01 Foreword & Contentstoyotaux.berrios.cl/procedimientos/mecanica-dyp...9.7:1 10.0: 1 rpm rpm rpm rpm ℓ (lmp.qt) ℓ (lmp.qt) ℓ (lmp.qt) kPa (kg/cm²) In-line, SOHC 4 Engine DSL

2010

Cerato

Table of Contents

Rio

Sportage

Picanto

All New Cerato / Forte*

Soul*

cee'd*

General Information

Magentis / Optima

Opirus

Carens

Sorento

Carnival / Sedona

K2500 / K2700 / K3000

Mohave / Borrego*

SA

JB

LD

MG

GH

UN

KM

BL

VQ

PU

GI

TD

AM

HM

ED

　Engine Mechanical System………………………SA-2　Engine Electrical System…………………………SA-9　Fuel System……………………………..…………SA-10　Clutch…………………………………….…………SA-10　Manual Transaxle……………………….…………SA-11　Automatic Transaxle………………………………SA-12　Driveshaft………………………………..…………SA-12　Suspension System…………………….…………SA-13　Steering System………………………………… SA-14　Restraints…………………………………………SA-15　Brake System………………………………………SA-16　Body (Interior & Exterior)……………….……… SA-19　Body Electrical System……………………………SA-21　Heating, Ventilation & Air Conditioning..………SA-22

Picanto (SA)

SA-1

General Specifications - PicantoGSL ε 1.0 GSL ε 1.1

mm (in.) 66 (2.5984)x 73 (2.8740)

67 (2.6378)x 73 (2.8740)

cc 999 1.0869.7:1 10.0: 1

rpmrpmrpmrpm

ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt)

kPa(kg/cm²)

In-line, SOHC4

DSL U 1.1Engine

TypeNumber of cylinders

In-line, DOHC3

Bore x Stroke

Total displacement

Firing order

Engine

Compression ratio

Above CH-4 or B4

1-3-4-2

Oil quality

Oil pressure (Idle)

Above SG

78.45 (0.8)

75 (2.9528) x 84.5 (3.3268)

750 ± 100BTDC 7˚ ± 5˚ -

890 ± 100

1.12017.8:11-2-3

Ignition Timing

Idle Speed

A/C OFFA/C ON D-range

Neutral,N,P-D-range

147.1 (1.5) [at 1000rpm,100°C(212°F)]

890 ± 100 890 ± 100 890 ± 100

Engine oil

Neutral,N,P-800 ± 100

750 ± 100800 ± 100

5.3 (5.10)4.8 (4.22)Oil quantity

3.3 (2.90)3.0 (2.64)0.3 (0.26)Oil filter

Oil pan0.5 (0.44)

Total

SA-2

mm (in.)mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

Intake valve

Bearing oil clearance

End play

Journal outer Diameter (Intake, Exhaust)

Intake

Intake

Opens (ATDC)Closes (ABDC)

Closes (ATDC)

Flatness of gasket surfaceFlatness of manifold mounting surface

Opens (BBDC)Exhaust valve

Cam height

Camshaft

Less than 0.03 (0.0012)Cylinder head

Less than 0.05 (0.0020)

5° (BTDC)16° ~ 24°

35°43° 19° ~ 27°

10° ~ 18°

Exhaust

Exhaust

Less than 0.025 (0.0010) for widthLess than 0.1(0.0039)

Less than 0.03 (0.0012)Less than 0.15 (0.0059)

33.941 ~ 34.141 (1.3363 ~ 1.3441)

34.055 ~ 34.255 (1.3407 ~ 1.3486)

0.045 ~ 0.085 (0.0018 ~ 0.0033)

0.07 ~ 0.19 (0.0028 ~ 0.0075)

40.940 ~ 40.955 (1.6118 ~ 1.6124)

LH: 35.700 ~ 35.900 (1.4055 ~ 1.4134)

RH: 35 452 ~ 35 652 (1 3957 ~20.944 ~ 20.960

(0.8246 ~ 0.8252)0.040 ~ 0.077

(0.0016 ~ 0.0030)0.10 ~ 0.20

(0.0039-0.0079)

Valve timing13° ~ 21°5°

LH: 35.452 ~ 35.652 (1.3957 ~ 1.4036)

RH: 35 537 ~ 35 737 (1 3991 ~

SA-3


mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.)

Engine

Exhaust

Valve99.55 (3.9193)99.05 (3.8996)

5.465 ~ 5.480 (0.2152 ~ 0.2157)Intake

Intake

5.430 ~ 5.450 (0.2138 ~ 0.2146)

Exhaust

Valve stem to valve guide clearance Exhaust

Thickness of valve head (margin)

Intake48.0 (1.8898)46.0 (1.8110)

5.500 ~ 5.512 (0.2165 ~ 0.2170)

Valve length

Stem outer diameter

45.58° ~ 45.75°

DSL U 1.1

93.0 (3.6614)93.7 (3.6890)

5.500 ~ 5.512 (0.2165 ~ 0.2170)

0.030 ~ 0.057(0.0012 ~ 0.0022)0.020 ~ 0.047 (0.0008 ~ 0.0019)Intake

5.455 ~ 5.470 (0.2148 ~ 0.2154)

5.435 ~ 5.450 (0.2140 ~ 0.2146)

Face angle 45° ~ 45°30'

Exhaust

0.050 ~ 0.077 (0.0020 ~ 0.0030)

-

Length Exhaust

0.050 ~ 0.082 (0.0020 ~ 0.0032)

Valve guideInner diameter Intake -

Exhaust

31.3 ~ 31.7(1.2323 ~ 1.2480)

1.1 (0.0433)1.2 (0.0472)

Intake 0.8 (0.0315)1.2 (0.0472)

SA-4

mm (in.)mm (in.)

mm (in.)

mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.) 66.000 ~ 67.030 (2.5984 ~ 2.5996)

66.970 ~ 67.000 (2.6366 ~ 2.6378)

mm (in.)

mm (in.)

mm (in.)

mm (in.) 2.51 ~ 2.53 (0.0988 ~ 0.0996)

2.01 ~ 2.03 (0.0791 ~ 0.0799)

Piston to cylinder clearance

No. 2 ring groove

Oil ring groove

Intake

3.02 ~ 3.04(0.1189 ~ 0.1197)

0.020 ~ 0.040 (0.0008 ~ 0.0016)

1.22 ~ 1.24 (0.0480 ~ 0.0488)

1.21 ~ 1.23 (0.0476 ~ 0.0484)

Less than 0.05 (0.002)

0.060 ~ 0.080 (0.0024 ~ 0.0031)

1.83 ~ 1.85(0.0720 ~ 0.0728)

1.82 ~ 1.84(0.0717 ~ 0.0724)

Rocker arm shaft outer diameter

Cylinder bore

Piston outer diameter

44.9 (1.7677)

75.00 ~ 75.03 (2.9528 ~ 2.9539)

Less than 0.05 (0.0020)Piston

0.8~1.4 (0.0315~0.0551)1.2~1.8 (0.0472~0.0709)

0.9 ~ 1.3 (0.0354 ~ 0.0512)

Valve springSeat angle

0.9 ~ 1.3 (0.0354 ~ 0.0512)43°30' ~ 44°

ExhaustWidth of seat contact

Free length 40.50 (1.5945)

Valve seat

17.5±0.9kg/ 32.0(1.2598)31.0±1kg/ 23.5(0.9252)

Rocker arm and rocker arm shaft-

Load mm (in.) 15.6±0.9kg / 32.0 (1.2598)33.3±1.8kg / 24.5 (0.9646)

44.5° ~ 45°

Cylinder block

Rocker arm inner diameter 17.010 ~ 17.028 (0.6697 ~ 0.6704)

Out of squareness Less than 1.5° Less than 1.5°

-16.985 ~ 16.998 (0.6687 ~ 0.6692)

74.93 ~ 74.96 (2.9500 ~ 2.9512)

67.000 ~ 67.030 (2.6378 ~ 2.6390)

Flatness of gasket surface

No. 1 ring groove

Ring groove width

SA-5


mm (in.)

mm (in.)

mm (in.) 0.01 ~ 0.13 (0.0003 ~ 0.0011)

0.06 ~ 0.15 (0.0024 ~

0 0059)mm (in.)

mm (in.) 0.25 ~ 0.40 (0.0098 ~ 0.0157)

0.30 ~ 0.50 (0.0098 ~ 0.0157)

mm (in.)

mm (in.)

mm (in.)

mm (in.) 0.008 ~ 0.015 (0.0003 ~ 0.0005)

0.008 ~ 0.014 (0.0003 ~ 0.0006

)mm (in.)

mm (in.)

Side clearance

No. 1 ring groove

Piston pin hole inner diameter

Engine

No. 2 ring groove

Oil ring groove

No. 2 ring groove

Oil ring groove

Piston pin hole clearance

17.011 ~ 17.015 (0.6697 ~ 0.6699)

0.20 ~ 0.70 (0.0079 ~ 0.0276)

0.02 ~ 0.06 (0.0008 ~ 0.0024)

0.15 ~ 0.30 (0.0059 ~ 0.0118)

0.004 ~ 0.015 (0.0002 ~ 0.0006)

DSL U 1.1

0.20 ~ 0.40 (0.0079 ~ 0.0157)

0.35 ~ 0.50 (0.0138 ~ 0.0197)End gap

28.004 ~ 28.010(1.1025 ~ 1.1028)

Piston ring0.09 ~ 0.13

(0.0035 ~ 0.0051)

Piston pin

0.08 ~ 0.12 (0.0031 ~ 0.0047)

27.995 ~ 28.000 (1.1022 ~ 1.1024)17.000 ~ 17.003 (0.6693 ~ 0.6694)Piston pin outer diameter

No. 1 ring groove 0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.20 ~ 0.35 (0.0079 ~ 0.0138)

28.022 ~ 28.034(1.1032 ~ 1.1037)

0.022 ~ 0.039(0.0009 ~ 0.0015)-0.029 ~ -0.015 (-0.0006 ~ -0.0003)Connecting rod small end hole clearance

16.974 ~ 16.985 (0.6683 ~ 0.6687)Connecting rod small end inner diameter

SA-6

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

kPa(kg/cm²)

ℓ(lmp.qt)

Pin journal outer diameter

0.08 ~ 0.28(0.0031 ~ 0.110)

Main bearing oil clearance

0.10 ~ 0.25 (0.0039 ~ 0.0098)

Crankshaft53.972 ~ 53.990

(2.1249 ~ 2.1256)

End play

Main journal outer diameter 41.982 ~ 42.000 (1.6528 ~ 1.6535)

End play

Connecting rod bearing oil clearance

490.33 ± 49.03 (5 ± 0.5)

0.012 ~ 0.041 (0.0005 ~ 0.0016)

490.33 ~ 588.40 (5.0 ~ 6.0)

45.997 ~ 46.015(1.8109 ~ 1.8116)

0.024 ~ 0.042(0.0009 ~ 0.0017)

Flywheel-

Oil pumpRunout 0.13 (0.0051 )

Relief valve opening pressure

- 5.3 (4.66)

0.025 ~ 0.043 (0.0010 ~ 0.0017)

0.050 ~ 0.302 (0.0020 ~ 0.0119)

Cooling system

37.980 ~ 38.000 (1.4953 ~ 1.4961)

0.020 ~ 0.038 (0.0008 ~ 0.0015)

0.05 ~ 0.25 (0.0020 ~ 0.0098)

Coolant quantity

Cooling method Forced circulation with cooling fan

Connecting rod49.000 ~ 49.018

(1.9291 ~ 1.9298)Connecting rod big end inner diameter 41.000 ~ 41.015 (1.6142 ~ 1.6148)

SA-7


°C (°F)°C (°F)

mm (in.)kPa

(kg/cm²)kPa

(kg/cm²)

kΩkΩ

Bolts

Long bolts

Cylinder head bolt

32.4 ~ 36.3 (3.3 ~ 3.7)

11.8 ~ 13.7 (1.2 ~ 1.4)49.0 (5.0) + 90° + 120°

Cylinder head-

0,3222

Engine DSL U 1.1

Pull opening 100 (212)85 ± 1.5 (185.0 ± 2.7)82 ± 1.5 (177 ± 2.7)

80°C (176°F)

Water temperature sensorType

Resistance

Connecting rod cap nuts or bolts

Crankshaftmain bearing cap

Main moving system

-

-

Short bolts

55.8 ~ 68.6 (6.0 ~ 7.0)

20°C (68°F)

Thermostat

Radiator cap

Full liftMain valve opening press.

Opening 95 (203)

Vacuum valve opening press.

Camshaft bearing cap nuts or bolts 7.8 ~ 9.8 (0.8 ~ 1.0)

8 (0.3150) or more

93.16 ~ 122.58 (0.95 ~ 1.25)

Thermister type2.45 ± 0.14

0,3222

19.6 ~ 22.6 (2.0 ~ 2.3) 12.7 (1.3) + 90°49.0 ~ 53.9 (5.0 ~ 5.5)

-

0.98 ~ 4.90 (0.01 ~ 0.05)

22.6 ~ 26.5 (2.3~2.7) + 90°~94°

2.45 ± 0.14

Tightening torque [N.m(kgf-m)]

SA-8

VA

Ω

kΩ

mm (in.)Unleaded (Gap)Spark plugs

34.3 ~ 44.1 (3.5 ~ 4.6)

Oil filter

34.3 ~ 44.1 (3.5 ~ 4.5)

Engine Electrical System

Voltage regulator type

Oil pan nuts24.5 (2.5)

Oil pan drain plug

Speed

Voltage

12V, 90A

Starter

Rated voltage

Amperage

Type

Type

Rated voltageSpeed in use

Regulator setting 147 ± 0.3V

12 V, 0.9 kW11.5 V60A

Electronic built-in type1,000 ~ 18,000 rpm

5,500 rpmBattery voltage sensing

13.5 V , 70A

BKR5ES-11RC10YC4 -

-11.8 ~ 15.7 (1.2 ~ 1.6)

13.0 ± 15 %

Lubrication system

-

12 V, 1.7 kW11 V

-

-

-

90A, MAX2,600 rpm, MIN

5.9 ~ 7.8 (0.6 ~ 0.8)

354 A

55 min

0.87 ± 10 %

1.280 ± 0.01

1,000 ~ 18,000 rpmBuilt-in I.C. regulator

-

CMF 60AH

550A

92min

MF 40AH

No-load charasteristics

Unleaded (NGK)

Generator

Battery

Ignition coil Secondary resistance

Specific gravity at 25°C (77°F)

Reserve capacity

Primary resistance

Cold cranking amperage at -18°C (-0 4°F)

SA-9


ℓ(lmp.qt)

MPa(kgf/cm²

)kPa(kgf/cm²

)ClutchClutch operationClutch discClutch cover assembly

Single dry with diaphragm Single dry with diaphragmDiaphragm spring strap Diaphragm spring strap

Cable type Hydraulic type

-

Fuel Pressure Regulator Regulated Fuel Pressure 350 (3.5)

Fuel Pressure (Maximum) Pressure

Fuel Pump Type-

ElectricalIn-tank type

Driven by Electric motor

Fuel Filter TypeInstallation location Built in Fuel Pump assembly

High pressure type Fuel Return System Type

Engine

Engine Management ManufacturerFuel Tank Capacity

Fuel System

High Pressure Fuel PumpMechanical

Bosch

Returnless type35 (30.80)

Return type

Plunger Pumping Type

DSL U 1.1

Built in engine room

Drive Belt

160 (1,632)

-

SA-10

Service standardmm (in.)mm (in.)

Manual TransaxleType

MT oil capacity ℓ(lmp.qt)

Clutch pedal free play

Clutch master cylinder mountingClutch release cylinderClutch cable bracket mounting

Clutch pedal bracket mounting

Clutch pedal stroke


1.90 (1.67) 1.90 (1.67)

1st

M/T oil quality SAE 75W/85, 75W/90 SAE 75W/85, API GL-4

5th 0,719 0,733

3,545

4th 1,000

Rev. 3,636 3,583FGR 4,800 3,650

Gear ratio

1,950

0,9433rd 1,192 1,286

1,8943,615

2nd

20~27 (2.0~2.7) -

145 (5.70) 145 (5.70)15~20 (0.58~0.78) 6~13 (0.24~0.51)

M5EF2 M5CF1

- 9~14 (0.9~1.4)- 15~22 (1.5~2.2)

15~22 (1.5~2.2) 15~22 (1.5~2.2)- 25~35 (2.5~3.5)

Clutch cover assembly

SA-11


Automatic TransaxleType

ℓ(lmp.qt)

Driveshaft

mm (in.)

A/T

Outer

Outer

Inner TJOuter BJ

1,0004th 0,7263rd

Matic D+ESSO JWS3314 Mixture

(Ratio=2:1)-ATF quality

3,977 -

FRA

-

ATF capacity 5.2 (4.6) -

Rev. 2,643 -FGR

-

-

Gear ratio

1st 2,914 -2nd 1,526 -

Engine DSL U 1.1

Joint typeM/T

Inner TJOuter BJ

A/TInner 23 or more˚

46˚ or more0.08 (0.003) or less

Max. permissible angleM/T

Inner 23˚ or more46˚ or more

Hub end play

SA-12

kgf/cm²(Psi)

Starting torque [N.m (kgf-m)]Wheel bearing 1.3 (0.13 )[NOTE]Inner: On transaxle sideOuter: On tire sideTightening torque [N.m (kgf-m)]Hub nutDriveshaft lock nut 100 ~ 240 (10.0 ~ 24.0)Knuckle to strut assembly nut 100 ~ 120 (10.0 ~ 12.0)Lower arm ball joint to knuckle nut 60 ~ 72 (6.0 ~ 7.2)Tie rod end to knuckle 16 ~ 34 (1.6 ~ 3.4)Brake caliper to knuckle 69 ~ 75 (6.9 ~ 7.5)Wheel nut 90 ~ 110 (9.0 ~ 11.0)Rear hub bearing flange bolt 100 ~ 120 (10.0 ~ 12.0)

Suspension type MacPherson strut Torsion beamShock absorber type

Wheel sizeSteelAluminum

Tire size

Oil filled

2.1 (30)

155/70 R13, 165/60 R14175/60 R14, 175/50 R15

5J × 14", 4B × 13" 4.5J × 13", 5J × 14", 5.5J × 15"

Suspension SystemFront Rear

Tire pressure

SA-13

General Specifications - Picanto

mm (in.)GSLDSL

ℓ(lmp.qt)kPa

(kgf/cm²)

King-pin 13°±30'

Camber-

Rear

0±2 (0±0.079) 2±2 (0.079±0.079)-

100 ~ 120 (10.0 ~ 12.0)

Tightening Torque [N.m(kgf-m)]14°±30' -

Front

Wheel alignment

0°±30' -1°±30'2°43'±30'

Toe-in

Hub nuts 90 ~ 110 (9.0 ~ 11.0)Front strut assembly to knuckle 100 ~ 120 (10.0 ~ 12.0)Front strut assembly self-locking nut 40 ~ 55 (4.0 ~ 5.5)Front lower arm to sub frame 95 ~ 120 (9.5 ~ 12.0)Front lower arm to knuckle 60 ~ 72 (6.0 ~ 7.2)Front stabilizer link to strut assembly 35 ~ 45 (3.5 ~ 4.5)

Torsion beam to body 100 ~ 120 (10.0 ~ 12.0)

Caster

Front stabilizer bar bracket mounting bolts 17 ~ 26 (1.7 ~ 2.6)Rear shock absorber to torsion beam

Power steering pump relief pressure 6570 ~ 7159 (67 ~ 73)

Steering SystemRack and Pinion, EPS (Electric Power Steering) System

Power steering fluidQuality PSF-3Quantity 0.75 ~ 0.8 (0.66 ~ 0.70)

Type

SA-14

ΩΩΩΩ

RestraintsType Depowered

Pressure hose to power steering pump

Steering wheel lock nut 40 ~ 50 (4.0 ~ 5.0)Steering column mounting bolt & nut 13 ~ 18 (1.3 ~ 1.8)Bolt connecting steering column to universal joint 13 ~ 18 (1.3 ~ 1.8)Bolt connecting universal joint to steering gear 30 ~ 35 (3.0 ~ 3.5)Tie rod end to knuckle 16 ~ 34 (1.6 ~ 3.4)Power steering pump to pump bracket 20 ~ 27 (2.0 ~ 2.7)

55 ~ 65 (5.5 ~ 6.5)Steering gear box to sub frame 60 ~ 80 (6.0 ~ 8.0)

ResistanceDriver Airbag (DAB) 1.6 ~ 6.1Passenger Airbag (PAB) 1.6 ~ 6.1Side Airbag (SAB) 1.6 ~ 6.1Seat Belt Pretensioner (BPT) 1.6 ~ 6.1Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB) 7.8 ~ 17.7 (0.8 ~ 1.8)Passenger Airbag (PAB) Nut 5.9 ~ 9.8 (0.6 ~ 1.0)Seat Belt Anchor Bolt (BPT) 39.2 ~ 53.9 (4.0 ~ 5.5)SRSCM Mounting Bolt 7.8 ~ 9.8 (0.8 ~ 1.0)

Tightening Torque [N.m(kgf-m)]

SA-15


Brake System

mm (in.)

kg/cm²(MPa)


mm (in.)

