20 NSm

TighteningTorque

2nd step:90° +10°

(148 + 15 lb-ft)

4. Remove the vibration damper assembly using the
puller.

5. Installation should follow the removal procedure in
the reverse order.

Notice: If possible, don’t separate the vibration damper
and the pulley.

DAEW OO MY_2000

1B1 --38 M162 ENGINE MECHANICAL

CRANKSHAFT FRONT RADIAL SEAL

Preceding Work: Removal of belt pulley and vibration damper

1 Center Bolt (M18 x 50)

1st step 200+20 NSm (148+15 lb-ft)..........

2nd step 90°+10°

2 Center Bolt Washer

3 Crankshaft Front Seal Installer
4 Crankshaft Front Seal
5Key

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 39

TighteningTorqu

e

Tools Required

601 589 03 14 00 Crankshaft Front Seal Installer

Replacement Procedure

1. Remove the radial seal with a screw driver.

Notice: Use a clean cloth not to damage the radialseal
mounting hole and the crankshaft.

2. Coat the radial sealing lip with engine oil.

3. Usingthe crankshaftfront sealinstaller 601 589 03 14
00, assemble the radial seal .

4. Align the sleeve groove and the woodruff key and
tighten the center bolt until the center bolt and the
damper disk stop in the movement.

Installation Notice

1st step: 200 + 20 NSm

TighteningTorque

2nd step:90° +10°

5. Remove the crankshaft front seal installer601 58903
14 00, and install the belt pulley and the vibration
damper.

6. Check for leaks while operating the engine.

(148 + 15 lb-ft)

DAEW OO MY_2000

1B1 --40 M162 ENGINE MECHANICAL

CRANKSHAFT REAR RADIAL SEAL

Preceding Work: Removal of flywheel or drive plate

1 Special T ool
2 Special T ool

3 Crankshaft Rear Seal

Tools Required

601 589 03 43 00 Crankshaft Rear Seal Installer

Replacement Procedure

1. Remove the radial seal with a screw driver.

Notice: Use a clean cloth not to damage the radialseal
mounting hole and the crankshaft.

2. Install the special tool (2) to the crankshaft.

3. Apply the engine oil on the special tool (2).

Notice: Do not use the grease.

4. Install the radial seal on the inner parts assembler.

5. Press in the special tool (1) until the radial seal is
stopped.

6. Check for leaks while operating the engine.

DAEW OO MY_2000

Preceding Work: Removal of engine assembly

Removal of timing gear case cover
Removal of cylinder head
Removal of oil pump
Removal of oil shield

M162 ENGINE MECHANICAL 1B1-- 41

CRANKSHAFT

1 12--sided Stretch Bolt

55 NSm (41 lb-ft) + 90°, Iubricate............

2 Crank Shaft Bearing Cap

DAEW OO MY_2000

3 Crank Shaft Low Main Bearing
4 Lower Thrust Bearing
5 Crankshaft

1B1 --42 M162 ENGINE MECHANICAL

Arrangement of the Thrust Bearing and the Main Bearing

1 Upper Main Bearing
2 Upper Thrust Bearing
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

(1) -- (12) Weight Balance/Color Marking Point
j1 -- j7 Journal Main Bearing #1 -- #7

D Color Dot Marking

Thecolor dot marking are put on the(1), (2), (4), (6), (8),
(10), (12) and it indicates the diameter of crankshaft
journal by color as below.

A Crankcase Side
B Bearing Cap Side (Oil Pan Side)
C Axial Fit Bearing (Number 5 Bearing Point)
D Radial Bearing

DAEW OO MY_2000

M162 ENGINE MECHANICAL 1B1-- 43

Color Dot

Marking

Blue 57.960 -- 57.965

Yellow 57.955 -- 57.960

Red 57.950 -- 57.955

White 57.945 -- 57.950

Violet 57.940 -- 57.945

Crankshaft Journal Diameter

(mm)

Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating sur-

face to oil pan. This mark is correspondent to the
bearing distinguished by color. Select the relevant
bearing according to the punching mark when re­paired.

Punching

Mark

F Blue

FF Yellow

FFF Red

Bearing Color Selected

2. Crankshaft Bearing Cap Side
Select the crankshaft main bearing according to the

marking letter on the crankshaft main journal when
repaired.

Marking

Letter

B Blue
Y Yellow

R Red

W White

V Violet

Bearing Color Selected

Service Data Unit: mm

Crankshaft Stan-

dard and Repair

Size

Standard size 57.940--57.965 58 24.50--24.533 47.935--47.965 27.958--28.042
1st repair size 57.705--57.715 47.700--47.715

2nd repair size 57.450--57.465 47.450--47.465

3rd repair size 57.205--57.215
4th repair size 56.955--56.965 46.950--46.965

Crankshaft

Bearing Jour-

nal Diameter

Crankshaft

Bearing

Diameter

Crankshaft

Journal Width

at fit bearing

--

Connecting Rod

Bearing Journal

Diameter

47.200--47.215

Connecting Rod

Bearing Jourmal

Width

--

DAEW OO MY_2000