Recommended lubricant DOT 3 or DOT 4Quantity As required

Engine

Brake fluid

DSL U 1.1

Proportioning valve (CBS)

26 (2.55)

Master cylinderTandem type

I.D. 20.64 (0.813)

Cut-in pressure (Split point)

Provided

Decompression ratio 0.27 : 1Brake boosterType VacuumEffective diameter Tandem type with 8 inBoosting ratio 7.5 : 1Front brake (Disc)

Floating type with ventilated discDisc O.D. 241 (9.48)Type

Single pistonCylinder I.D. 51.1 (2.01)

Disc thickness 18 (0.71)Pad thickness 10 (0.39)

Type

Fluid level warning sensor

Cylinder type

SA-16


mm (in.)


Service standardmm (in.)mm (in.)mm (in.)

mm (in.)

mm (in.)

33.96 (1.34)

TypeDisc O.D.

Cylinder type

Floating type with solid disc234 (9.21)10 (0.39)9 (0.35)

Single piston

Disc thickness

Rear brake (Drum)Leading trailing

Drum I.D. 180 (7.09)Type

Brake lining thickness

Pad thickness

Cylinder I.D.

Rear brake (Disc)

Clearance adjustment Automatic

HECU 4 channel 4 sensor (MGH-25)

Parking brakeMechanical brake acting on rear wheels

Lever

I.D = Inner Diameter

System

O.D = Outer Diameter

Anti-lock Brake System(ABS)/ Electronic Stability Program(ESP)

Brake pedal height 189 (7.24 )Brake pedal stroke 122 ~ 127 (4.8 ~ 5.0)Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)Stop lamp switch outer case to pedal stopper clearance

0.5 ~ 1.0 (0.02 ~ 0.04)

Booster push rod to master cylinder piston clearance

0.6 ~ 1.4 (0.023 ~ 0.055)(at 500 mmHg vacuum)

TypeActuation

4.5 (0.18)

SA-17


mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

Engine DSL U 1.18 ~ 9 clicks : Rear Disc type,

8 clicks : Rear Drum typeParking brake lever stroke when lever assembly is pulled with 196N (20kgf, 44lb force)Front disc brake pad thickness 2.0 (0.079)Front disc thickness (minimum) 18 (0.708)Front disc run out 0.05 (0.002)Front disc parallelism 0.005 (0.0002)Rear drum brake lining thickness 1.0 (0.039)Rear drum brake drum I.D (maximum) 182 (7.165)Rear disc brake pad thickness 2.0 (0.079)Rear disc brake disc thickness 8 (0.315)Rear disc run out 0.03 (0.0012)Rear disc parallelism 0.005 (0.0002)Tightening torque [N.m (kgf-m)]Master cylinder to booster mounting nut 8 ~ 12 (0.8 ~ 1.2)Brake booster mounting nut 13 ~ 16 (1.3 ~ 1.6)Bleeder screw 7 ~ 9 (0.7 ~ 0.9)Brake tube nut, brake hose 13 ~ 17 (1.3 ~ 1.7)Caliper guide rod bolt 22 ~ 32 (2.2 ~ 3.2)Caliper assembly 69 ~ 85 (6.9 ~ 8.5)Member assembly bracket mounting bolt 8 ~ 12 (0.8 ~ 1.2)Brake hose to front caliper 25 ~ 30 (2.5 ~ 3.0)Brake pedal mounting bolt 25~ 35 (2.5 ~ 3.5)Stop lamp switch mounting nut 8 ~ 10 (0.8 ~ 1.0)Brake hub flange nut 200 ~ 260 (20 ~ 26)

SA-18

Body (Interior & Exterior)

mm (in.)mm (in.)mm (in.)mm (in.)

Hood Type Rear hinged, front opening type (open stay rod type)

Wheel cylinder mounting bolt 5 ~ 11 (0.5 ~ 1.1)Rear drum backing plate mounting bolt 50 ~ 60 (5.0 ~ 6.0)proportioning valve to master cylinder 35 ~ 55 (3.5 ~ 5.5)Sensor mounting bolt (ABS)

Front 8 ~ 9 (0.8 ~ 0.9)Rear 8 ~ 9 (0.8 ~ 0.9)

HECU mounting bolt (ABS) 11 ~ 14 (1.1 ~ 1.4)HECU mounting bracket bolt (ABS) 17 ~ 26 (1.7 ~ 2.6)Brake tube nut (ABS) 13 ~ 17 (1.3 ~ 1.7)Bleeder screw (ABS) 7 ~ 13 (1.7 ~ 1.3)

Front doorConstruction Front hinged, full door constructionRegulator system Wire drum type

Rear doorConstruction Front hinged, full door constructionRegulator system Single arm type

Tailgate Type Inner hinged, gas lifter type

Glass thickness

Windshield 5.0 (0.1969)Front door 3.2 (0.1260)Rear door glass 3.2 (0.1260)Rear window 3.5 (0.1378)

Seat beltsDriver's seat 3 point typePassenger's seat 3 point typeRear seat (center) Fixed 2 point type

SA-19

GSL ε 1.0 GSL ε 1.1Engine DSL U 1.1

Tailgate

Hinge nut (body side) 21~30 (2.1~3.1)Hinge bolt (tail gate 7~11 (0.7~1.1)Latch bolt 7~11 (0.7~1.1)Striker bolt

General Specifications - Picanto

Tightening Torque [N.m(Kgf-m)]Front fender Mounting bolts 7~9 (0.7~0.9)

Front and rear doors

Hinge (body side) 33~41 (3.4~4.2)Hinge (door side) 10~20 (1.0~2.0)Checker bolt (body side) 22~32 (2.2~3.3)Checker bolt (door side) 7~11 (0.7~1.1)Latch screw 8~11 (0.8~1.1)Striker screw 17~22 (1.7~2.2)Outside handle bolt 8~12 (0.8~1.2)

9~14 (0.9~1.4)Actuator nut 7~11 (0.7~1.1)Lifter stud ball (body 22~27 (2.2~2.7)Lifter bracket bolt 7~11 (0.7~1.1)Outside handle 7~11 (0.7~1.1)Side guide bumper 7~9 (0.7~0.9)

Striker bolt 7~11 (0.7~1.1)Hinge bolt (Hood side) 22~27 (2.2~2.7)

Latch bolt 7~11 (0.7~1.1)Front seat Mounting bolt 34~54 (3.5~5.5)

Hood

Hinge bolt (body side) 22~27 (2.2~2.7)Hinge nut (body side) 22~27 (2.2~2.7)

SA-20

Body Electrical System

AM/FM AM/FM/Cassette

4Ω x 2

Keyless Entry And Burglar Alarm

Rear seat

Seat cushion nut 34~54 (3.5~5.5)Seatback bolt 34~54 (3.5~5.5)Seatback nut 17~25 (1.7~2.6)Seatback striker nut 17~25 (1.7~2.6)

Seat belt Anchor bolt 39~54 (4.0~5.5)

Type AM/FM/Cassette/MP3Audio

Tuning type

Frequency range /Channel space

FM

AMMW

Max 20W x 4Speaker impedanceAntenna

Power supplyRated output

Keyless entry transmitter Power sourceTransmissible distance 10m or more

LW

ItemsLithium 3V battery (1EA)

313.85 MHz (General)433.92 (Europe)

Life of batteryButton

2 years or more (at 20 times per day)Door lock, door unlock

Transmission frequency

PLL synthesized type87.5~108.0 MHz/100KHz(General)87.5~108.0 MHz/50KHz(Europe)

4Ω x 480PF 75Ω

Max 20W x 2DC 14.4V

531~1602 KHz/9KHz(General)531~1602 KHz/9KHz(Europe)153~279 KHz/9KHz(Europe)

Transmitter(TX)

SA-21


WWWWWWWWWWW

Heating Ventilation & Air ConditioningAir conditioner

Engine DSL U 1.1

6055

Head lampHighLow

Front turn signal lampFront position lamp

21(Europe), 27(General)5

Pulley type 4PK - TYPE

Rear stop/tail lamp (Outside) 21/5 (Europe), 27/8 (General)

Side repeaterRoom lamp

510

Rear fog lamp - EuropeLicense plate lamp

Displacement 110 cc/revCondeser Heat rejection 8,500 ± 10% Kcal/hr

Compressor

Type HS - 11 (Swash plate)Oil type & Capacity FD46CG (PAG) , 120 ±10cc

TypeManufacturer

Rear turn signal lamp21(Europe), 27(General)21(Europe), 27(General)

Back up lamp

215

Lighting system

Other systemSMARTRA system

BoschImmobilizer

SA-22

oz.(g)

Mode operating method

Tripple switch

ON : 370 ± 2.8(26.0 ± 0.2)OFF : 455 ± 2.8(32.0 ± 0.2)

ON : 28.6 ~ 36.3(2.00 ~ 2.55)OFF : 28.4 ± 2.8 (2.0 ± 0.2)ON : 256 ± 11.4(18.0 ± 0.8)OFF : 199 ± 17.1(14.0 ± 1.2)

High psi(kg/cm²)

Expansion valve Type Block

RefrigerantType R - 134a

15.87 ± 0.88(450 ± 25)Capacity Blower unitFresh and recirculation Operating method Cable

4,058 ± 5% Kcal/hr

Heater and evaporator unit

Blower Type Siroco fanSpeed step 4 speedSpeed control Resistor

Evaporator

Type Drawn cupTemperature control type Thermistor

Off : 1.9 ± 0.4 (35.4 ± 32.9)ON : 3.0 ± 0.5 (37.4 ± 32.9)

A/C ON/OFF °C (°F)

Cable

CableTemperature operating method

Air filter Type

Heater

Particle filter

Type Pin & Tube typeHeating capacity

Low psi(kg/cm²)

Medium psi(kg/cm²)

SA-23

　Engine Mechanical System………………………JB-2　Engine Electrical System…………………………JB-9　Fuel System……………………………..…………JB-10　Clutch…………………………………….…………JB-11　Manual Transaxle……………………….…………JB-11　Automatic Transaxle………………………………JB-12　Driveshaft………………………………..…………JB-12　Suspension System…………………….…………JB-14　Steering System………………………………… JB-15　Restraints…………………………………………JB-16　Brake System………………………………………JB-17　Body (Interior & Exterior)……………….……… JB-20　Body Electrical System……………………………JB-22　Heating, Ventilation & Air Conditioning..………JB-24

Rio (JB)

JB-1

General Specifications - RioGSL α 1.4 GSL α 1.6

EngineIn-line, DOHC In-line, DOHC

4 4

mm (in.) 75.5 (2.9724)x 78.1 (3.0748)

76.5 (3.0118) x 87 (3.4252)

cc 1.399 1.599

rpmrpmrpmrpm

ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt)

kPa(kg/cm²) 78.4 (0.8) 107.8 (1.1)

In-line, DOHC4

75 (2.9528)x 84.5 (3.3268)

1.493

-

720 ± 100660 ± 100

Above SJ / SL

3.0 (2.64)

-

750 ± 100750 ± 100

DSL U1.5

5.3 (4.66)4.8 (4.22)0.5 (0.44)

700 ± 100700 ± 100

17.8 : 1

-1-3-4-2

3.3 (2.90)

Firing order

Idle Speed

Total

A/C ON

Neutral,N,P-D-rangeNeutral,N,P-D-range

Ignition Timing

Oil panOil filterDrain and refill

Engine oil

Engine


Compression ratio

Bore x Stroke

Total displacement

Oil quality

Oil quantity

Oil pressure (Idle)

10.0 : 1

720 ± 100660 ± 100

BTDC 5˚ ± 5˚A/C OFF

0.3 (0.26)

78.4 (0.8)

Above API CH-4, Above ACEA B4

JB-2

9° -8°31° 60°43° 46°5° 10°

mm (in.)

mm (in.)

mm (in.)

LH mm (in.)

RH mm (in.)

LH mm (in.)

RH mm (in.)

mm (in.)

mm (in.)mm (in.)

6°34°46°4°

0.03 (0.0012) for width0.09 (0.0035) for length


Intake

Exhaust

43.3484~43.5484 (1.70663~1.7145

0)

43.5486~43.7486(1.71451~1.7223

8)

43.7492~43.9492(1.72241~1.7302

8)

44.1494~44.3494(1.73816~1.7460

4)

35.452 ~ 35.652 (1.3957 ~ 1.4036)

35.537 ~ 35.737 (1.3991 ~ 1.4070)

0.10 ~ 0.20 (0.0039-0.0079)

Valve timing

Cylinder head

End play

35.700 ~ 35.900 (1.4055 ~ 1.4134)

35.452 ~ 35.652 (1.3957 ~ 1.4036)

20.944 ~ 20.960 (0.8246 ~ 0.8252)

0.040 ~ 0.077 (0.0016 ~ 0.0030)



Cam height

Opens (BTDC)Intake valve

Intake

Closes (ATDC)


Flatness of manifold mounting surface Exhaust

Exhaust valve

Journal outer Diameter (Intake, Exhaust) / (LH,RH) 26.964 ~ 26.980 (1.0616 ~ 1.0622)

0.02 ~ 0.061 (0.0008 ~ 0.0024)0.10 ~ 0.20 (0.0039 ~ 0.0079)

Less than 0.03 (0.0012)

Less than 0.15 (0.0059)

Less than 0.15 (0.0059)

Camshaft

Closes (ABDC)Opens (BBDC)

JB-3





mm (in.)mm (in.)


93.0 (3.6614)93.7 (3.6890)

5.455 ~ 5.470 (0.2148 ~ 0.2154)

0.05 ~ 0.08 (0.0020 ~ 0.0031)

5.435 ~ 5.450 (0.2140 ~ 0.2146)45.5° ~ 45.75°1.1 (0.0433)1.2 (0.0472)

0.030 ~ 0.057 (0.0012 ~ 0.0022)0.050 ~ 0.077 (0.0020 ~ 0.0030)

0.03 ~ 0.06 (0.0012 ~ 0.0024)

Valve

Face angle

Valve stem to valve guide clearance

IntakeExhaust

Exhaust

45° ~ 45°30'Exhaust

IntakeExhaust

Valve guide

Intake

IntakeExhaust

Valve spring45˚ ~ 45˚ 30'

--

Seat angle

5.500 ~ 5.512 (0.2165 ~ 0.2170)5.500 ~ 5.512 (0.2165 ~ 0.2170)

Less than 1.5˚

44.0 (1.7323) 44.9 (1.7677)

Out of squareness31.0±1.6kg/23.5(0.9252)

Less than 1.5°

Inner diameter

Length

Valve length

Stem outer diameter Intake

Width of seat contact

IntakeExhaust

Intake

17.5±0.9kg/32.0(1.2598)21.6±1.1kg/35(1.3780)45.1±2.2kg/27.2(1.0709)

Exhaust


Valve opened

Free length

Load (Intake, Exhaust) Installed

36.3 ~ 36.7 (1.4291 ~ 1.4449)40.8 ~ 41.2 (1.6063 ~ 1.6220)

0.8 ~ 1.2 (0.0315 ~ 0.0472)1.3 ~ 1.7 (0.0512 ~ 0.0669)

Valve seat

5.935 ~ 5.950 (0.2337 ~ 0.2343)45° ~ 45˚ 30'1.1 (0.0433)1.3 (0.0512)

91.8 (3.6142)92.4 (3.6378)

5.955 ~ 5.970 (0.2344 ~ 0.2350)

Engine DSL U1.5

31.3 ~ 31.7 (1.2323 ~ 1.2480)31.3 ~ 31.7 (1.2323 ~ 1.2480)

0.8 ~ 1.4 (0.0315 ~ 0.0551)1.2 ~ 1.8 (0.0472 ~ 0.0709)

JB-4

mm (in.) 75.50 ~ 75.53(2.9724 ~ 2.9736)

76.50 ~ 76.53(3.0118 ~ 3.0130)

mm (in.)

mm (in.) 75.47 ~ 75.50(2.9713 ~ 2.9724)

76.47 ~ 76.50(3.0106 ~ 3.0118)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

0.09 ~ 0.13 (0.0035 ~ 0.0051)

2.030 ~ 2.055 (0.0799 ~ 0.0809) 3.02 ~ 3.04 (0.1189 ~ 0.1197)

0.08 ~ 0.12 (0.0031 ~ 0.0047)

0.08 ~ 0.175 (0.0031 ~ 0.0069)Oil ring groove

0.04 ~ 0.085 (0.0016 ~ 0.0033)

0.04 ~ 0.085 (0.0016 ~ 0.0033)

0.03 ~ 0.07 (0.0012 ~ 0.0028)

Piston

Less than 0.05 (0.0020)

No. 2ring groove

Cylinder bore

Cylinder block


75.000 ~ 75.030 (2.9528 ~ 2.9539)Less than 0.05 (0.0020) (Overhaul)

Less than 0.03 (0.0012) (Per I cylder)

0.060 ~ 0.080 (0.0024 ~ 0.0031)0.020 ~ 0.040 (0.0008 ~ 0.0016)

1.82 ~ 1.84 (0.0717 ~ 0.0724)

Oil ring groove



Ring groove width

Piston ring

No. 1 ring groove 1.230 ~ 1.255 (0.0484 ~ 0.0494) 1.83 ~ 1.85 (0.0720 ~ 0.0728)

Side clearance

No. 1 ring grooveNo. 2ring groove

74.930 ~ 74.960 (2.9500 ~ 2.9512)

1.230 ~ 1.255 (0.0484 ~ 0.0494)

JB-5


mm (in.) 0.20 ~ 0.35 (0.0079 ~ 0.0138)

0.15 ~ 0.30 (0.0059 ~ 0.0118)

mm (in.) 0.37 ~ 0.52 (0.0146 ~ 0.0205)

0.35 ~ 0.50 (0.0138 ~ 0.0197)

mm (in.) 0.20 ~ 0.70 (0.0079 ~ 0.0276)

0.20 ~ 0.70 (0.0079 ~ 0.0276)

mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)



0.20 ~ 0.35 (0.0079 ~ 0.0138)

0.004 ~ 0.015 (0.0002 ~ 0.0006)

Piston pin

Connecting rod small end inner diameter0.011 ~ 0.018 (0.0004 ~ 0.0007)

28.004 ~ 28.010 (1.1025 ~ 1.1028)

17.974 ~ 17.985 (0.7076 ~ 0.7081)

18.001 ~ 18.007 (0.7087 ~ 0.7089)18.016 ~ 18.021 (0.7093 ~ 0.7095)

Connecting rod bearing oil clearance0.050 ~ 0.302 (0.0020 ~ 0.0119)

53.972 ~ 53.990 (2.1249 ~ 2.1256)45.997 ~ 46.015 (1.8109 ~ 1.8116)

0.025 ~ 0.043 (0.0010 ~ 0.0017)End play

Main journal outer diameterPin journal outer diameter 44.954 ~ 44.972 (1.7698 ~ 1.7705)

49.950 ~ 49.968 (1.9665 ~ 1.9672)

0.022 ~ 0.039 (0.0009 ~ 0.0015)

49.000 ~ 49.018 (1.9291 ~ 1.9298)Connecting rod

28.022 ~ 28.034 (1.1032 ~ 1.1037)

0.35 ~ 0.50 (0.0138 ~ 0.0197)

27.995 ~ 28.000 (1.1022 ~ 1.1024)

0.20 ~ 0.40 (0.0079 ~ 0.0157)

Piston pin hole clearancePiston pin hole inner diameter

48.000 ~ 48.018 (1.8898 ~ 1.8905)

Connecting rod small end hole clearance

No. 1 ring groove

End gap No. 2ring groove

Oil ring groove

Piston pin outer diameter

Connecting rod big end inner diameter

-0.033 ~ -0.016 (-0.0013 ~ -0.0006)

0.022 ~ 0.040 (0.0009 ~ 0.0016)0.028 ~ 0.046 (0.0011 ~ 0.0018)0.05 ~ 0.175 (0.0020 ~ 0.0069)

0.018 ~ 0.036 (0.0007 ~ 0.0014)0.10 ~ 0.25 (0.0039 ~ 0.0098)

Crankshaft

0.024 ~ 0.042 (0.0009 ~ 0.0017)NO 3

0.08 ~ 0.28 (0.0031 ~ 0.110)

NO 1, 2, 4, 5

End play


Engine DSL U1.5

JB-6

mm (in.)

kPa(kg/cm²)

ℓ(lmp.qt)

°C (°F)

°C (°F)

kPa(kg/cm²)

kPa(kg/cm²)

kΩkΩ

82±1.5 (179.6±2.7)

100 (212) [Lift : 8mm, (0.3150 in)]

Main valve opening press.

Forced circulation with cooling fan Forced circulation with electrical fan

85±1.5 (185.0±2.7) [Lift : 0.35mm, (0.0138in)]

2.45±0.14

Oil pump


Cooling system

Water temperature sensor

Opening temperature

500±49.0 (5.1±0.5)

Type

Radiator cap

95 (203)


490±49.0 (5±0.5)

0.10 (0.0039) 0.10 (0.0039)

5.5 ~ 5.8 (4.84 ~5.10) 5.3 ~ 5.5 (4.66 ~ 4.84)

93.16 ~ 122.58 (0.95 ~ 1.25)

0.98 ~ 4.90 (0.01 ~ 0.05)

20°C (68°F)80°C (176°F)

RunoutFlywheel

Thermostat

Coolant quantity

Cooling method

Full opening temperature

Thermister type

0,3222Resistance

JB-7



34.3 (3.5) +90° → Release all bolts

→ 34.3 (3.5) + 90°

29.4 (3.0) +90° → Release all bolts → 29.4 (3.0) +90°

- 24.5 (2.5) + 90°

12.7 (1.3) + 90°-

Connecting rod cap nuts or boltsMain moving system

Engine

49.0 (5.0)+90°+120°

-

31.4 ~ 34.3 (3.2 ~ 3.5)53.9 ~ 58.8 (5.5 ~ 6.0)

Lubrication system

Cylinder head


-Short bolts

Oil pan and transaxle fixing bolt

Oil pan bolts or nuts

DSL U1.5

BoltsLong bolts

Oil pan drain plug

Oil filter

Camshaft bearing cap nuts or bolts

Cylinder head bolt

Oil filter cap

32.4 ~ 36.3 (3.3 ~ 3.7)

24.5 (2.5)

34.3 ~ 44.1 (3.5 ~ 4.5)29.4 ~ 41.2 (3.0 ~ 4.2)

39.2 ~ 44.1 (4.0 ~ 4.5)9.8 ~ 11.8 (1.0 ~ 1.2)

12.7 ~ 13.7 (1.3 ~ 1.4)

-

-11.8 ~ 15.7 (1.2 ~ 1.6)

11.8 ~ 13.7 (1.2 ~ 1.4)

9.8 ~ 11.8 (1.0 ~ 1.2)

JB-8


VA

MF 45AH MF 55AH

410 A 500 A

80 min 85 min

1.280 ± 0.01 1.280 ± 0.01

Ω 0.87 ± 10 % 0.7 ± 15 %

kΩ 13.0 ± 15 % -

Amperage

TypeCold cranking amperage at -18°C (-0 4°F)

Voltage

TypeRated voltage


Primary resistanceSecondary resistance


Battery

Ignition coil

Reserve capacity

Regulator setting

Starter No-load charasteristics

1,000 ~ 18,000 rpmElectronic built-in type

1,000 ~ 18,000 rpmSpeed in use

Rated voltage

Speed

Generator13.5 V, 90A

Battery voltage sensing

12 V, 1.7 kW11

14.55 ± 0.2 V

110 min

1.280 ± 0.01

14.55 ± 0.2 VMF 68AH

MAX 354,350 rpm, MIN

-

-

Electronic built-in type

12 V, 120A

2,600 rpm, MINMAX 90


12 V, 0.9 kW

600 A

11,5

JB-9


mm(in.)

mm(in.)

Fuel Systemℓ(lmp.qt

)Return type

MPa(kgf/cm²

)kPa(kgf/cm²

)

160 (1,632)

-


Plunger Pumping TypeDrive Belt

Fuel Pressure (Maximum) Pressure -

Fuel Pressure Regulator Regulated Fuel Pressure 343 (3.5)

Fuel Pump Type-



Fuel Filter Type High pressure type Installation location Built in Fuel Pump assembly Built in engine room

Returnless type

Engine Management ManufacturerFuel Tank CapacityFuel Return System Type

Bosch45 (39.60)

Leaded (Gap)

Spark plugs

Unleaded (NGK)

Unleaded (Gap)Leaded (NGK)Leaded (CHAMPION)

-

BKR5ESRC10YC

0.9 ~ 1.0 (0.0354 ~ 0.0394)-

1.0 ~ 1.1 (0.0394 ~ 0.0433) --

Unleaded (CHAMPION)BKR5ES-11RC10YC4 -

-Engine DSL U1.5

JB-10

ClutchClutch operationClutch discClutch cover assembly

Clutch cover assemblyClutch pedal bracket mountingClutch master cylinder mountingClutch release cylinderService standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)Manual TransaxleType

FGR 4,056 3,471

5th 0,837 0,702Rev. 3,583 3,583

M5CF1 M5CF21st 3,615 3,6152nd

Diaphragm spring strapTightening torque [N.m(kgf-m)]

Hydraulic typeSingle dry with diaphragm

15~22 (1.5~2.2) 12~15 (1.2~1.5)

15~22 (1.5~2.2) 15~22 (1.5~2.2)

25~35 (2.5~3.5) 25~35 (2.5~3.5)9~14 (0.9~1.4) 19~20 (1.9~2.0)

145 (5.70)6~13 (0.24~0.51)

Gear ratio

2,053 1,9623rd 1,370 1,2574th 1,031 0,905

JB-11




ℓ(lmp.qt)

Driveshaft

Hub end play mm(in.) 0.008 (0.0003) or less

Max. permissible angleInner 23˚ 23˚Outer 45˚ 46˚

TJ24Outer BJ22 BJ24

UTJ-II24Outer BJ22 BJ24

ATF capacity 6.1 (5.37) -

Joint typeLH

Inner UTJ-II22

RHInner TJ22

ATF quality Diamond ATF SP III or SK ATF SP III -

Gear ratio

1st 2,846 -

Rev. 2,176 -FGR 4.381/4.041 -

3rd 1,000 -4th 0,685 -

2nd 1,581 -

M/T oil quality SAE 75W/85, API GL-41.90 (1.67) 2.0 (1.76)

A4AF3 -

Engine DSL U1.5

JB-12

Rear strut to torsion beam axle nut 110 ~ 120 (11 ~ 12) -Rear torsion beam axle to rear hub bearing mounting nut 50 ~ 60 (5 ~ 6) -

Rear hub bearing flange nut 200 ~ 260 (20 ~ 26) -Rear brake to rear torsion beam axle mounting 65 ~ 75 (6.5 ~ 7.5) -

Inner shaft bracket to engine block bolts - 40 ~ 50 (4 ~ 5)Wheel nut 90 ~ 110 (9 ~ 11)

Tie rod end to knuckle bolt 16 ~ 34 (1.6 ~ 3.4) 24 ~ 34 (2.4 ~ 3.4)Brake caliper to knuckle bolt 69 ~ 75 (6.9 ~ 7.5) -

Knuckle to strut assembly bolt 100 ~ 120 (10 ~ 12)Lower arm ball joint to knuckle bolt 100 ~ 120 (10 ~ 12)

TJ: Tripod JointUTJ-ll: U Type-ll Tri-pod JointTightening torque [N.m (kgf-m)]Driveshaft lock nut 200 ~ 260 (20 ~ 26)

Wheel bearing 1.8 (0.18 )[NOTE]BJ: Birfield Joint

Starting torque [N.m (kgf-m)]

JB-13

General Specifications - Rio

mm (in.)

Gas pressurized5J × 14", 5.5J × 14"

5.5J × 14", 5.5J × 15", 6.5J × 16" 175/70 R14, 185/65 R14195/55 R15, 205/45 R16

Rear shock absorber to wheel housing panel 40 ~ 60 (4.0 ~ 6.0)

Front stabilizer link to strut assembly 35 ~ 45 (3.5 ~ 4.5)Front stabilizer bar bracket mounting 45 ~ 55 (4.5 ~ 5.5)

Front lower arm to sub frame FR: 120 ~ 140 (12.0 ~ 14.0), RR: 100 ~ 120 (10.0 ~ 12.0)Front lower arm to knuckle 100 ~ 120 (10.0 ~ 12.0)

Front strut assembly to knuckle 100 ~ 120 (10.0 ~ 12.0)Front strut assembly self-locking nut 50 ~ 70 (5.0 ~ 7.0)

Hub nuts 90 ~ 110 (9.0 ~ 11.0)Front strut assembly to wheel housing panel 20 ~ 30 (2.0 ~ 3.0)

King-pin 13°±30' -Tightening Torque [N.m(kgf-m)]

Wheel alignment

Camber 0°±30' -1°±30'

-Toe-in 0±2 (0±0.079) 4±2 (0.157±0.079)

Caster Power steering 4°00'±30' -Manual steering 0°35'±30'

GasolineDiesel

2.1kgf/cm2, (30psi)2.2kgf/cm2, (32psi)

Tire size

Tire pressure

Aluminum

Suspension System

Suspension type MacPherson strut Torsion beam

Steel

RearFront

Shock absorber type

Wheel size

JB-14

Type

ℓ(lmp.qt)

Steering gear box to sub frame 90 ~ 110 (9.0 ~ 11.0)

Power steering pump to pump bracket 20 ~ 27 (2.0 ~ 2.7)Pressure hose to power steering pump 55 ~ 65 (5.5 ~ 6.5)

Bolt connecting universal joint to steering gear 13 ~ 18 (1.3 ~ 1.8)Tie rod end to knuckle 16 ~ 34 (1.6 ~ 3.4)

Steering column mounting bolt & nut 13 ~ 18 (1.3 ~ 1.8)Bolt connecting steering column to universal joint 13 ~ 18 (1.3 ~ 1.8)

Tightening Torque [N.m(kgf-m)]Steering wheel lock nut 35 ~ 45 (3.5 ~ 4.5)

Power steering pumprelief pressure

Gasoline kPa(kgf/cm²

)

6669 ~ 7355 (68 ~ 75)Diesel 7551 ~ 8041 (77 ~ 82)

Rack strokeManual

mm (in.)144 (5.67)

Power (175 tire) 142 (5.59)Power (others) 135 (5.43)

Steering SystemRack and Pinion

Power steering fluid Quality PSF-3Quantity 0.8 (0.70)

Rear shock absorber self-locking nut 22 ~ 32 (2.2 ~ 3.2)Torsion beam to body 100 ~ 120 (10.0 ~ 12.0)

Rear shock absorber to torsion beam 100 ~ 120 (10.0 ~ 12.0)

JB-15


Ω

Front Impact Sensor (FIS) Mounting Bolt 9.5 ~ 13.6 (1.0 ~ 1.4)Side Impact Sensor (SIS) Mounting Bolt 9.5 ~ 13.6 (1.0 ~ 1.4)

Seat Belt Anchor Bolt (BPT) 39.2 ~ 53.9 (4.0 ~ 5.5)SRSCM Mounting Bolt 9.5 ~ 13.5 (1.0 ~ 1.4)

Curtain Airbag (CAB) 4.9 ~ 6.9 (0.5 ~ 0.7)Side Airbag (SAB) 4.9 ~ 6.9 (0.5 ~ 0.7)

Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB) 7.9 ~ 10.8 (0.8 ~ 1.1)Passenger Airbag (PAB)

Bolt 8.8 ~ 13.7 (0.9 ~ 1.4)Nut 3.9 ~ 6.9 (0.4 ~ 0.7)

Seat Belt Pretensioner (BPT)

DriverΩ

1.943 ~ 2.806Passenger 1.950 ~ 2.814

Curtain Airbag (CAB)Driver

Ω1.940 ~ 2.704

Passenger 1.948 ~ 2.712

Passenger Airbag (PAB) 1.878 ~ 2.442

Side Airbag (SAB)Driver

Ω1.804 ~ 2.568

Passenger 1.812 ~ 2.576

Resistance

Driver Airbag (DAB)Gasoline

Ω1.925 ~ 3.074

Diesel 20.25 ~ 2.974


Engine DSL U1.5

JB-16

Brake System

mm (in.)mm (in.)

MPa(kgf/cm²

)

mm (in.)


mm (in.)Cylinder I.D. 54 (2.12)

Pad thickness 11 (0.43)Cylinder type Single piston

Disc O.D. 256 (10)Disc thickness 22 (0.87)

Boosting ratio 7:01Front brake (Disc)Type Floating type with ventilated disc

Brake boosterType VacuumEffective diameter 254 (10)

Proportioning valve (CBS)

2.94 (30)

Decompression ratio 0.27 : 1


Piston stroke 29 ~ 31(1.14 ~ 1.22)Fluid level warning sensor Provided

Master cylinderType Tandem typeI.D. 22.22 (0.875)

Brake fluidRecommended lubricant DOT 3 or DOT 4

Quantity As required

JB-17



mm (in.)


mm (in.)O.D=Outer DiameterI.D=Inner DiameterAnti-lock Brake System (ABS) / Electronic Stability Program (ESP)

mm(in.)teeth

Acitve wheel speed sensor

Air gap 0.4 ~ 1.5 (0.016 ~ 0.059)Tone wheel 48

Manufacturer and NameHECU System 4 channel 4 sensor (Solenoid)

Actuation LeverDrum I.D. 168 (6.61)

Clearance adjustment AutomaticType Mechanical brake acting on rear wheels

Drum I.D. 203.2 (8)Brake lining thickness 4.3 (0.17)

Cylinder I.D. 31 (1.22)Rear brake (Drum)Type Leading trailing


Disc O.D. 262 (10.3)Disc thickness 10 (0.39)

Rear brake (Disc)Type Floating type with ventilated disc

Engine DSL U1.5

JB-18

Service standardmm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

mm (in.)

mm (in.)


Caliper mounting bolt 83.36 ~ 93.16 (8.5 ~ 9.5)Brake pedal member assembly bracket 7.9 ~ 11.8 (0.8 ~ 1.2)

Brake tube nut, brake hose 12.74 ~ 16.64 (1.3 ~ 1.7)Caliper guide rod bolt 21.56 ~ 32.36 (2.2 ~ 3.2)

Brake booster mounting nut 12.74 ~ 15.68 (1.3 ~ 1.6)Bleeder screw 5.88 ~ 9.8 (0.6 ~ 1.0)

Rear disc brake disc thickness 10 (0.4)Tightening torque [N.m (kgf-m)]Master cylinder to booster mounting nut 7.9 ~ 111.8 (0.8 ~ 1.2)

Rear drum brake drum I.D 203.2 (8)Rear disc brake pad thickness 10 (0.4)

Front disc thickness 22 (0.87)Rear drum brake lining thickness 4.3 (0.17)

6 ~ 8 clicks

Front disc brake pad thickness 11 (0.43)

Parking brake lever stroke when lever assembly is pulled with 196N (20kgf, 44lb force)

Stop lamp switch outer case to pedal 0.5 ~ 1.0 (0.02 ~ 0.04)Booster push rod to master cylinder piston clearance

0 (at 500 mmHg vacuum)

Brake pedal stroke 125 (4.92)Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)

Brake pedal heightLHD 164.8 (6.49 )RHD 168.2 (6.62)

JB-19



mm (in.)mm (in.)mm (in.)mm (in.)Rear window 3.2 (0.1260)

Trunk lid Type Torsion bar type

Glass thickness

Windshield 5.0 (0.1969)Front door 3.2 (0.1260)Rear door glass 3.2 (0.1260)

Rear doorConstruction Front hinged, full door constructionRegulator system Wire drum typeLocking system Pin-fork system

Front doorConstruction Front hinged, full door constructionRegulator system Wire drum typeLocking system Pin-fork system

Master cylinder pressure sensor 22.56 ~ 26.48 (2.3 ~ 2.7)

Hood Type Rear hinged, gas lifter type

proportioning valve to master cylinder 34.3 ~ 44.1 (3.5 ~ 4.5)Yaw rate ＆ lateral G sensor mounting bolt 7.9 ~ 10.79 (0.8 ~ 1.1)

HECU union screw 11.76 ~ 15.68 (1.2 ~ 1.6)Rear drum backing plate mounting bolt 9.8 ~ 12.74 (1 ~ 1.3)

Wheel speed sensor mounting bolt 8.04 ~ 9.51 (0.82 ~ 0.97)HECU mounting bracket bolt 7.9 ~ 9.8 (0.8 ~ 1.0)

Engine DSL U1.5

Rear drum backe bleeder screw 5.88 ~ 8.82 (0.6 ~ 0.9)

Brake pedal mounting nut 24.51~ 34.32 (2.5 ~ 3.5)Stop lamp switch mounting nut 7.9 ~ 9.8 (0.8 ~ 1.0)

JB-20

Front seat belt

Seat belt height adjuster 39.2~53.9 (4.0~5.5)Seat belt buckle

39.2~53.9 (4.0~5.5)Seat belt lower anchor 39.2~53.9 (4.0~5.5)

39.2~53.9 (4.0~5.5)Seat belt upper anchor

39.2~53.9 (4.0~5.5)

Rear seat beltSeat belt anchor 39.2~53.9 (4.0~5.5)Seat belt retractor 39.2~53.9 (4.0~5.5)

34.3~53.9 (3.5~5.5)Front seat mounting nut 23.5~35.3 (2.4~3.6)Rear seat mounting 43.1~64.7 (4.4~6.6)

Seat belt anchor

HoodHood hinge to body 21.6~26.5 (2.2~2.7)Hood hinge to hood 21.6~26.5 (2.2~2.7)Hood latch to body 9.8~14.7 (1.0~1.5)

SeatFront seat mounting

Trunk lidTrunk lid lift to trunk lid 6.9~10.8 (0.7~1.1)Trunk lid latch to trunk 6.9~10.8 (0.7~1.1)

Tightening Torque [N.m(Kgf-m)]

Front and rear doorsDoor hinge to body 12.7~25.5 (1.3~2.6)Door hinge to door 12.7~25.5 (1.3~2.6)

Seat beltsFront 3 point type with Emergency Locking Retractor (E.L.R)Rear 3 point type with Emergency Locking Retractor (E.L.R), 2point type

JB-21


Body Electrical SystemAudio

AM/FM/Cassette (M420)

AM/FM/CD (M445)

AM/FM/Cassette/MP3 (M455)

AM/FM/Cassette/6CDC (M465)

Max 55W x 410kΩ x 4


Transmission frequency433.92 MHz (Europe, Austrailia, Middle east)

315.00 MHZ (General)

Life of battery 2 years or more (at 20 times per day)Button Door lock/unlock

Keyless entry transmitter Power source Lithium 3V battery (1EA)Transmissible distance 10m or more

LW 153~279 KHz/ 1KHz (Europe)

Items Transmitter(TX)

80PF 75ΩTuning type PLL synthesized type


FM 87.5~108 MHz/ 100KHz (General), 50KHz(Europe)AM 531~1602 KHz/ 9KHz (General)MW 522~1620 KHz/ 9KHz (Europe)

Type

Power supply DC 14.4VRated output Max 43W x 4Speaker impedance 4Ω x 4Antenna

Engine DSL U1.5

JB-22

Lighting systemWWWWWWWWWWWWW

W

WOther system

Rear parking assist system

Luggage lamp 5

Immobilizer

2 channel

Type SMARTRA systemManufacturer Bosch

Overhead console lamp 10 x 2

High mounted stop lamp 16

Side repeater 5Room lamp 10

Rear fog lamp - Europe 21License plate lamp 5

Back up lamp 16Rear turn signal lamp 21

Front fog lamp 27Rear tail/stop lamp 12/5

Front turn signal lamp 21Front position lamp 5

Head lampHigh 60Low 55

JB-23



kcal/hr

oz.(g)

The method tomeasure the pressure

Heat rejectionCondeser 12,000 ± 5%

Compressor

Type 6SBU16Oil type & Capacity ND-OIL8(PAG), 120 ± 100ccPulley type

APT(A/C pressure transducer)

voltage = 0.025 * pressure + 0.1

Voltage = 0.001758 * Pressure + 0.074162 [PSIA]

9,500 ± 5%

L5OS - TYPE

Engine DSL U1.5

Blower unitFresh and recirculation Operating method Actuator

Block


17.6 ± 0.88(500 ± 25)Capacity

Expansion valve Type

Blower Type Siroco fanSpeed step Auto + 8speed (Automatic) , 4speed (Manual)Speed control Power mosfet (Automatic) , Blower resistor (Manual)

Displacement 160cc/rev

Air filter Type Particle filter

JB-24


Mode operating methodHeater

Type Pin & Tube typeHeating capacity 4,450 ± 10% Kcal/hrPTC heater capacity 1,000W + 5% / -10%

AcuatorAcuator(Automatic) , (cable(Manyal)Temperature operating

EvaporatorTemperature control type Evaporator temperature sensor

OFF : 5.0 ± 0.5 (41 ± 32.9)ON : 3.0 ± 0.5 (37.4 ± 32.9)

A/C ON/OFF ()

JB-25

　Engine Mechanical System………………………LD-2　Engine Electrical System…………………………LD-9　Fuel System……………………………..…………LD-10　Clutch…………………………………….…………LD-11　Manual Transaxle……………………….…………LD-11　Automatic Transaxle………………………………LD-12　Driveshaft………………………………..…………LD-12　Suspension System…………………….…………LD-14　Steering System………………………………… LD-15　Restraints…………………………………………LD-16　Brake System………………………………………LD-17　Body (Interior & Exterior)……………….……… LD-21　Body Electrical System……………………………LD-23　Heating, Ventilation & Air Conditioning..………LD-25

Cerato (LD)

LD-1

General Specifications - CeratoGSL γ 1.6 GSL β 2.0 DSL U 1.6

EngineIn-line, DOHC In-line, DOHC In-line, DOHC

4 4 4

mm (in.) 77 (3.0315)x 85.44 (3.3638)

82 (3.2283)x 93.5 (3.6811)

77.2 (3.0315)x 84.5 (3.3638)

cc 1.591 1.975 1.58217.3 : 1 10.1 : 1 17.3 : 11-3-4-2 1-3-4-2 1-3-4-2

-rpm 830 ± 100rpm 830 ± 100rpm 830 ± 100rpm 830 ± 100

ℓ (lmp.qt) 3.7 (3.26) 4.1 (3.60 ) 5.3 (4.66 )ℓ (lmp.qt) 3.0 (2.64) 3.7 (3.26 ) 4.8 (4.22 )ℓ (lmp.qt) - 0.3 (0.26) 0.5 (0.44)ℓ (lmp.qt) 3.3 (2.90) 4.0 (3.52) 3.3 (2.91)

Above SL / GF - 3 - Above API CH-4kPa

(kg/cm²) - 245 (2.5) /1500 rpm 78.4 (0.8) / IDLE

10° (BTDC 40°) 11° 17°5' ± 4° 63° (ABDC 13°) 59° 14°6' ± 4°

Firing order

Intake valve

BTDC 5˚ ± 10˚A/C OFFA/C ON

Neutral,N,P-D-rangeNeutral,N,P-Idle Speed

Total

Valve timing


Oil quality

Oil quantity

D-rangeEngine oil

Oil pressure


Engine


Compression ratio

Bore x Stroke

Total displacement

Ignition Timing660 ± 100660 ± 100660 ± 100660 ± 100

LD-2

40° 42° 23°25' ± 4°3° 6° 20° ± 4°

mm (in.) Less than 0.05 (0.0020) Less than 0.03 (0.0012) 0.03 (0.0012) for width0.09 (0.0035) for length

mm (in.) -0.025 (0.0010) for width

0.160 (0.0063) for length

mm (in.) -0.025 (0.0010) for width

0.160 (0.0063) for length

mm (in.) 43.85 (1.7264) 44.618 (1.7566)

LH : 35.452 ~ 35.652(1.3957 ~ 1.4036)

RH : 35.537 ~ 35.737(1.3991 ~ 1.4070)

mm (in.) 42.85 (1.6870) 44.518 (1.7527)

LH : 35.700 ~ 35.900 (1.4055 ~ 1.4134)

RH : 35.452 ~ 35.652(1.3957 ~ 1.4036)

mm (in.) 22.964 ~ 22.980 (0.9041 ~ 0.9047) 28 (1.1023) 20.944 ~ 20.960

(0.8246 ~ 0.8252)

mm (in.) 0.020 ~ 0.057(0.0008 ~ 0.0022)

0.02 ~ 0.061 (0.0008 ~ 0.0024)

0.040 ~ 0.077 (0.0016 ~ 0.0030)

mm (in.) 0.10 ~ 0.20 (0.0039 ~ 0.0079)

0.1 ~ 0.2 (0.0040 ~ 0.0079)

0.10 ~ 0.20 (0.0040-0.0079)

mm (in.) 93.15 (3.6673) 114.34 (4.5016) 93.0 (3.6614)mm (in.) 92.8 (3.6457) 116.8 (4.598) 93.7 (3.6890)Exhaust

Cylinder head

Valve

End play

Intake

Exhaust valve


Opens (BBDC)Closes (ATDC)


Intake

Valve length

Exhaust

Exhaust


Intake

Flatness of manifold mounting surface

Camshaft

Cam height

Max. 0.15 (0.0059)

LD-3


mm (in.) 5.465 ~ 5.480 (0.2152 ~ 0.2157)

5.965 ~ 5.98 (0.2348 ~ 0.2354)

5.455 ~ 5.470 (0.2148 ~ 0.2154)

mm (in.) 5.458 ~ 5.470 (0.2149 ~ 0.2154)

5.950 ~ 5.965(0.2343 ~ 0.2348)

5.435 ~ 5.450(0.2140 ~ 0.2146)

45.25° ~ 45.75° - 45.5° ~ 45.75°

mm (in.) 1.1 (0.0433) 1.6±0.15(0.0630±0.0059) 1.1 (0.0433)

mm (in.) 1.26 (0.0496) 1.8±0.15(0.0709±0.0059) 1.2 (0.0472)

mm (in.) 0.020 ~ 0.047 (0.0008 ~ 0.0019)

0.02 ~ 0.05 (0.0008 ~ 0.0019)

0.030 ~ 0.057 (0.0012 ~ 0.0022)

mm (in.) 0.030 ~ 0.054 (0.0012 ~ 0.0021)

0.035 ~ 0.065 (0.0014 ~ 0.0026)

0.050 ~ 0.077 (0.0020 ~ 0.0030)

mm (in.) - - 5.500 ~ 5.512 (0.2165 ~ 0.2170)

mm (in.) - - 5.500 ~ 5.512 (0.2165 ~ 0.2170)

mm (in.) 40.3 ~ 40.7 (1.5866 ~ 1.6024) - 31.3 ~ 31.7

(1.2323 ~ 1.2480)

mm (in.) 40.3 ~ 40.7(1.5866 ~ 1.6024) - 31.3 ~ 31.7

(1.2323 ~ 1.2480)

mm (in.) - 1.1 ~ 1.5 (0.043 ~ 0.059)

0.8 ~ 1.4(0.0315~0.0551)

Engine

Exhaust


Exhaust

Intake

Exhaust

Intake

Inner diameter

Length

Intake

Exhaust

Intake

Stem outer diameter

Thickness of valve head (margine)

Face angle

Intake

Intake

Valve guide

Valve seat

Width of seat contactLD-4

mm (in.) - 1.3 ~ 1.7 (0.051 ~ 0.066)

1.2 ~ 1.8(0.0472~0.0709)

- - 45° ~ 45°30'

Exhaust

Seat angle


LD-5

mm (in.) 44.0mm (1.7323) 48.86mm (1.9236) 44.9mm (1.7677)

mm (in.) -

18.8k±0.9kg/39.0(1.5354)

41.0±1.5kg/30.5(1.2008)

17.5±0.9kg/32.0(1.2598)

31.0±1.6kg/23.5(0.9252)

Less than 1.5° 1.5° or less Less than 1.5°

mm (in.) - 0.20 (0.0079) -mm (in.) - 0.29 (0.0114) -mm (in.) - 0.28 (0.0110) -mm (in.) - 0.34 (0.0134) -

mm (in.) 77.00 ~ 77.03 (3.0315 ~ 3.0327)

82.00 ~ 82.03(3.2283 ~ 3.2295)

77.200 ~ 77.230(3.0394 ~ 3.0405)

mm (in.) Less than 0.05 (0.0020) - Less than 0.05 (0.0020)

mm (in.) 76.97 ~ 77.00 (3.0303 ~ 3.0315)

81.97 ~ 82.00 (3.2271 ~ 3.2283)

77.130 ~ 77.160 (3.0366 ~ 3.0378)

mm (in.) 0.020 ~ 0.040 (0.0008 ~ 0.0016)

0.02 ~ 0.04 (0.0008 ~ 0.0016)

0.060 ~ 0.080 (0.0024 ~ 0.0031)

mm (in.) 1.22 ~ 1.24 (0.0480 ~ 0.0488) - 1.83 ~ 1.85

(0.0720 ~ 0.0728)

mm (in.) 1.22 ~ 1.24 (0.0480 ~ 0.0488) - 1.82 ~ 1.84

(0.0717 ~ 0.0724)

mm (in.) 2.01 ~ 2.03 (0.0791 ~ 0.0799) - 3.02 ~ 3.04

(0.1189 ~ 0.1197)- 0.25, 0.50 (0.010,

0 020) -

Ring groove width

80°C (176°F)

No. 2 ring groove

Oil ring groove

Piston OS

20°C (68°F)

Intake

Valve clearanceOut of squareness

Free lengthValve spring

Cylinder block


Cylinder bore

Piston

No. 1 ring groove

Load

80°C (176°F)Exhaust

20°C (68°F)



LD-6


mm (in.) 0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.04 ~ 0.08 (0.0015 ~ 0.0031)

0.09 ~ 0.13 (0.0035 ~ 0.0051)

mm (in.) 0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.03 ~ 0.07 (0.0012 ~ 0.0027)

0.08 ~ 0.12 (0.0031 ~ 0.0047)

mm (in.) 0.06 ~ 0.15 (0.0024 ~ 0.0059)

0.20 ~ 0.60 (0.0078 ~ 0.0236)

0.03 ~ 0.07 (0.0012 ~ 0.0028)

mm (in.) 0.14 ~ 0.28 (0.0055 ~ 0.0110)

0.20 ~ 0.35 (0.0079 ~ 0.0138)

0.20 ~ 0.35 (0.0079 ~ 0.0138)

mm (in.) 0.30 ~ 0.45 (0.0118 ~ 0.0177)

0.37 ~ 0.52 (0.0146 ~ 0.0205)

0.35 ~ 0.50 (0.0138 ~ 0.0197)

mm (in.) 0.20 ~ 0.70 (0.0079 ~ 0.0276)

0.20 ~ 0.60 (0.0078 ~ 0.0236)

0.20 ~ 0.40 (0.0079 ~ 0.0157)

mm (in.) 18.001 ~ 18.006 (0.7087 ~ 0.7089)

20.001 ~ 20.006 (0.7874 ~ 0.7876)

27.995 ~ 28.000 (1.1022 ~ 1.1024)

mm (in.) 18.016 ~ 18.021 (0.7093 ~ 0.7095)

20.016 ~ 20.021 (0.7880 ~ 0.7882)

28.004 ~ 28.010 (1.1025 ~ 1.1028)

mm (in.) 0.010 ~ 0.020 (0.0004 ~ 0.0008)

0.010 ~ 0.020 (0.0004 ~ 0.0008)

0.004 ~ 0.015 (0.0002 ~ 0.0006)

mm (in.) 17.974 ~ 17.985 (0.7076 ~ 0.7081)

19.974 ~ 19.985 (0.7864 ~ 0.7868)

28.022 ~ 28.034 (1.1032 ~ 1.1037)

mm (in.) - 0.010 ~ 0.020 (0.0004 ~ 0.0008)

0.022 ~ 0.039 (0.0009 ~ 0.0015)

Engine

Side clearance

No. 1 ring groove

Oil ring groove

Oil ring groove

Piston ring

End gap

No. 1 ring groove

Piston pin



Connecting rod small end inner diameter


No. 2 ring groove


No. 2 ring groove

LD-7

mm (in.) 45.000 ~ 45.018 (1.7717 ~ 1.7724) - 49.000 ~ 49.018

(1.9291 ~ 1.9298)

mm (in.) 0.032 ~ 0.052 (0.0013 ~ 0.0020)

0.024 ~ 0.042 (0.0009 ~ 0.0017)

0.025 ~ 0.043 (0.0010 ~ 0.0017)

mm (in.) 0.10 ~ 0.25 (0.0039 ~ 0.0098) - 0.10 ~ 0.25

(0.0039 ~ 0.0098)

mm (in.) - 56.942 ~ 56.962 (2.2418 ~ 2.2426)

53.972 ~ 53.990 (2.1249 ~ 2.1256)

mm (in.) - 44.946 ~ 44.966 (1.7695 ~ 1.7703)

45.997 ~ 46.015 (1.8109 ~ 1.8116)

mm (in.) 0.021 ~ 0.042 (0.0008 ~ 0.0017) - 0.024 ~ 0.042

(0.0009 ~ 0.0017)

mm (in.) 0.05 ~ 0.25 (0.0020 ~ 0.0098)

0.06 ~ 0.260 (0.0023 ~ 0.010)

0.08 ~ 0.28 (0.0031 ~ 0.0110)

mm (in.) - 0.1 (0.0039) 0.1 (0.0039)

kPa(kg/cm²) - - 490±49.0 (5±0.5)

Forced circulation with cooling fan

Forced circulation with electrical fan


ℓ(lmp.qt)

5.8 ~ 5.9 (5.10 ~ 5.19) 6.5~6.6 (5.72 ~ 5.81) 6.97 (6.13)

Crankshaft


Runout


Coolant quantity

Cooling method

Cooling system

Oil pump

End play

Flywheel



Connecting rod

End play

Main journal outer diameter


LD-8


°C (°F) 82 ± 1.5 (179.6 ± 2.7) 82 (177) 85 ± 1.5 (185.0 ± 2.7)°C (°F) 95 (203) 95 (203) 100 (212)

kPa(kg/cm²)

93.16 ~ 122.58(0.95 ~ 1.25)

93.16 ~ 122.58(0.95 ~ 1.25)

93.16 ~ 122.58 (0.95 ~ 1.25)

kPa(kg/cm²) MAX. 6.86 (0.07) MAX. 6.86 (0.07) 0.98 ~ 4.90 (0.01 ~

0.05)

Thermister type Thermister type Thermister typekΩ 2.45 ± 0.14 2.45 ± 0.14 2.45 ± 0.14 kΩ 0,3222 0,3222 0,3222


17.7~21.6 (1.8~2.2) + 90˚ ± 2˚ 49.0 ~ 52.0 (5.0 ~ 5.3) 12.7 (1.3) + 90°

19.6 (2.0) + 90˚ 27.5~31.4 (2.8~3.2) + 60°~64° -

- - 24.5 (2.5) + 90°- - 32.4 ~ 36.3 (3.3 ~ 3.7)

11.8 ~ 13.7(1.2 ~ 1.4) 13.7 ~ 14.7 (1.4 ~ 1.5) 12.7 ~ 13.7 (1.3 ~ 1.4)18.6 ~ 22.6(1.9 ~ 2.3)

Engine

Type

Main valve opening press.Vacuum valve opening press.

Opening


Pull opening

Radiator cap

Thermostat


Bolts

Long bolts Short bolts


Main moving system

20°C (68°F)80°C (176°F)Resistance

Cylinder headM6Camshaft bearing

cap nuts or bolts M8

LD-9

17.7 ~ 21.6 (1.8 ~ 2.2)+ 90 ~ 95˚ + 100

~105˚

27.5 ~ 31.4 (2.8 ~ 3.2)+ 60°~ 65° + 60°~ 65° 49.0 (5.0) + 90° + 120°

- 22.6~26.5 (2.3 ~ 2.7)+ 60°~ 65° + 60° ~ 65° -

11.8 ~ 15.7 (1.2 ~ 1.6) 11.8 ~ 15.7 (1.2 ~ 1.6) 11.8 ~ 15.7 (1.2 ~ 1.6)9.8 ~ 11.8 (1.0 ~ 1.2) 9.8 ~ 11.8 (1.0 ~ 1.2) 9.8 ~ 11.8 (1.0 ~ 1.2)

34.3 ~ 44.1 (3.5 ~ 4.5) 34.3 ~ 44.1 (3.5 ~ 4.5) 34.3 ~ 44.1 (3.5 ~ 4.5)

Engine Electrical System12.V, 0.9 kW 12.V, 0.9 kW 12 V, 1.7 kW

V 11,5 11 11A 60 MAX 90 MAX 90 MAX

5.500 rpm, MIN 3,000 rpm, MIN 2,600 rpm, MINBattery voltage sensing Battery voltage sensing Battery voltage sensing

13.5 V, 90A 13.5 V, 90A 12 V, 120A1,000 ~ 18,000 rpm 1,000 ~ 18,000 rpm 1,000 ~ 18,000 rpmIC Regulator built-in

typeIC Regulator built-in

type Electronic built-in type14.55 ± 0.2 V 14.55 ± 0.2 V 14.55 ± 0.2 V

MF 45AH CMF 60AH MF 60AH

410 A 550 A 550 A

80 min 92 min 92 min

Rated voltage

Generator

Regulator setting

TypeRated voltage

Voltage regulator typeSpeed in use


Oil pan drain plug

SpeedAmperage

Battery

Oil filterOil pan bolts

Lubrication system

VoltageStarter

1.280 ± 0.01

Cylinder head boltLong bolts

Short bolts


Reserve capacity


LD-10


Ω 0.7 ± 15 % 0.58 ± 10 % -kΩ - 8.8 ± 15 % -

ZFR5F-11 BKR5ES-11 -mm (in.) -

Fuel SystemBosch Siemens Bosch

ℓ(lmp.qt)

Return type

Built in engine roomHigh Pressure

Fuel PumpMechanical

Plunger Pumping TypeDrive Belt

MPa(kgf/cm²

)160 (1,632)

KPa(kgf/cm²

)-

Engine


Fuel Pressure Regulator Regulated Fuel Pressure 338 ~ 348 (3.45 ~ 3.55)

Fuel Pump Type-



Fuel Filter Type High pressure type Installation location Built in Fuel Pump assembly

55 (48.39)Fuel Return System Type Returnless type

Engine Management ManufacturerFuel Tank Capacity

Ignition coil

Spark plugs

Primary Secondary

Unleaded (Gap) 1.0 ~ 1.1 (0.0394 ~ 0.0433)Unleaded (NGK)

LD-11


Clutch cover assembly 15~22 (1.5~2.2) 15~22 (1.5~2.2) 12~15 (1.2~1.5)Clutch pedal bracket mounting 25~35 (2.5~3.5) 25~35 (2.5~3.5) 25~35 (2.5~3.5)Clutch master cylinder mounting 9~14 (0.9~1.4) 19~20 (1.9~2.0) 19~20 (1.9~2.0)Clutch release cylinder 15~22 (1.5~2.2) 15~22 (1.5~2.2) 15~22 (1.5~2.2)Service standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)Manual TransaxleType M5CF1 M5BF2 M5CF3

3,615 3,615 3,6362,053 2,053 1,9621,370 1,393 1,1891,031 1,061 0,8440,837 0,837 0,6603,583 3,250 3,583

4,056 3.650 (EUR)3.842 (GEN) 3,941

MT oil capacity ℓ (lmp.qt) 1.90 (1.67) 2.15 (1.95) 2.0 (1.76)M/T oil quality SAE 75W/85, API GL-4

FGR

Gear ratio

Hydraulic typeSingle dry with diaphragmDiaphragm spring strap


145 (5.70)6~13 (0.24~0.51)

1st2nd3rd4th5thRev.

LD-12


Automatic TransaxleType A4CF1 A4CF2 A4CF2

2,846 2,919 2,9191,581 1,551 1,5511,000 1,000 1,0000,685 0,713 0,7132,176 2,480 2,480

4.381/4.041 3,849 3,532

ℓ (lmp.qt) 6.1 (5.37) 6.6 (5.81) 6.6 (5.81)

DriveshaftUTJ-II UTJ-II UTJ-II

BJ BJ BJUTJ-II UTJ-II UTJ-II

BJ BJ BJ

Diamond ATF SP III or SK ATF SP IIIATF capacity

Gear ratio

1st2nd3rd4th

ATF quality

Engine

Wheel bearing 1.8 (0.18 )

Hub end play mm (in.) 0.008 (0.0003) or lessStarting torque [N.m (kgf-m)]

Max. permissible angleInner 23˚ or moreOuter 46˚ or more

Joint typeM/T

InnerOuter

A/TInnerOuter

Rev.FGR

LD-13

Brake disc to hub 5 ~ 6 (0.5 ~ 0.6)

Trailing arm to rear axle carrier mounting nut 100 ~ 120 (11 ~ 12)Rear suspension arm to rear axle carrier mounting nut

130 ~150 (13 ~ 15)

Rear brake to rear axle carrier mounting bolt 65 ~ 75 (6.5 ~ 7.5)Rear strut to carrier nut 110 ~ 130 (11 ~ 13)

Wheel nut 90 ~ 110 (9 ~ 11)Rear hub bearing flange nut 200 ~ 260 (20 ~ 26)

Tie rod end to knuckle 16 ~ 34 (1.6 ~ 3.4)Brake caliper to knuckle 69 ~ 85 (6.9 ~ 8.5)

Knuckle to strut assembly nut 130 ~ 150 (13 ~ 15)Lower arm ball joint to knuckle nut 60 ~ 72 (6 ~ 7.2)

TJ: Tripod JointUTJ-ll: U Type-ll Tri-pod JointTightening torque [N.m (kgf-m)]Driveshaft lock nut 200 ~ 250 (20 ~ 25)

[NOTE]BJ: Birfield Joint

LD-14

General Specifications - Cerato

RearDual link

-55'±30'-

mm (in.) 4±2 (0.157±0.079)-

Rear strut assembly self-locking nut 40 ~ 55 (4.0 ~ 5.5)

Rear strut assembly to wheel housing panel 30 ~ 40 (3.0 ~ 4.0)Rear strut assembly to carrier 110 ~ 130 (11.0 ~ 13.0)

Front stabilizer link to strut assembly 44 ~ 62 (4.4 ~ 62)Front stabilizer bar bracket mounting bolts 30 ~ 45 (3.0 ~ 4.5)

Front lower arm to sub frame 130 ~ 150 (13.0 ~ 15.0)Front lower arm to knuckle 60 ~ 72 (6.0 ~ 7.2)



King-pin 12°10'±30'Tightening Torque [N.m(kgf-m)]

Wheel alignment

Camber 0°±30'Caster 2°36'±30'Toe-in 0±2 (0±0.079)

Tire sizeTire pressure

185/65 R15, 195/60 R16, 205/50 R162.1kgf/cm2, (30psi)


6.0J × 15" 6.0J × 15", 6.0J × 16"

Suspension type MacPherson strutShock absorber type Gas pressurized

Suspension SystemFront

LD-15

Type

ℓ (lmp.qt)mm (in.)

kPa(kgf/cm²

)

Pressure hose to power steering pump 55 ~ 65 (5.5 ~ 6.5)Steering gear box to sub frame 60 ~ 80 (6.0 ~ 8.0)

Tie rod end to knuckle 16 ~ 34 (1.6 ~ 3.4)Power steering pump to pump bracket 17 ~ 26 (1.7 ~ 2.6), GSL β 2.0: 35 ~ 50 (3.0 ~ 5.0)

Bolt connecting steering column to universal joint 15 ~ 20 (1.5 ~ 2.0)Bolt connecting universal joint to steering gear 15 ~ 20 (1.5 ~ 2.0)

Steering wheel lock nut 35 ~ 45 (3.5 ~ 4.5)Steering column mounting bolt & nut 13 ~ 18 (1.3 ~ 1.8)

Power steering pump relief pressure 8,336 ~ 8,826 (85 ~ 90)


Rack stroke 144 (5.67)

Steering angleInner 37°±0.5°Outer 31.8°

Power steering fluidQuality PSF-3Quantity 0.75 ~ 0.8 (0.66 ~ 0.70)

Trailing arm to rear carrier 100 ~ 120 (10.0 ~ 12.0)


Trailing arm to bracket 100 ~ 120 (10.0 ~ 12.0)Trailing arm bracket to body frame 40 ~ 50 (4.0 ~ 5.0)

Rear suspension arm mounting bolt 160 ~ 180 (16.0 ~ 18.0)Rear cross member mounting bolt 100 ~ 120 (10.0 ~ 12.0)

Rear stabilizer bar bracket mounting bolts 17 ~ 26 (1.7 ~ 2.6)Rear suspension arm tie rod nut 50 ~ 60 (5.0 ~ 6.0)

Rear stabilizer link to stabilizer bar 35 ~ 45 (3.5 ~ 4.5)

LD-16


ΩΩΩΩΩ

Engine

8 ~ 10 (0.8 ~ 1.0)SRSCM Mounting Bolt

5 ~ 7 (0.5 ~ 0.7)Side Airbag (SAB) 6 ~ 8 (0.6 ~ 0.8)Seat Belt Anchor Bolt (BPT) 40 ~ 55 (4.0 ~ 5.5)

Curtain Airbag (CAB)

Driver Airbag (DAB) 8 ~ 10 (0.8 ~ 1.0)19 ~ 27 (1.9 ~ 2.7)NutPassenger Airbag (PAB)

0.9 ~ 0.1Unbuckled 360 ~ 440


Seat Belt Pretensioner (BPT) 1.7 ~ 5.0

Seat Belt Buckle Switch (BS)

BuckledmA

8.7 ~ 16.5Unbuckled 3.0 ~ 8.2Buckled

kΩ

Side Airbag (SAB) 1.7 ~ 5.0Curtain Airbag (CAB) 1.7 ~ 5.0

Driver Airbag (DAB) 1.7 ~ 5.0Passenger Airbag (PAB) 1.7 ~ 5.0

RestraintsType DepoweredResistance

LD-17

Brake System

MPa(kgf/cm²

)MPa(kgf/cm²

)

mm (in.)

mm (in.) 275 (10.83)mm (in.) 275 (10.83)mm (in.) 26 (1.02)mm (in.) 26 (1.02)mm (in.)Pad thickness 11 (0.43)

Disc thicknessCBS 24 (0.945)ABS 26 (1.02)

Front brake (Disc)Type Floating type with ventilated disc

Disc O.D.CBS 257 (10.11)ABS 275 (10.83)

Effective diameter Tandem type with 7 + 8 in

Boosting ratioCBS 7.5 :1ABS/TCS 7.5 : 1/11.0 :1

Decompression ratio 0.27 : 1Brake boosterType Vacuum

Fluid level warning sensor ProvidedProportioning valve (CBS)


2.55 (26)

3.92 (40)

Rear drum

Rear disc

Brake fluidRecommended lubricant DOT 3 or DOT 4Quantity As required

Master cylinderType Tandem type

I.D.CBS

mm (in.)22.2 (0.874)

ABS,TCS 23.8 (0.937)

LD-18


mm (in.) 57.2 (2.25)mm (in.) 57.2 (2.25)


mm (in.)


[NOTEO.D: Outer DiameterI.D: Inner DiameterCBS: Conventional Brake SystemTCS: Traction Control System

Engine

Parking brakeType Mechanical brake acting on rear wheelsActuation Lever

Brake lining thickness 4.5 (0.18)Clearance adjustment Automatic

Rear brake (Drum)Type Leading trailingDrum I.D. 203.2 (8)

Cylinder type Single pistonCylinder I.D 33.96 (1.34)


Rear brake (Disc)Type Floating type with solid discDisc O.D. 258 (10.16)

Cylinder I.D.CBS 54 (2.12)ABS 57.2 (2.25)

Cylinder type Double piston

LD-19

Anti-lock Brake System (ABS) / Electronic Stability Program (ESP)


mm (in.)

mm (in.)

mm (in.)mm (in.) 24 (0.945)mm (in.) 24 (0.945)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

Rear disc run out 0.03 (0.0012)Rear disc parallelism 0.005 (0.0002)

Rear disc brake pad thickness 2.0 (0.079)Rear disc brake disc thickness 8 (0.315)

Rear drum brake lining thickness 1.0 (0.039)Rear drum brake drum I.D (maximum) 205.2 (8.08)

Front disc run out 0.03 (0.0012)Front disc parallelism 0.005 (0.0002)

Front disc thickness (minimum)

CBS 22 (0.866)ABS 24 (0.945)



8 ~ 9 clicks : Rear Disc type,8 clicks : Rear Drum type

Front disc brake pad thickness 2.0 (0.079)


Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)Stop lamp switch outer case to pedalstopper clearance

0.5 ~ 1.0 (0.02 ~ 0.04)

Brake pedal height 189 (7.24 )Brake pedal stroke 122 ~ 127 (4.8 ~ 5.0)

Manufacturer and NameHECU System 4 channel 4 sensor (MGH-25)

LD-20

General Specifications - CeratoGSL γ 1.6 GSL β 2.0 DSL U 1.6Engine

Brake tube nut (ABS & TCS) 13 ~ 17 (1.3 ~ 1.7)Bleeder screw (ABS & TCS) 7 ~ 13 (0.7 ~ 1.3)

HECU mounting bolt (ABS & TCS) 11 ~ 14 (1.1 ~ 1.4)HECU mounting bracket bolt (ABS & TCS) 17 ~ 26 (1.7 ~ 2.6)

Sensor mounting bolt (ABS & TCS)

Front 8 ~ 9 (0.8 ~ 0.9)Rear 8 ~ 9 (0.8 ~ 0.9)

Rear drum backing plate mounting bolt 50 ~ 60 (5 ~ 6)proportioning valve to master cylinder 35 ~ 55 (3.5 ~ 5.5)

Brake hub flange nut 200 ~ 260 (20 ~ 26)Wheel cylinder mounting bolt 5 ~ 11 (0.5 ~ 1.1)

Caliper assembly to knuckle 69 ~ 85 (6.9 ~ 8.5)Brake hose to front caliper 25 ~ 30 (2.5 ~ 3.0)

Brake pedal mounting bolt 25 ~ 35 (2.5 ~ 3.5)Stop lamp switch mounting nut 8 ~ 10 (0.8 ~ 1.0)

Caliper guide rod bolt 22 ~ 32 (2.2 ~ 3.2)Member assembly bracket mounting bolt 8 ~ 12 (0.8 ~ 1.2)

Bleeder screw 7 ~ 9 (0.7 ~ 0.9)Brake tube nut, brake hose 13 ~ 17 (1.3 ~ 1.7)

Tightening torque [N.m (kgf-m)]Master cylinder to booster mounting nut 8 ~ 12 (0.8 ~ 1.2)Brake booster mounting nut 13 ~ 16 (1.3 ~ 1.6)

LD-21




Rear window 3.5 (0.1378)

Seat beltsFront 3 point type Front passenger seat 3 point type Rear seat (Center) Fixed 2 point type

Trunk lid Type Torsion bar type

Glass thickness

Windshield 5.0 (0.1969)Front door 3.2 (0.1260)Rear door glass 3.2 (0.1260)

Rear doorConstruction Front hinged, full door constructionRegulator system X-ARM type


Front doorConstruction Front hinged, full door constructionRegulator system X-ARM type

LD-22

General Specifications - CeratoGSL γ 1.6 GSL β 2.0 DSL U 1.6Engine

Sunroof

Mounting nuts 9~13 (0.9~1.3)Mounting bolts 9~13 (0.9~1.3)Glass height adjustmentscrews

2~4 (0.2~0.4)

Trunk lid

Hinge bolts (Body side) 7~9 (0.7~0.9)Hinge bolts (Trunk lidside)

7~9 (0.7~0.9)

Latch bolts 7~11 (0.7~1.1)Striker bolts 7~11 (0.7~1.1)

Latch screws 7~11 (0.7~1.1)Striker screws 7~11 (0.7~1.1)

Outside handle screw 7~11 (0.7~1.1)Inside handle screw 4 ~ 8 (0.4~0.8)

Door channel bracket 8~12 (0.8~1.2)Outside handle bolts 7~11 (0.7~1.1)

Glass mounting bolts 8~12 (0.8~1.2)Door glass grip bolts 8~12 (0.8~1.2)

8~12 (0.8~1.2)Door module nuts 8~12 (0.8~1.2)Door speaker bolts 8~12 (0.8~1.2)


Hinge bolts (Body side) 35~42 (3.5~4.2)Hinge bolts (Door side) 13~26 (1.3~2.6)Checker bolts (Body 17~22 (1.7~2.2)Checker bolts (Door 7~11 (0.7~1.1)Door module bolts

LD-23


AM/FM/CD AM/FM/CD/MP3 AM/FM/6CDC/MP3

522 ~ 1620 KHz/9 KHz (Europe)LW 153 ~ 279 KHz/1 KHz (Europe)

Tuning type PLL synthesized type


FM 87.5~108 MHz / 100KHz (General)AM 531 ~ 1602 KHz/9 KHz (General)FM 87.5 ~ 108.0 MHz/50 KHz (Europe)MW

Speaker impedance 4Ω x 4Antenna 80PF 75Ω

TypePower supply DC 14.4VRated output Max 43W x 4

Rear seat Front seat mounting 17~26 (1.7~2.6)

Seat beltAnchor bolt 40~55 (4.0~5.5)Rear seat belt buckle 40~55 (4.0~5.5)Retractor mounting bolt 40~55 (4.0~5.5)

Front seatFront seat mounting 35~55 (3.5~5.5)Rear seat mounting 35~55 (3.5~5.5)

Front bumper Bumper rail mounting 22~27 (2.2~2.7)Rear bumper Mounting bolts 35~55 (3.5~5.5)

Outside rearview mirror Mounting nuts 7~11 (0.7~1.1)

HoodHinge bolts (Body side) 22~27 (2.2~2.7)Hinge bolts (Hood side) 22~27 (2.2~2.7)

LD-24



Lighting systemWWWWWWWWWWWWWGlove box lamp 5

Room lamp 10Overhead console lamp 10 x 2

License plate lamp 5Side repeater 5

Rear turn signal lamp 21Rear fog lamp - Europe 21

Rear stop/tail lamp (Outside) 21/5Back up lamp 16

Front turn signal lamp 21Front fog lamp 27

Transmission frequency 433.92 MHz


Life of battery 2 years or more (at 10 times per day)

Button4 Door : 4 (Door lock, Door unlock, Trunk open, Panic)

5 Door : 3 (Door lock, Door unlock, Panic)

Keyless entry transmitter Power source Lithium 3V battery (1EA)Transmissible distance 30m or more


Engine

LD-25

Other system


Blower unit

Air filter Type

Blower Type

Particle filter

Fresh and recirculation Operating method ActuatorSiroco

Speed step Auto + 7speed (Autometic) , 4 speed (Manual)Speed control Power mosfet (Autometic)


RefrigerantType R - 134aCapacity [oz.(g)] 17.64 ± 0.88 (500 ± 25)

Condeser Heat rejection 12,000 ± 10% Kcal/hr

APT(A/C pressuretransducer)

The method to measure the pressure

Voltage = 0.00878835 * pressure + 0.5

Compressor

Type 6SBU16Oil type & Capacity ND-OIL8(PAG) 120 ± 10ccPulley type 5PK - typeDisplacement 160 cc/rev

ImmobilizerType SMARTRA systemManufacturer Bosch

LD-26




EvaporatorTemperature control type Evaporator temperture sensor

ON : 7.0 ± 0.5 (44.6 ± 32.9)OFF : 5.0 ± 0.5 (41.0 ± 32.9)


Heater

Type Pin & Tube typeHeating capacity 5,000 ± 5% Kcal/hr

Actuator

ActuatorTemperature operatingmethod

Engine

LD-27

ED-1

General specifications - cee'dPetrol Υ 1.4 Petrol Υ 1.6 Petrol β 2.0 Diesel U 1.6 Diesel D 2.0

In-line, SOHC

mm (in.) 77 (3.0315) x 74.49 (2.952)

77 (3.0315) x 85.44 (3.3638)

82 (3.228) x 93.5 (3.681)

77.2 (3.0394) x 84.5 (3.3268) 83 (3.27) x 92 (3.62)

cc 1.396 1.591 1.925 1.582 1.99110.1 : 1

- -

rpmrpmrpmrpm

ℓ (lmp.qt) 4.1 (3.60) 5.7 (5.02) 7.4 (6.51)

ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt) 4.0 (3.52) 5.3 (4.66) 6.7 (5.89)

kPa(kg/cm²) - - 245 (2.5) - -

12°/BTDC 38° 10°/BTDC 40° 11° 17°5' ±4° 7° (BTDC)49°/BBDC 1° 63°/ABDC 13° 59° 14°6' ± 4° 35° (ABDC)

40° 40° 42° 23°25' ± 4° 52° (BBDC)3° 3° 6° 20° ± 4° 6° (ATDC)

850 ± 100

4

10.5 : 1 17.3 : 11 - 3 - 4 - 2

Engine oil3.7 (3.26)

3.3 (2.90)

5.5 (4.84)

EngineType In-line, DOHC

Above SJ or SL

BTDC 5° ± 10°

660 ± 100 830 ± 100

Number of cylinders

Bore x Stroke

Oil panOil filter 0.4 (0.35)

Drain and refillOil quality

Oil pressure (Idle)

Total displacementCompression ratio

A/C ON

Neutral,N,P-D-range

Oil quantity

Total

Firing orderIgnition Timing

Idle Speed

A/C OFF

Neutral,N,P-D-range

Intake valve Opens (ATDC)Closes (ABDC)

Exhaust valve Opens (BBDC)Closes (ATDC)

Valve timing

ED-2

mm (in.) Max. 0.03 (0.0012)

0.05(0.0020) for all

0.03(0.0012) for each cylinder

0.03(0.0012) for width

0.09(0.0035) for length

0.012(0.00047)/51×51mm

mm (in.) - -

mm (in.) - -

mm (in.) 42.85 (1.687) 43.85 (1.726) 44.618 (1.7566)LH:

35.452~35.652(1.3957~1.4036)

34.697 (1.366)

mm (in.) 42.85 (1.687) 42.85 (1.687) 44.518 (1.7527)LH:

35.700~35.737(1.3991~1.4070)

34.570 (1.361)

mm (in.) 28 (1.1023) 20.944~20.960(0.8246~0.8252) 28 (1.10)

mm (in.)

mm (in.) 0.05 ~ 0.15(0.002 ~ 0.06)

Max. 0.15 (0.0059)

0.025(0.0010) for width

0.160(0.0063) for length

0.020 ~ 0.057 (0.0008 ~ 0.0022)

Less than 0.05 (0.0020)

0.03(0.0012) for width

0.09(0.0035) for length

22.964 ~ 22.980 (0.9041 ~ 0.9047)



Intake

Exhaust

Cam heightIntake

Exhaust



End play 0.10 ~ 0.20 (0.0039 ~ 0.0079)

Camshaft

Cylinder head

ED-3

Petrol Υ 1.4 Petrol Υ 1.6 Petrol β 2.0 Diesel U 1.6 Diesel D 2.0

mm (in.) 114.34 (4.5016) 93.0 (3.6614) 95.7 (3.77)

mm (in.) 116.8 (4.598) 93.7 (3.6890) 95.4 (3.76)

mm (in.) 5.965 ~ 5.98(0.2348 ~ 0.2354)

5.455 ~ 5.470(0.2148~0.2154) 5.953 (0.234)

mm (in.) 5.950 ~ 5.965(0.2343 ~ 0.2348)

5.435~5.450(0.2140~0.2146) 5.925 (0.233)

- 45.5° ~ 45.75° 45.5°

mm (in.) 1.6 ± 0.15 (0.0630 ± 0.0059) 1.1 (0.0433) 1.6 (0.063)

mm (in.) 1.8 ± 0.15 (0.0709 ± 0.0059) 1.2 (0.0472) 1.3 (0.0512)

mm (in.) 0.020 ~ 0.050(0.0008 ~ 0.9919)

0.030 ~ 0.057(0.0012 ~ 0.0022)

0.022 ~ 0.067(0.00086 ~ 0.00263)

mm (in.) 0.035 ~ 0.065(0.0014 ~ 0.0026)

0.050 ~ 0.077(0.0020 ~ 0.0030)

0.050 ~ 0.095(0.0020 ~ 0.0037)

mm (in.) - - Outter: 45.8 ~ 46.2(1.8031 ~ 1.8189) 36.5mm (1.437in.)

mm (in.) - - Outter: 52.8 ~ 53.2(2.0787 ~ 2.0945) 36.5mm (1.437in.)

mm (in.) -

mm (in.) -

mm (in.) - - 1.1 ~ 1.5 (0.043 ~ 0.059)

0.8 ~ 1.4(0.0315 ~ 0.0551)

mm (in.) - - 1.3 ~ 1.7 (0.051 ~ 0.066)

1.2 ~ 1.8(0.0472 ~ 0.0709)

- - - 45° ~ 45°30' 44° ~ 44.5°

Engine

Exhaust

Stem outer diameterIntake

Exhaust

Exhaust

1.26 (0.0496)

5.458 ~ 5.470 (0.2149 ~ 0.2154)

1.21 ~ 1.61(0.0477 ~ 0.6634)

36.5 (1.437)

Inner: 5.500 ~ 5.512(0.2165~0.2170)

0.020 ~ 0.047 (0.0008 ~ 0.0019)

5.465 ~ 5.480 (0.2152 ~ 0.2157)

93.15 (3.6673)92.6 (3.6457)

0.030 ~ 0.054 (0.0012 ~ 0.0021)

1.1 (0.0433)

45.25° ~ 45.75°

Valve length Intake

40.3 ~ 40.7 (1.5866 ~ 1.6024) 31.3 ~ 31.7(1.2323 ~ 1.2480)40.3 ~ 40.7 (1.5866 ~ 1.6024)

Seat angle

Width of seat contactIntake

Exhaust

Inner. diameterIntake

Exhaust

Length IntakeExhaust

General specifications - cee'dValve

Valve guide

Valve seat

Face angle


Intake

Exhaust


Intake

ED-4

mm (in.) 48.86 (1.9236) 44.9 (1.7677) 38.8 (1.527)

- - 18.8k±0.9kg/39.0(41.4±2.0lb/1.5354)

17.5±0.9kg/32.0(38.6±2.0 lb/1.2598)

- - 41.0±1.5kg/30.5(90.4±3.3lb/1.2008)

31.0±1.6kg/23.5(68.3±3.5 lb/0.9252)

1.5° or less Less than 1.5° -

MLA outer Intake mm (in.) - -

Exhaust mm (in.) - -Cylinder head Intake mm (in.) - -

Exhaust mm (in.) - -MLA to tappet Intake mm (in.) - -

Exhaust mm (in.) - -

Valve clearancemm (in.) - 0.20mm (0.0079in)

mm (in.) - 0.28mm (0.0110in)

mm (in.) 82.00 ~ 82.03 (3.2283 ~ 3.2295)

77.200 ~ 77.230(3.0394 ~ 3.0405)

83 + 0.03 (3.27 + 0.0012)

mm (in.) - Less than 0.05 (0.0020)

0.042 (0.00165) for width

0.096 (0.00378) for length

mm (in.) 81.97 ~ 82.00 (3.2271 ~ 3.2283)

77.130 ~ 77.160(3.0366 ~ 3.0378)

82.92 ~ 82.95(3.26 ~ 3.27)

mm (in.) - 0.060 ~ 0.080(0.0024 ~ 0.0031)

0.07 ~ 0.09(0.0027 ~ 0.0036)

Piston

0.020 ~ 0.061 (0.0008 ~ 0.0024)0.020 ~ 0.061 (0.0008 ~ 0.0024)



76.97 ~ 77.00 (3.0303 ~ 3.0315)

0.020 ~ 0.040 (0.0008 ~ 0.0016)

44.0 (1.7323)

MLALess than 1.5°Out of squareness

34.964 ~ 34.980 (1.3765 ~ 1.3772)34.964 ~ 34.980 (1.3765 ~ 1.3772)35.000 ~ 35.025 (1.3779 ~ 1.3789)35.000 ~ 35.025 (1.3779 ~ 1.3789)

Load

Valve springFree length

mm (in.) 21.25kg/32.0(47.2lb/1.26)

IntakeExhaust

Flatness of gasket surface Less than 0.05 (0.0020)

Cylinder block

Cylinder bore 77.00 ~ 77.03 (3.0315 ~ 3.0327)

- -

ED-5

Petrol Υ 1.4 Petrol Υ 1.6 Petrol β 2.0 Diesel U 1.6 Diesel D 2.0

mm (in.) - 1.83 ~ 1.85(0.0720 ~ 0.0728)

1.915 ~ 1.945(0.075 ~ 0.076)

mm (in.) - 1.82 ~ 1.84(0.0717 ~ 0.0724)

2.06 ~ 2.08(0.08 ~ 0.082)

mm (in.) -

mm (in.) 0.09 ~ 0.13(0.0035 ~ 0.0051)

0.064 ~ 0.114(0.00252 ~ 0.00449)

mm (in.) 0.08 ~ 0.12(0.0031 ~ 0.0047)

0.065 ~ 0.11(0.00256~0.00433)

mm (in.) - - -

mm (in.)

mm (in.) 0.35 ~ 0.50(0.0138 ~ 0.0197)

0.40 ~ 0.50(0.016 ~ 0.024)

mm (in.) - - - 0.20 ~ 0.40(0.0079 ~ 0.0157)

0.2 ~ 0.45(0.0079 ~ 0.0177)

mm (in.) 27.995 ~ 28.000(1.1022 ~ 1.1024) -

mm (in.) 28.004 ~ 28.010(1.1025 ~ 1.1028) -

mm (in.) 0.004 ~ 0.015(0.0002 ~ 0.0006) -

mm (in.) 28.022 ~ 28.034(1.1032 ~ 1.1037) -

mm (in.) - - - 0.022 ~ 0.039 (0.0009 ~ 0.0015) -

0.04 ~ 0.08 (0.0015 ~ 0.0031)

0.03 ~ 0.07 (0.0012 ~ 0.0027)

0.03 ~ 0.07(0.00118 ~ 0.00275)

Side clearance

No. 1 ring groove

No. 2 ring groove

Oil ring groove

0.20 ~ 0.35 (0.0079 ~ 0.0138)

0.37 ~ 0.52 (0.0146 ~ 0.0205)

Piston pin

Connecting rod

General specifications - cee'dEngine

2.01 ~ 2.03 (0.0791 ~ 0.0799) 3.02 ~ 3.04(0.1189 ~ 0.1197)

Ring groove width

No. 1 ring groove

Oil ring groove

1.22 ~ 1.24 (0.0480 ~ 0.0488)

Piston OS -

Piston ring

1.22 ~ 1.24 (0.0480 ~ 0.0488)No. 2 ring groove

20.001 ~ 20.006 (0.7874 ~ 0.7876)

20.016 ~ 20.021 (0.7880 ~ 0.7882)

No. 2 ring groove

Oil ring groove



End gap

No. 1 ring groove



0.010 ~ 0.020 (0.0004 ~ 0.0008)

19.974 ~ 19.985 (0.7864 ~ 0.7868)


ED-6

mm (in.) - 49.000 ~ 49.018(1.9291 ~ 1.9298)

0.100 ~ 0.250mm (0.0039 ~ 0.010in)

mm (in.) 0.024 ~ 0.042 (0.0009 ~ 0.0017)

0.025 ~ 0.043(0.0010 ~ 0.0017)

0.024 ~ 0.042(0.0009 ~ 0.0016)

mm (in.)

mm (in.) - - 56.942 ~ 56.962 (2.2418 ~ 2.2426)

53.972 ~ 53.990(2.1249 ~ 2.1256)

60.002 ~ 06.020(2.362 ~ 2.363)

mm (in.) - - 44.946 ~ 44.966 (1.7695 ~ 1.7703)

45.997 ~ 46.015(1.8190 ~ 1.8116)

50.008 ~ 50.026(1.9688 ~ 1.9695)

mm (in.) -

mm (in.) 0.06 ~ 0.260 (0.0023 ~ 0.010)

0.08 ~ 0.28(0.0031 ~ 0.110)

0.09 ~ 0.32(0.0035 ~ 0.0126)

kPa(kg/cm²) - - - 490±49.0

(5±0.5, 71±7.1psi)570±50.0

(82.67±7.25psi)

Water-cooled, pressurized. Forced

circulation withℓ

(lmp.qt)6.2 ~ 6.3 (5.46 ~ 5.54) 6.3 (5.54) 7.3L (6.42)

°C (°F) 82 (177) 85 ± 1.5 (185.0 ± 2.7)

83.5 ~ 86.5(182 ~ 188)

°C (°F) 95 (201)

mm (in.)

kPa(kg/cm²)

93.16 ~ 122.58(0.95 ~ 1.25)

107.9±14.7(1.1±0.15,

15.64±2.13psi)

kPa(kg/cm²) MAX. 6.86 (0.07) -6.86 (-0.07)

Oil pump

93.16 ~ 122.58(0.95 ~ 1.25)

Connecting rod big end inner diameter 45.000 ~ 45.018 (1.7717 ~ 1.7724)


End play 0.1 ~ 0.25 (0.0039 ~ 0.0098)

0.032 ~ 0.052 (0.0013 ~ 0.0020)

Crankshaft



Radiator cap


MAX. 6.86 (0.07)

5.5 ~ 5.8 (4.84~5.10)

Cooling system


10 (0.3937)


End play

0.021 ~ 0.042 (0.0008 ~ 0.0017) 0.024 ~ 0.042(0.0009 ~ 00017)

0.05 ~ 0.25 (0.0020 ~ 0.0098)

Cooling method

Coolant quantity

Forced circulation with cooling fan Forced circulation with cooling fan

Thermostat

Opening temperaturePull opening Full lift

95 (203) 100 (212)

82 ± 1.5 (179.6 ± 2.7)

ED-7


Heat-sensitive thermistor type

kΩ 2.31 ~ 2.59

kΩTightening torque [N.m(kgf-m)]

12.7 + (87~93°) 24.5 + 90°(22.6~26.5) + (90~94°) 27.5~31.4) + 120°

32.4 ~ 36.3 26.5 ~ 29.4

19.6 ~ 26.5(2.0 ~ 2.7)

22.6 ~ 24.5(2.3 ~ 2.5)

39.2 ~ 44.1 (4.0 ~ 4.5)


VA

rpm 1,000 ~ 18,000 1,00 ~ 12,000

49.0 + 120° + 90°

Alternator voltage sensing2,600 rpm, MIN

90A, MAX

12 V, 1.7 kW11

14.2 ~ 14.8V 14.1 ± 0.3 V

17.7~21.6+90°±2°(1.8~2.2+90°±2°)

19.6 + 90° (2.0 + 90°)


18.62 ~ 23.52 (1.9 ~ 2.4)

(47.1~51.0) + (88~92°)

+ (118~122°)

12 V, 1.2 kW

34.3 ~ 44.1 (3.5 ~ 4.5)

12V, 120A1,000 ~ 18,000

IC regulator built-in type IC regulator built-in type

Thermister type

2.45±0.14

Max. 95

9.8 ~ 11.8 (1.0 ~ 1.2) 9.8 ~ 11.8 (1.0 ~ 1.2)34.3 ~ 44.1 (3.5 ~ 4.5)

0,3222

Thermister type

2.45±0.140,3222

Oil filter cap

Engine

Type

Crankshaft main bearing cap Inner bolt (M11)

Main moving systemConnecting rod cap nuts or bolts

Resistance 20°C (68°F)80°C (176°F)

Speed 2,500 rpm

Cylinder headCamshaft bearing cap nuts or bolts

Cylinder head boltLong boltsShort bolts

9.80 ~ 11.76 (1.0 ~ 1.2)

39.2 (4.0) + 120˚ + 90˚

Lubrication system

Voltage regulator typeRegulator setting voltage

Oil pan drain plug

11.8 ~ 15.7 (1.2 ~ 1.6)

Lower oil pan bolt

Starter

Rated voltage


VoltageAmperage

13.5V, 90A

Generator

TypeRated voltageSpeed in use

ED-8

Ω 0.58 ± 10% - -

kΩ 8.8 ± 15% - -

- -

mm(in.) - -

CMF 80AH

1.280 ± 0.01

130 min 110 min

600 A

54 - 26 GL

Battery

TypeCold cranking amparage at -18°C (-0.4°F)Reserve capacitySpecific gravity at 25°C (77°F)

630 A

Ignition coil


0.7 ± 15%

-

Spark plugs Unleaded (NGK)Unleaded (Gap)

ZFR5F-111.0 ~ 1.1 (0.0394 ~ 0.0433)

ED-9


Fuel SystemBosch Bosch Siemens Bosch Bosch

ℓ(lmp.qt)

Chain CamshaftMPa

(kgf/cm²) kPa

(kgf/cm²)

M5CF2 M5CF3 M6GF23,786 3,615 3,308 3,636 3,6152,053 1,950 1,962 1,962 1,794

1,257 1,189 1,5420,976 0,844 1,1760,778 0,660 0,921

- - - - 0,7323,583 3,583 3,416

4,412 4,294 4,188 3,941 4.063 / 2.955

ℓ (lmp qt)

2.0 (1.76) 2.0 (1.76) 1.9 (1.67)

Manual TransaxleBefore Dec. 15, 2008

M5CF-1

1,371,0310,837

6th

FGR (Final Gear Ratio)

2nd

SAE 75W/85, API GL-4, TGO-7 (MS517-14),

ZIC G-F TOP 75W/85, HD GEAR OIL XLS 75W/85

Reverse 3,583

SAE 75W/85, API GL-4, TGO-7 (MS517-14), ZIC G-F TOP 75W/85, HD GEAR OIL XLS 75W/85

1.9 (1.67)

After Dec. 15, 2008

M/T oil quality

M/T oil capacity

Gear ratio

Engine

Engine Management Manufacturer

in-tank type

TypeInstallation location

High pressure type

Electrical-

55 (12.1) 55 (12.1)Returnless Return type

Fuel Tank CapacityFuel Return System Type

High pressure typeBuilt in Fuel pump assy Built in Engine room

Fuel Pump Type

Driven by Electric motorPlunger pumping type

Fuel Filter

Mechanical

-

Fuel Pressure Regulator Regulated Fuel Pressure

338 ~ 348 (3.45 ~ 3.55) 1,600 bar (160 Mpa / 23,206 psi)


3rd4th5th

1stType

ED-10

- - -3,769 3,615 - - -2,045 1,962 - - -

- - -- - -- - -

- - - - -- - -

4,400 4,267 - - -

- - -

ℓ(lmp qt) - - -

Automatic TransaxleType - - A4CF2 A4CF2 -

- - 2,919 2,919 -- - 1,551 1,551 -- - 1,000 1,000 -- - 0,713 0,713 -- - 2,480 2,480 -- - 3,849 3,849 -- - -

ℓ(lmp.qt) - - 6.6 (5.81) 6.6 (5.81) -

DriveshaftAAR2300iAC2300i

AAR2300iAC2300i

Center bearingType Radial ball bearing

DimensionInner 30 mm (1.18 in.)

Outer 62 mm (2.44 in.)

Type

M/T oil quality

1st

-21˚ 21˚45˚ 45˚

AC2000i

M/T oil capacity

3,545

SAE 75W/85, API GL-4, TGO-7 (MS517-14)

1.92 (1.67)

ReverseFGR (Final Gear Ratio)

3rd

AAR3300iAC2000i AC3300i

AAR2000i -

AAR2000i

Outer

OuterJoint type

M/T

A/T

Inner

Inner

Inner

ATF qualityATF capacity

M5CF1-1

OuterMax. Permissible

1st2nd3rd4th

Rev.FGR

Driveshaft

Genuine Diamond ATF SP-III, SK ATF SP-II

Gear ratio 4th5th6th

Gear ratio

1,0360,839

1,372nd

ED-11


kgf/(psi)

185/65 R15, 195/65 R15, 205/55 R16, 225/45 R17

2.4 (34), 2.6 (37)

45 mm (1.77 in.)87 mm (3.43 in.)

28 (0.18 )

Front Rear

Driveshaft lock nutKnuckle to strut assy nutTie rod end castle knuckleBrake caliper to knuckle

Double row angular contact ball bearing

Front wheel bearing

Front wheel bearing

Type

DimensionInnerOuter

Engine

Starting torque [N.m (kgf-m)]

34.3~53.9(3.5~5.5)137.3~156.9(14.0~16.0)

Tightening torque [N.m (kgf-m)]196.1 ~ 274.6 (20.0 ~ 28.0) 196.1 ~ 274.6 (20.0 ~ 28.0)

88.3 ~ 107.9 (9.0 ~ 11.0) 88.3 ~ 107.9 (9.0 ~ 11.0)58.8~68.6(6.0~7.0)

78.5~98.1(8.0~10.0)

Trailing arm to carrier assembly bolts

44.1~53.9(4.5~5.5)

34.3 ~ 53.9 (3.5 ~ 5.5) 34.3 ~ 53.9 (3.5 ~ 5.5)49.0~58.8(5.0~6.0)

Assist arm to carrier assembly bolts

Rear shock absorber assembly to carrier assembly Trailing arm to rear axle carrier mounting nut

Wheel nutCarrier assembly to rear hub assembly bolts

Gas pressurized5.5J × 15, 6.0J × 16, 7.0J × 17

McPherson strut

Shock absorber typeWheel size

Suspension type

Suspension System

Multi-link coil spring

Rear caliper assembly to carrier assembly bolts

Tire size

Tire pressure

[NOTE]

137.3~156.9(14.0~16.0)23.5 ~ 33.3 (2.4 ~ 3.4) 23.5 ~ 33.3 (2.4 ~ 3.4)

Inner: On transaxle side UFi : Under Cut Free improved (GKN) Outer : On tire side AARi : Angular Adjusted Roller improved (GKN)

ED-12

mm (in.)

Tightening Torque [N.m(kgf-m)]Hub nuts

-1˚9' ± 30'-0.6˚ ± 30'

0 ± 2 (0 ± 0.079)13˚39' ± 30'

-2.2 ± 2 (0.087 ± 0.079)

-

Front strut assy to sheel housing panelFront strut assy to knuckleFront strut assy self-locking nutFront lower arm to sub frame

Rear stabiliser link to stabiliser barRear stabiliser bar bracket mounting bolts

Caster

Front stabilizser bar bracket mounting bolts

Toe-inWheel alignment

Camber

Front lower arm to knuckle

King-pin

Rear strut assy to wheel housing panelRear strub assy to carrierRear strut assy self-locking nut

Front stabilizer lik to strut assy

140 ~ 160 (14.0 ~ 16.0)

4˚26' ± 30'

100 ~ 120 (10.0 ~ 12.0)

90 ~ 110 (9.0 ~ 11.0)45 ~ 60 (4.5 ~ 6.0)

140 ~ 160 (14.0 ~ 16.0)50 ~ 70 (5.0 ~ 7.0)

100 ~ 120 (10.0 ~ 12.0)100 ~ 120 (10.0 ~ 12.0)

--

Rear suspension arm tie rod nutRear suspension arm mounting bolt

140 ~ 160 (14.0 ~ 16.0)20 ~ 25 (2.0 ~ 2.5)

-45 ~ 55 (4.5 ~ 5.5)

Trailing arm bracket to body frameTrailing arm to rear carrier

--

140 ~ 160 (14.0 ~ 16.0)35 ~ 55 (3.5 ~ 5.5)

Rear cross member mounting boltTrailing arm to bracket

50 ~ 65 (5.0 ~ 6.5)

ED-13


Type

mm (in.)

kPa(kgf/cm²)

50 ~ 65 (5.0 ~ 6.5)45 ~ 55 (4.5 ~ 5.5)

100 ~ 120 (10.0 ~ 12.0)

Electric Power Steering (Column assist type)

140mm (5.51in.)

EngineFront stabilizer link to stabilizer barFront stabilizer bar bracket mounting boltsRear shock absorber to wheel housing panelRear shock absorber to carrierRear shock absorber self-locking nut

140 ~ 160 (14.0 ~ 16.0)20 ~ 25 (2.0 ~ 2.5)

Rear upper arm to carrierRear upper arm to cross member

80 ~ 90 (8.0 ~ 9.0)100 ~ 120 (10.0 ~ 12.0)

Rear lower arm to carrierRear lower arm to cross member

140 ~ 160 (14.0 ~ 16.0)100 ~ 120 (10.0 ~ 12.0)

Assist arm to carrierAssist arm to cross member

140 ~ 160 (14.0 ~ 16.0)100 ~ 120 (10.0 ~ 12.0)

Trailing arm to carrierTrailing arm to body

140 ~ 160 (14.0 ~ 16.0)140 ~ 160 (14.0 ~ 16.0)

Rear stabilizer link to carrierRear stabilizer link to stabilizer bar

35 ~ 45 (3.5 ~ 4.5)35 ~ 45 (3.5 ~ 4.5)

Rear stabilizer bar bracket mounting boltsRear cross member mounting bolts

45 ~ 55 (4.5 ~ 5.5)140 ~ 160 (14.0 ~ 16.0)

Power steering fluidRack stroke

Steering System

Steering angle InnerOuter

36.9°±1°30'30.27°

PSF-4

Power steering pump relief pressure


9807 ~ 10199 (100 ~ 104)

Steering wheel lock nutSteering column mounting bolt & nut

40 ~ 50 (4.0 ~ 5.0)13 ~ 18 (1.3 ~ 1.8)

Bolt connecting steering column to universal jointBolt connecting universal joint to steering gear

15 ~ 20 (1.5 ~ 2.0)30 ~ 35 (3.0 ~ 3.5)

ED-14

Tie rod end to knuckleSteering gear box to sub frame

24 ~ 34 (2.4 ~ 3.4)60 ~ 80 (6.0 ~ 8.0)

Pressure hose to power steering pumpPower steering pump mounting bolts

55 ~ 65 (5.5 ~ 6.5)35 ~ 55 (3.5 ~ 5.5)

ED-15


Brake System

mm (in.)mm (in.)


mm (in.)


mm (in.)

mm (in.)

Engine

Brake fluid Recommended lubricant DOT 3 or DOT 4

Quantity As required


I.D. 25.4 (1.0)

Piston stroke 30 ~ 32 (1.18 ~ 1.26)

Fluid level warning sensor Provided

Brake boosterType vacuum

Boosting ratio 9 : 1

Front brake(Disc)Type Floating type with ventilated disc

Disc O.D. 303 (11.93)

Disc thickness 28 (1.10)

Pad thickness 11 (0.43)

Cylinder type Single piston

Cylinder I.D. 60 (2.36)

Rear brake(Disc)Type Floating type with solid disc

Disc O.D. 284 (11.18)



Cylinder type Single piston

Cylinder I.D 34 (1.34)

Parking brakeType Mechanical brake acting on rear wheels

Actuation Foot Type

Drum I.D. 190 (7.48)

ED-16

O.D=Outer DiameterI.D=Inner DiameterAnti-lock Brake System(ABS)/ Electronic Stability Program(ESP)

teeth

Service standardmm (in.)mm (in.)mm (in.)mm (in.)

mm (in.)

Manufacturer and NameAcitve wheel speed sensor Tone wheel 47

Brake pedal height 193.5 (7.62 )

Brake pedal full stroke 126.7± 3 (4.99 ± 0.12)

Adjust Brake pedal full stroke 63.6 ± 2 (2.50 ± 0.08)

Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)

Stop lamp switch outer case to pedal stopper clearance

1.2 ~ 1.8 (0.05 ~ 0.07)

ED-17


mm (in.)

mm (in.)


EngineBooster push rod to master cylinder piston clearance

0 (at 500 mmHg)

Parking brake pedal stroke when stroke assembly is pushed with 196N (20kgf, 44lb force)

88 ~ 98 (3.46 ~ 3.86)


Front disc thickness 28 (1.10)

Rear disc brake pad thickness 10 (0.39)

Rear disc brake disc thickness 10 (0.39)

Rear parking brake liner thickness 4.3 (0.17)

Tightening torque [N.m (kgf-m)]Master cylinder to booster mounting nut 8 ~ 12 (0.8 ~ 1.2)

Brake booster mounting nut 13 ~ 16 (1.3 ~ 1.6)

Bleeder screw 7 ~ 13 (0.7 ~ 1.3)

Brake tube nut, brake hose 13 ~ 17 (1.3 ~ 1.7)

Caliper assembly to knuckle 80 ~ 100 (8 ~ 10)

Brake hose to front caliper 25 ~ 30 (2.5 ~ 3.0)

Caliper guide rod bolt 22 ~ 32 (2.2 ~ 3.2)

Stop lamp switch mounting nut 8 ~ 10 (0.8 ~ 1.0)

Brake pedal assembly bracket mounting nut 13 ~ 16 (1.3 ~ 1.6)

Brake pedal mounting nut 25 ~ 35 (2.5 ~ 3.5)

Active wheel speed sensor mounting bolt on the brake plate

8 ~ 10 (0.8 ~ 1.0)

HECU mounting bolt 8 ~ 10 (0.8 ~ 1.0)

HECU mounting bracket bolt 17 ~ 26 (1.7 ~ 2.6)

HECU port 12.2 ~ 16.3 (1.22 ~ 1.63)

Yaw rate ＆ lateral acceleration sensor bolt 8 ~ 10 (0.8 ~ 1.0)

Master cylinder pressure sensor 26 ~ 30 (2.6 ~ 3.0)

ED-18

Body(Interior & Exterior)


Hood Type Rear hinged, front opening type (gas lifter type)

Front doorConstruction Front hinged, full door construction

Regulator system X-ARM type

Locking system Pin-fork system

Rear doorConstruction Front hinged, full door construction

Regulator system X-ARM type


Trunk lid Type Inner hinged, gas lifter type

Glass thickness

Windshield 5 (0.1969)

Front door 5 (0.1969)

Rear door glass 5 (0.1969)

Rear door fixed 4 (0.1575)

Rear window 3.5 (0.1378)

Seat belts Front 3 point type with Emergency Locking Retractor (E.L.R)

ED-19

General specifications - cee'dPetrol Υ 1.4 Petrol Υ 1.6 Petrol β 2.0 Diesel U 1.6 Diesel D 2.0Engine


Front fender

Mounting bolts 7~9 (0.7~0.9)

Hinge bolts(Body side) 22~27 (2.2~2.7)

Hinge nuts(Body side) 22~27 (2.2~2.7)

Hinge bolts(Hood side) 22~27 (2.2~2.7)

Lifter bracket bolts(Body side)

22~27 (2.2~2.7)

Lifter stud ball(Hood side) 22~27 (2.2~2.7)

Safety hook & Release lever bolts

7~11 (0.7~1.1)

Safety hook catch bolts 7~11 (0.7~1.1)

Hood latch bolts 7~11 (0.7~1.1)



Hinge bolts(Door side) 10~20 (1.0~2.0)

Checker bolts(Body side) 17~22 (1.7~2.2)

Checker nuts(Door side) 7~11 (0.7~1.1)

Door module bolts 7~11 (0.7~1.1)

Door module nuts 7~11 (0.7~1.1)

Glass bolts 8~12 (0.8~1.2)

Glass grip bolts 8~12 (0.8~1.2)

Outer handle bolts 7~11 (0.7~1.1)

Latch screws 7~11 (0.7~1.1)

Striker screws 7~22 (0.7~2.2)

Glass guide bolt 7~11 (0.7~1.1)

Outer handle bolts 7~11 (0.7~1.1)

Hinge bolts(Trunk lid side) 22~27 (2.2~2.7)

Outside rearview mirror Mounting bolts 7~11 (0.7~1.1)

Trunk lid


Latch bolts 7~11 (0.7~1.1)

Striker bolts 7~11 (0.7~1.1)

Crash pad Mounting bolts 7~11 (0.7~1.1) ED-20

Cowl cross barMounting bolts-Side(M10) 33~55 (3.3~5.5)

Mounting bolts-Lower(M8)

17~26 (1.7~2.6)

Front bumper Reinforcement nuts 9~14 (0.9~1.4)

Rear bumper Mounting bolts 35~55 (3.5~5.5)

Front seat Mounting nuts 45~55 (4.5~5.5)

Front seat mounting bolts 45~55 (4.5~5.5)

Rear seat

Cushion bolts(Power seat)

17~26 (1.7~2.6)

Seatback bolts 17~26 (1.7~2.6)

Frame bolts(Power seat) 17~26 (1.7~2.6)

Frame nuts(Power seat) 17~26 (1.7~2.6)

Sunroof Glass mounting screws 2~4 (0.2~0.4)

Mounting bolts and nut 7~9 (0.7~0.9)

Seat belt Upper anchor bolt 40~55 (4.0~5.5)

Lower anchor bolt 40~55 (4.0~5.5)

ED-21




Lighting systemWWWWWWWWW

Engine

Type H285 H295

Power supply DC 14.4V

Rated output Max 20W x 4 Max 35W x 6

Speaker impedance 4Ω x 4 2Ω x 6

Antenna 80PF 75ΩTuning type PLL synthesized type


FM 87.5~108 MHz / 100KHz (General)

AM 531 ~ 1602 KHz/9 KHz (General)

FM 87.5 ~ 108.0 MHz/50 KHz (Europe)

MW 531 ~ 1602 KHz/9 KHz (Europe)

LW 153 ~ 279 KHz/1 KHz (Europe)


Keyless entry transmitter Power source Lithium 3V battery (1EA)

Transmissible distance 10m or more

Life of battery 2 years or more (at 20 times per day)

Button 3 (Door lock, Door unlock, Trunk lid open)


Head lamp High 55

Low 35

Front turn signal lamp 14.5 (LED) / 5 (BULB)

Front position lamp 5

Front fog lamp 55

Rear stop/tail lamp (Outside) 27/8

Back up lamp 18

Rear turn signal lamp 28

Rear fog lamp 5ED-22

WWWWWWW

Other system

License plate lamp 5

Side repeater 5

Room lamp 10

Overhead console lamp 5

High mounted stop lamp 2.5 (LED)

Glove box lamp 5

Trunk lamp 5

Immobilizer Type SMARTRA system

Manufacturer Bosch

Rear parking assist system Front 4 channel/ Rear 4 channel

Smart key Type Touch sensor type (Front door)

Manufacturer SIEMENS

ED-23



oz.(g)



Engine

Compressor

Type VS16

Oil type & Capacity FD46XG (PAG) , 150 ± 10cc

Pulley type 6PK - TYPE

Displacement 180 cc/rev

Condeser Heat rejection 15,000 - 5% Kcal/hr

APT(A/C pressure




Refrigerant Type R - 134a

Capacity 22.9 ± 0.88 (650 ± 25)


Blower Type Siroco fan

Speed step Auto + 8 speed (Autometic)

Speed control Power mosfet

Heating capacity 4,058 ± 5% Kcal/hrActuator

Temperature operating

Evaporator

Type Laminated type

Temperature control type Evaporator sensor

A/C ON/OFF °C (°F)OFF : 0.5 ± 0.5 (32.9 ± 32.9)ON : 3.0 ± 0.5 (37.4 ± 32.9)

Actuator


Heater

Type Pin & Tube type

ED-24

　Engine Mechanical System………………………ED-2　Engine Electrical System…………………………ED-8　Fuel System……………………………..…………ED-10　Clutch…………………………………….…………ED-10　Manual Transaxle……………………….…………ED-10　Automatic Transaxle………………………………ED-11　Driveshaft………………………………..…………ED-11　Suspension System…………………….…………ED-12　Steering System………………………………… ED-14　Brake System………………………………………ED-16　Body (Interior & Exterior)……………….……… ED-19　Body Electrical System……………………………ED-22　Heating, Ventilation & Air Conditioning..………ED-24

cee'd (ED)

　Engine Mechanical System………………………TD-2　Engine Electrical System…………………………TD-9　Fuel System……………………………..…………TD-10　Clutch…………………………………….…………TD-10　Manual Transaxle……………………….…………TD-11　Automatic Transaxle………………………………TD-12　Suspension System…………………….…………TD-14　Steering System………………………………… TD-15　Restraints…………………………………………TD-16　Brake System………………………………………TD-16　Body (Interior & Exterior)……………….……… TD-20　Body Electrical System……………………………TD-23　Heating, Ventilation & Air Conditioning..………TD-24

Forte (TD)

TD-1

General Specifications - TDGSL γ 1.6 GSL θ 2.0 DSL U 1.6

EngineIn-line, DOHC In-line, DOHC

4 4

mm (in.) 77 (3.0315)x 85.44 (3.3638)

86 (3.385)x 86 (3.385)

cc 1.591 1.99810.5:1 10.5 : 11-3-4-2 1-3-4-2

BTDC 0˚ ± 10˚ BTDC 10° ± 5°rpm 660 ± 100 650 ± 100rpm 660 ± 100rpm 660 ± 100 650 ± 100rpm 690 ± 100

ℓ (lmp.qt) 3.7 (3.26)ℓ (lmp.qt) 3.0 (2.64)ℓ (lmp.qt) 3.3 (2.90)

kPa(kg/cm²) 1.1(at 1,000rpm, 110°C) 1.1(at 1,000rpm, 110°C)

ATDC 10°/BTDC 40° ATDC 7° ~ BTDC 38°ABDC 63°/ABDC 13° ABDC 63° ~ 18°

BBDC 40° BBDC 38°ATDC 3° ATDC 6°

mm (in.) Less than 0.05 (0.0020) Max. 0.05 (0.0019)

mm (in.)

mm (in.)

Engine


Bore x Stroke

Total displacementCompression ratioFiring orderIgnition Timing

Idle Speed

A/C OFF

Neutral,N,P-D-range

A/C ON

Neutral,N,P-D-range

Engine oil

Oil quantityTotalOil panDrain and refill

Oil quality

Oil pressure

Valve timing

Intake valve Opens (ATDC)Closes (ABDC)

Above API SL or SM, SEA 5W-20(For Middle East area :

Exhaust valve Opens (BBDC)Closes (ATDC)

Cylinder head



Intake

Exhaust

TD-2

mm (in.) 43.85 (1.726) 43.8 (1.7244)mm (in.) 42.85 (1.687) 45.00 (1.7716)

mm (in.) 22.964 ~ 22.980(0.9041 ~ 0.9047)

mm (in.)

mm (in.)0.10 ~ 0.20

(0.0039 ~ 0.0079)0.04 ~ 0.16

(0.0015 ~ 0.0062)

mm (in.) 93.15 (3.6673) 113.18 (4.4559)mm (in.) 92.6 (3.6457) 105.84 (4.1669)

Camshaft

Cam height IntakeExhaust



End play

Valve

Valve length IntakeExhaust

TD-3


mm (in.)5.465 ~ 5.480

(0.2152 ~ 0.2157)5.465 ~ 5.480

(0.2151 ~ 0.2157)

mm (in.)5.458 ~ 5.470

(0.2149 ~ 0.2154)5.458 ~ 5.470mm

(0.2149 ~ 0.2153in.)45.25° ~ 45.75° 45.25° ~ 45.75°

mm (in.) 1.1 (0.0433) 1.02 (0.0401)mm (in.) 1.26 (0.0496) 1.09 (0.0429)

mm (in.)0.020 ~ 0.047

(0.0008 ~ 0.0019)0.020 ~ 0.047

(0.00078 ~ 0.00185)

mm (in.)0.030 ~ 0.054

(0.0012 ~ 0.0021)0.030 ~ 0.054

(0.00118 ~ 0.00212)

mm (in.) - -

mm (in.) - -

mm (in.)40.3 ~ 40.7

(1.5866 ~ 1.6024)43.8 ~ 44.2

(1.7244 ~ 1.7401)

mm (in.)40.3 ~ 40.7

(1.5866 ~ 1.6024)43.8 ~ 44.2

(1.7244 ~ 1.7401)

mm (in.)mm (in.)

mm (in.) 44.0 (1.7323) 47.44 (1.8677)

mm (in.) -

19.0 ± 0.6kg/35.0mm(41.88 ± 1.32lb/1.3779in)

39.8 ± 1.2kg/26.0mm(87.74 ± 2.64lb/1.0236in.)

Less than 1.5° 1.5° MAX.

20°C (68°F) mm (in.) - -80°C (176°F) mm (in.) - -


Exhaust

Face angleThickness of valve head (margine)

IntakeExhaust


Intake

Exhaust

Valve guide

Inner diameterIntake

Exhaust

LengthIntake

Exhaust

Valve seat

Width of seat contact IntakeExhaust

Seat angleValve springFree length

Load

Out of squarenessValve clearance

Intake 0.17 ~ 0.23 (0.0067 ~ 0.0090)

Engine

TD-4

20°C (68°F) mm (in.) - -80°C (176°F) mm (in.) - -

mm (in.)86.00 ~ 86.03

(3.3858 ~ 3.3870)

mm (in.) -

mm (in.)76.97 ~ 77.00

(3.0303 ~ 3.0315)85.975 ~ 86.0050(3.3848 ~ 3.3860)

mm (in.)0.020 ~ 0.040

(0.0008 ~ 0.0016)

mm (in.)1.22 ~ 1.24

(0.0480 ~ 0.0488)1.235 ~ 1.250

(0.0486 ~ 0.0492)

mm (in.)1.22 ~ 1.24

(0.0480 ~ 0.0488)1.230 ~ 1.250

(0.0484 ~ 0.0492)

mm (in.)2.01 ~ 2.03

(0.0791 ~ 0.0799)2.01 ~ 2.03

(0.0791 ~ 0.0799)

-

Cylinder block

0.27 ~ 0.33 (0.0106 ~ 0.0129)Exhaust

Cylinder bore

Flatness of gasket surfacePiston



Ring groove width

No. 1 ring groove

No. 2 ring groove

Oil ring groove

Piston OS

TD-5


mm (in.)0.03 ~ 0.07

(0.0012 ~ 0.0028)0.05 ~ 0.08

(0.0019 ~ 0.0031)

mm (in.)0.03 ~ 0.07

(0.0012 ~ 0.0028)0.04 ~ 0.08

(0.0015 ~ 0.003)

mm (in.)0.06 ~ 0.15

(0.0024 ~ 0.0059)0.06 ~ 0.15

(0.0023 ~ 0.0059)

mm (in.)0.14 ~ 0.28

(0.0055 ~ 0.0110)0.15 ~ 0.30

(0.0059 ~ 0.0118)

mm (in.)0.30 ~ 0.45

(0.0118 ~ 0.0177)0.37 ~ 0.52

(0.0145 ~ 0.0204)

mm (in.)0.20 ~ 0.70

(0.0079 ~ 0.0276)0.20 ~ 0.70

(0.0078 ~ 0.0275)

mm (in.)18.001 ~ 18.006

(0.7087 ~ 0.7089)

mm (in.)18.016 ~ 18.021

(0.7093 ~ 0.7095)

mm (in.)0.010 ~ 0.020

(0.0004 ~ 0.0008)

mm (in.)17.974 ~ 17.985

(0.7076 ~ 0.7081)

mm (in.) -

mm (in.)45.000 ~ 45.018

(1.7717 ~ 1.7724)

mm (in.)0.100 ~ 0.250

(0.0039 ~ 0.010)

mm (in.) -

Piston ring

Side clearance

No. 1 ring groove

No. 2 ring groove

Oil ring groove

End gap

No. 1 ring groove

No. 2 ring groove

Oil ring groove

Piston pin






Connecting rod



End play

Engine

TD-6

mm (in.)51.942 ~ 51.960

(2.0449 ~ 2.0456)

mm (in.)47.954 ~ 47.972

(1.8879 ~ 1.8886)

mm (in.) 0.021 ~ 0.042(0.0008 ~ 0.0017)

0.020 ~ 0.038(0.0007 ~ 0.0014)

mm (in.)0.05 ~ 0.25

(0.0020 ~ 0.0098)0.07 ~ 0.25

(0.0027 ~ 0.0098)

mm (in.) -

kPa(kg/cm²) - -


Water-cooled, pressurized. Forced circulation

ith tℓ(lmp.qt)

5.5 ~ 5.8L(5.81~6.13US qt., 4.84~5.10lmp qt.)

Crankshaft




End play

FlywheelRunoutOil pump


Cooling system

Cooling method

Coolant quantity

TD-7


°C (°F) 82 ± 1.5 (179.6 ± 2.7) 82 (177)°C (°F) 101 (214) 95 (201)

kPa(kg/cm²)

93.16 ~ 122.58(0.95 ~ 1.25)

83 ~ 110(0.83 ~ 1.1)

kPa(kg/cm²) MAX. 6.86 (0.07) -7kpa (-0.07) or less

Thermister type Thermister typekΩ 2.45 ± 0.14 2.45 ± 0.14 kΩ 0,3222 0,3222


17.7~21.6+90°±2°(1.8~2.2+90°±2°)

19.6 (2.0) + 90˚

- -- -

11.8 ~ 13.7(1.2 ~ 1.4) 10.8 ~ 12.7(1.1 ~ 1.3)18.6 ~ 22.6(1.9 ~ 2.3) 27.4 ~ 31.4(2.8 ~ 3.2)17.7 ~ 21.6 (1.8 ~ 2.2)

+ 90 ~ 95˚ + 100 ~105˚34.3 + 90° + 90°(3.5 + 90° +90°)

- -

11.8 ~ 15.7 (1.2 ~ 1.6) 11.8 ~ 15.7 (1.2 ~ 1.6)

9.8 ~ 11.8(1.0 ~ 1.2)

M6 x 10:9.8 ~ 11.8(1.0 ~ 1.2)

M8 x 103:26.5 ~ 30.4(2 7 ~ 3 1)

34.3 ~ 44.1(3.5 ~ 4.5)

Engine

Radiator cap


Water temperature sensorType

Resistance

Thermostat Opening Pull opening

20°C (68°F)80°C (176°F)

Main moving system



Bolts



M6M8


Short bolts

Lubrication systemOil filter

Oil pan bolts

Oil pan drain plug

TD-8

Engine Electrical System12.V, 0.9 kW 12 V, 1.2 kW

V 11,5 11,5A 60 MAX 90A, MAX

5500 rpm, MIN 2,600 rpm, MIN

36 - 21GL 48-23 GL

410 A 550 A

80 min 92 min

Starter

Rated voltage


VoltageAmperageSpeed

Generator

TypeRated voltageSpeed in useVoltage regulator typeRegulator setting voltage

1.280 ± 0.01

Battery

TypeCold cranking amperage at -18°C (-0.4°F)Reserve capacity

Specific gravity [at 20°C(68°F)]

14.55 ± 0.2 V (At 20°C full chareged batt)

Battery voltage sensing13.5 V, 90A

1,000 ~ 18,000 rpmIC Regulator built-in type

TD-9


Ω 0.7 ± 15 % 0.62 ± 10 %kΩ - 7.0 ± 15 %

mm (in.) 1.0 ~ 1.1(0.0394~0.0433) 1.0 ~ 1.1(0.0394~0.0433)

Fuel System

ℓ(lmp.qt)

Type

MPa(kgf/cm²)

KPa(kgf/cm²)


Clutch cover assembly 15~22 (1.5~2.2) 15~22 (1.5~2.2)Clutch pedal bracket mountingClutch master cylinder mountingClutch release cylinder 15~22 (1.5~2.2) 15~22 (1.5~2.2)Service standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)

Engine

Spark plugs Unleaded (NGK)Unleaded

Ignition coil Primary Secondary

Engine Management ManufacturerFuel Tank CapacityFuel Return System Type Returnless

Fuel Filter TypeInstallation location

Fuel Pump

-



-

Fuel Pressure Regulator

Regulated Fuel Pressure

6 ~ 13 (0.24 ~ 0.51)

50 ( 44.0)

Paper type

Gasoline : 140 ± 3 (5.5 ± 0.12)




TD-10


3,615 3,3081,95 1,962

1,286 1,1890,971 0,9050,774 0,7023,545 3,583

4,267 4,188

MT oil capacity ℓ (lmp.qt)

Gear ratio

1st2nd3rd4th5thRev.

FGR

M/T oil quality

TD-11



2,919 2,9191,551 1,551

1 10,713 0,7132,48 2,48

4,375 3,681

ℓ (lmp.qt)

Driveshaft

80 ~ 100 (8.0 ~ 10.0)

Inner

Gear ratio

1st2nd3rd4thRev.FGR

Engine


Joint typeM/T

Outer

A/TInnerOuter

Max. permissible angleInner 23˚Outer 46˚

Hub end play mm (in.)Starting torque [N.m (kgf-m)]Wheel bearing[NOTE]BJ: Birfield JointTJ: Tripod JointUTJ-ll: U Type-ll Tri-pod JointTightening torque [N.m (kgf-m)]Driveshaft lock nut 196 ~ 274 (20.2 ~28.0)

Tie rod end to knuckleBrake caliper to knuckle

Knuckle to strut assembly nutLower arm ball joint to knuckle nut

Wheel nut

TD-12

Rear brake to rear axle carrier mounting boltRear strut to carrier nut

Rear hub bearing flange nut

Brake disc to hub

Trailing arm to rear axle carrier mounting nutRear suspension arm to rear axle carrier mounting nut

TD-13

General Specifications - TDSuspension System

Front RearMacPherson strut Torsion Beam Axle

-0.64°±0.5° -1.5°±0.5°4.38°±0.5° -

mm (in.) 0±2.0 4.4±2.213.61°±0.5° -

100 ~ 120 (10 ~ 12)

Wheel size SteelAluminum

Suspension typeShock absorber type


Wheel alignment

CamberCasterToe-inKing-pin

Tightening Torque [N.m(kgf-m)]Hub nutsFront strut assembly to wheel housing panelFront strut assembly to knuckleFront strut assembly self-locking nutFront lower arm to sub frameFront lower arm to knuckleFront stabilizer link to strut assemblyFront stabilizer bar bracket mounting boltsRear strut assembly to wheel housing panelRear strut assembly to carrierRear strut assembly self-locking nutRear stabilizer link to stabilizer barRear stabilizer bar bracket mounting boltsRear suspension arm tie rod nutRear suspension arm mounting boltRear cross member mounting boltTrailing arm to bracketTrailing arm bracket to body frameTrailing arm to rear carrier

Gas pressurized5.5J x 15

5.0J x 15, 6.0J x 16, 7.0J x 17185/70 R15, 195/65 R15, 205/60 R16, 215/50 R17

2.2kg/cm² (32psi)

90 ~ 110 (9.0 ~ 11.0)

TD-14

Type

ℓ (lmp.qt)mm (in.)

kPa(kgf/cm²)

13 ~ 18 (1.3 ~ 1.8)30 ~ 35 (3.0 ~ 3.5)

85 ~ 90


40.96°±2°, 38.38°±2° (215Tire) 32.33°, 30.90 (215Tire)

Power steering fluid QualityQuantity

PSF-3

Rack stroke

Steering angle InnerOuter


Tightening Torque [N.m(kgf-m)]Steering wheel lock nutSteering column mounting bolt & nutBolt connecting steering column to universal jointBolt connecting universal joint to steering gearTie rod end to knucklePower steering pump to pump bracketPressure hose to power steering pumpSteering gear box to sub frame

TD-15


Type

ΩΩΩΩΩ

Nut 7.8 ~ 8.8 (0.8 ~ 0.9)10.8 ~ 14.7 (1.1 ~ 1.5)

39.2 ~53.9 (4.0 ~ 5.5)9.8 ~ 13.7 (1.0 ~ 1.4)

Brake System

MPa(kgf/cm²)

MPa(kgf/cm²)

Engine

Side Airbag (SAB)

SRSCM Mounting Bolt

Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB)Passenger Airbag (PAB)

Seat Belt Buckle Switch (BS)

Side Airbag (SAB)Curtain Airbag (CAB)Seat Belt Pretensioner (BPT)

BuckledkΩ

Unbuckled

Restraints

ResistanceDriver Airbag (DAB)Passenger Airbag (PAB)

1.6 ~ 5.8

BuckledmA

Unbuckled


Seat Belt Anchor Bolt (BPT)

Brake fluid Recommended lubricantQuantity


I.D. CBSmm (in.)

ABS,TCSFluid level warning sensor ProvidedProportioning valve (CBS)


Rear drum

Rear disc

Decompression ratioTD-16

mm (in.)


280 (11.02)172 (6.77)26 (1.02)

Brake boosterType VacuumEffective diameter

Boosting ratio CBS 7.5 :1ABS/TCS

Front brake (Disc)Type Floating type with ventilated disc

Disc O.D. CBSABS

Disc thickness CBSABS


TD-17


mm (in.)mm (in.)


mm (in.)


[NOTE]O.D: Outer DiameterI.D: Inner DiameterCBS: Conventional Brake SystemTCS: Traction Control SystemAnti-lock Brake System (ABS) / Electronic Stability Program (ESP)


EngineCylinder type Single piston

Cylinder I.D. CBSABS

Ø57.15 (2.25)

Rear brake (Disc)Type Floating type with solid discDisc O.D. 262 (10.31)Disc thickness 10 (0.39)Pad thickness 10 (0.39)Cylinder type Single pistonCylinder I.D Ø31 (1.22)Rear brake (Drum)Type Leading trailingDrum I.D. Ø203 (7.99)Brake lining thickness 4.3 (0.17)Clearance adjustment AutomaticParking brakeType LeverActuation DIH (Drum in hat)

Manufacturer and NameHECU System 4 Channel 4 Sensor (Solenoid)

Brake pedal height LHD : 190.7 (7.51), RHD : 167.5 (6.59)Brake pedal stroke 135 (5.31)Brake pedal free play 3 ~ 8 (0.08 ~ 0.20)

TD-18

mm (in.)

mm (in.)

mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

Front disc run outFront disc parallelismRear drum brake lining thickness 3 (0.12)

Stop lamp switch outer case to pedalstopper clearance LHD : 1.0 ~ 2.0 (0.04 ~ 0.08), RHD : 0.5 ~ 1.0 (0.02 ~ 0.04)

Booster push rod to master cylinder piston clearance 0.6 ~ 1.4 (at 500 mmHg vacuum)

Parking brake lever stroke when lever assembly is pulled with 196N (20kgf, 44lb force) 6 ~ 8 clicks

Front disc brake pad thickness 11 (0.43)Front disc thickness (minimum)

CBSABS

26 (1.02)

Rear drum brake drum I.D (maximum)Rear disc brake pad thickness 10 (0.35)Rear disc brake disc thickness 10 (0.39)Rear disc run outRear disc parallelism

TD-19



EngineTightening torque [N.m (kgf-m)]Master cylinder to booster mounting nut 9.8 ~ 15.7 (1.0 ~ 1.6)Brake booster mounting nut 12.7 ~ 15.7 (1.3 ~ 1.6)Bleeder screw 6.9 ~ 12.7 (0.7 ~ 1.3)Brake tube nut, brake hoseCaliper guide rod bolt 21.6 ~ 31.4 (2.2 ~ 3.2)Member assembly bracket mounting boltBrake pedal mounting boltStop lamp switch mounting nutCaliper assembly to knuckle F:78.5 ~ 98.1 (8.0 ~ 10.0), R:63.7 ~ 73.6 (6.5 ~ 7.5)Brake hose to front caliper 24.5 ~ 29.4 (2.5 ~ 3.0)Brake hub flange nutWheel cylinder mounting boltRear drum backing plate mounting boltproportioning valve to master cylinderSensor mounting bolt (ABS & TCS)

FrontRear

HECU mounting bolt (ABS & TCS)HECU mounting bracket bolt (ABS & TCS)Brake tube nut (ABS & TCS)Bleeder screw (ABS & TCS)

Hood Type Rear hinged, Front opening type, stay type

Front door Construction Front hinged, full door constructionRegulator system X-arm type

Rear door Construction Front hinged, full door constructionRegulator system X-arm type

Trunk lid Type Inner hinged, torsion bar

TD-20


Rear seat

Glass thickness

Windshield Front door Rear door Rear window

Seat beltsFront - LH : 3 point type P.T (pretensioner) with Emergency Locking Retractor (E.L.R)Front passenger seat

LH / RH / CTR : 3 point type with E.L.R & A.L.RTightening Torque [N.m(Kgf-m)]Front fender Mounting bolts

TD-21

General Specifications - TDGSL γ 1.6 GSL θ 2.0 DSL U 1.6Engine

Glass height adjustmentscrews


Hinge bolts (Body side) 34.3~41.2 (3.5~4.2)Hinge bolts (Door side) 21.6~26.5 (2.2~2.7)Checker bolts (Body side) 16.7~21.6 (1.7~2.2)Checker bolts (Door side) 16.7~21.6 (0.7~1.1)Door module boltsDoor module nutsDoor speaker boltsGlass mounting boltsDoor glass grip boltsDoor channel bracket Outside handle boltsOutside handle screwInside handle screwLatch screwsStriker screws

Trunk lid

Hinge bolts (Body side)Hinge bolts (Trunk lidside)Latch bolts 6.9~10.8 (0.7~1.1)Striker bolts

Sunroof

Mounting nutsMounting bolts

Outside rearview mirror Mounting nuts

Hood Hinge bolts (Body side) 21.6~26.5 (2.2~2.7)Hinge bolts (Hood side) 21.6~26.5 (2.7~2.7)

Front bumper Bumper rail mounting boltsRear bumper Mounting bolts

TD-22


RADIO/CD(A100) RADIO/CD/MP3(A200) RADIO/CDC/MP3(A300)

Rated output

Retractor mounting bolt

Type

Tuning type

Front seat Front seat mounting bolts 6.9~10.8 (3.5~5.5)Rear seat mounting bolts 34.3~53.9 (3.5~5.5)


Rear seat Front seat mounting bolts

Seat beltAnchor boltRear seat belt buckle

Speaker impedance 4.0 ± 0.6(Front, Rear), 3.4 ± 0.5(Tweeter)Antenna 80PF 75Ω

Power supply DC 14.5VRated output Rated output : Min. 12W

FM 87.5~108 MHz / 100KHz (General)AM 531 ~ 1602 KHz/9 KHz (General)

LW

FM 87.5 ~ 108.0 MHz/50 KHz (Europe)MW 522 ~ 1620 KHz/9 KHz (Europe)

153 ~ 279 KHz/1 KHz (Europe)

PLL SYNTHESIZED TUNING

TD-23




Other system


Engine

ItemsKeyless entry transmitter Power source Lithium 3V battery (1EA)Transmissible distance 30m or moreLife of battery 2 years or more (at 20 times per day)

Button4 Door : 4 (Door lock, Door unlock, Trunk open, Panic)


Rear stop/tail lamp (Outside) 39954Back up lamp 16Rear turn signal lamp 21Rear fog lamp - Europe 21License plate lamp 5Side repeater 5Room lamp 8Overhead console lamp 8Glove box lamp

Immobilizer TypeManufacturer

Compressor

Type 6SBU16DOil type & Capacity FD46XG(PAG) 120 ± 10ccPulley type 6PK-TYPEDisplacement 180cc/rev

Front fog lamp

5555

4004627

Head lamp HighLow

Front turn signal lamp

TD-24

The method to

TypeSpeed stepSpeed control


Temperature control type

Heating capacityMode operating method

Evaporator A/C ON/OFF

Heater Temperature operatingmethod

Condeser Heat rejection 13,400 - 5% kcal/hr

APT(A/C pressuretransducer)

Voltage = 0.00878835 * Pressure + 0.5


Refrigerant Type R-134aCapacity [oz.(g)] 17.63 ± 0.88 (500 ± 25)


Auto + 8 speed (Automatic) 0~4 (Manual)Power mosfet


Blower

Evaporator temperature sensor

°C (°F)ON : 3.0 ± 0.5 (37.4 ± 32.9) OFF: 1.0 ± 0.5 (33.8 ± 32.9)

Type Pin & Tube type

Actuator

Actuator

Sirocco

Min 4,600 kcal/hr

TD-25

　Engine Mechanical System………………………MG-2　Engine Electrical System…………………………MG-11　Fuel System……………………………..…………MG-12　Clutch…………………………………….…………MG-13　Manual Transaxle……………………….…………MG-14　Automatic Transaxle………………………………MG-14　Driveshaft………………………………..…………MG-15　Suspension System…………………….…………MG-16　Steering System………………………………… MG-18　Restraints…………………………………………MG-19　Brake System………………………………………MG-20　Body (Interior & Exterior)……………….……… MG-23　Body Electrical System……………………………MG-25　Heating, Ventilation & Air Conditioning..………MG-27

Magentis / Optima(MG)

MG-1

General specifications - Magentis/OptimaGSL θ 2.0 GSL θ 2.4 GSL μ 2.7 DSL D 2.0 VGT

EngineV-type, DOHC In-line, SOHC

6 4

mm (in.) 86 (3.3858) x 86 (3.3858)

88 (3.464)x 97 (3.819)

86.7 (3.4134)x 75 (2.9528)

83 (3.27)x 92 (3.62)

cc 1.998 2.359 2.656 1.99110.4 : 1 17.3 : 1

1-2-3-4-5-6 1-3-4-2BTDC 7˚ ± 10˚ -

rpm 650 ± 100 850 ± 100rpm 650 ± 100 850 ± 100rpm 650 ± 100 850 ± 100rpm 650 ± 100 850 ± 100

ℓ (lmp.qt) 4.5 (3.96) -ℓ (lmp.qt) 4.2 (3.70) -ℓ (lmp.qt) 0.3 (0.26) -ℓ (lmp.qt) - -ℓ (lmp.qt) - -

5W-20(SJ or SL above/GF-3) ACEA : C3

kPa(kg/cm²)

130 (1.32) [at 1000rpm,110°C(2

30°F)]-

10.5 : 1

-

650 ± 100

Oil quality

Oil quantity

Oil pressure (Idle)

Engine oil

4.3 (3.78)

5W-20(SJ or SL above/GF-3)

-

Engine


Compression ratio

Bore x Stroke

Total displacement

A/C OFFA/C ON


Total

Including oil filter

Firing orderBTDC 8˚ ± 5˚

650 ± 100650 ± 100650 ± 100

Idle Speed

In-line, DOHC4

Excluding oil filte 4.0 (3.52)

5.1 (4.49)-

Ignition Timing

Oil panOil filter

1-3-4-2

MG-2

-4° ~ 56° 7°60° ~ 0° 43°

46° 52°10° 6°

mm (in.) 0.03(0.0012) or less

0.03 (0.0012) for width

0.09 (0.0035) for length

mm (in.) 0.15(0.0059) or less -

mm (in.) 0.15(0.0059) or less -

mm (in.) 34.697 (1.366)mm (in.) 34.570 (1.361)

mm (in.)

mm (in.)28 (1.10)

Less than 0.05 (0.0020)

Less than 0.10 (0.0039)

Less than 0.10 (0.0039)

-11° ~ 34°22° ~ 67°

34°10°

43.80 (1.7244)45.00 (1.7716)

No.1 : 30 (1.1811)No.2,3,4,5 : 24 (0.9449)

Intake

Opens (BTDC)Closes (ABDC)Opens (BBDC)Closes (ATDC)



Exhaust

Intake

Cam height

ExhaustJournal outer Diameter

No.1 : 40 (1.5748)No.2,3,4,5 : 24 (0.9449)

Camshaft

Intake valve

27.964 ~ 27.980 (1.1009 ~ 1.1016)

Intake

Exhaust

Valve timing

Cylinder head

44.5(1.7520)

Exhaust valve

MG-3


mm (in.)

mm (in.)

mm (in.) 0.1 ~ 0.2 (0.0039 ~ 0.0079)

0.05 ~ 0.15 (0.002 ~ 0.006)

mm (in.) 110.1 (4.3346) 95.7 (3.77)mm (in.) 111.1 (4.3740) 95.4 (3.76)

mm (in.) 5.965 ~ 5.980 (0.2348 ~ 0.2354) 5.953 (0.234)

mm (in.) 5.950 ~ 5.965 (0.2343 ~ 0.2348) 5.925 (0.233)

45° ~ 45.5° 44.5°mm (in.) 1.0 (0.0394) 1.6 (0.063)mm (in.) 1.3 (0.0512) 1.3 (0.0512)

mm (in.) 0.020 ~ 0.050 (0.0008 ~ 0.0020)

0.022 ~ 0.067 (0.00086 ~ 0.00263)

mm (in.) 0.035 ~ 0.065 (0.0014 ~ 0.0026)

0.050 ~ 0.095 (0.0020 ~ 0.0037)

1.02 (0.0401)1.09 (0.0429)

0.020 ~ 0.047 (0.00078 ~ 0.00185)

No.1 : 0.020 ~ 0.057 (0.00078 ~ 0.00224)

No.2,3,4,5 : 0.045 ~ 0.082 (0.00177 ~ 0.00323)

113.18 (4.4559)105.89 (4.1689)

5.465 ~ 5.480 (0.2151 ~ 0.2157)

5.458 ~ 5.470 (0.2149 ~ 0.2153)

45.25° ~ 45.75°

0.1 ~ 0.22 (0.0039 ~ 0.0086)

ExhaustStem outer diameter

Intake

Valve length

Engine

Valve


Exhaust



IntakeExhaust

Intake

Face angle

0.040 ~ 0.074(0.0020 ~ 0.0029)

Exhaust

0.030 ~ 0.054 (0.00118 ~ 0.00212)

End play

Intake

Intake0.020 ~ 0.057

(0.0008 ~ 0.0022)

Exhaust No.1,2,3,4,5 : 0.045 ~ 0.082 (0.00177 ~ 0.00323)

MG-4

mm (in.) -

mm (in.) -

mm (in.) 45.8 ~ 46.2(1.8031 ~ 1.8189)

mm (in.) 46.8 ~ 47.2(1.8425 ~ 1.8583)

mm (in.) - 1.21 (0.0477)

mm (in.) - 1.61 (0.0634)

- 44° ~ 44.5°

mm (in.) 46.8 (1.8425) 38.8 (1.527)

mm (in.)

18.4 ~ 20.3Kg / 35 (1.3779),34.9 ~ 38.6Kg / 26.5 (1.0433)

21.25kg / 32 (1.26)

1.5° or less -


Length

Inner diameter

Valve seat

Intake

Exhaust

Seat angle

Free length

44.75° ~ 45.10°

19.0 ± 0.6kg / 35.0 (1.3779),39.8±1.2kg / 26.0 (1.0236 )

Less than 1.5°Out of squareness

Valve guide

Intake

Exhaust5.500~5.512 (0.2165 ~ 0.2170) 6.000 ~ 6.015

(2.2362 ~ 2.2368)

43.8 ~ 44.2 (1.7244 ~ 1.7401) 36.5 (1.437)

1.16 ~ 1.46 (0.0457 ~ 0.0575)

1.35 ~ 1.65 (0.0531 ~ 0.0649)

Intake

Valve spring

Exhaust

Load

47.44 (1.8677)

MG-5


mm (in.) 29.964 ~ 29.980(1.1797 ~ 1.1803) -

mm (in.) 30.000 ~ 30.025(1.1811 ~ 1.1821) -

mm (in.) 0.020 ~ 0.061(0.0008 ~ 0.0024) -

mm (in.) 0.17 ~ 0.23(0.0067 ~ 0.0090) -

mm (in.) 0.27 ~ 0.33(0.0106 ~ 0.0129) -

mm (in.) 86.00 ~ 86.03 (3.3858 ~ 3.3870)

88.00 ~ 88.03 (3.4645 ~ 3.4657)

86.70 ~ 86.73 (3.4134 ~ 3.4146)

83 + 0.03 (3.27 + 0.0012)

mm (in.) Less than 0.05 (0.0019)

0.096 (0.00378) for length

mm (in.)85.975 ~ 86.005 (3.3848 ~ 3.3860

)

87.975 ~ 88.005 (3.4636 ~ 3.4648

)

86.67 ~ 86.70(3.4122 ~ 3.4134)

82.92 ~ 82.95 (3.26 ~ 3.27)

mm (in.) 0.02 ~ 0.04(0.0008 ~ 0.0016)

0.07 ~ 0.09 (0.0027 ~ 0.0036)

Less than 0.05 (0.0020)

0.015 ~ 0.035 (0.0028 ~ 0.0014)

0.020 ~ 0.061 (0.0008 ~ 0.0024)

Intake

Exhaust



Cylinder block


Cylinder head tappet bore inner diameter

MLA to tappet bore clearance

MLA

32.000 ~ 32.025 (1.2598 ~ 1.2608)

Engine

Cylinder bore

Valve clearance

Piston

0.17 ~ 0.23(0.0067 ~ 0.0090)

0.27 ~ 0.33(0.0106 ~ 0.0129)

31.964 ~31.980 (1.2584 ~ 1.2591)MLA outer diameter

MG-6

mm (in.) 1.23 ~ 1.25 (0.0484 ~ 0.0492)

1.915 ~ 1.945 (0.075 ~ 0.076)

mm (in.) 1.22 ~ 1.24 (0.0480 ~ 0.0488)

2.06 ~ 2.08 (0.08 ~ 0.082)

mm (in.) 2.01 ~ 2.03 (0.0791 ~ 0.0799)

3.02 ~ 3.04 (0.119 ~ 0.1196)

mm (in.) 0.04 ~ 0.08(0.0016 ~ 0.0031)

0.064 ~ 0.114 (0.0025~0.0045)

mm (in.) 0.03 ~ 0.07(0.0012 ~ 0.0027)

0.065 ~ 0.11 (0.0026~0.0043)

mm (in.) 0.06 ~ 0.15(0.0024 ~ 0.0059)

0.03 ~ 0.07 (0.0012~0.0028)

mm (in.) 0.15 ~ 0.30(0.0059 ~ 0.0118)

0.2 ~ 0.3 (0.0079~0.0118)

mm (in.) 0.30 ~ 0.45(0.0118 ~ 0.0177)

0.3 ~ 0.45 (0.0118~0.0177)

mm (in.) 0.20 ~ 0.70(0.0078 ~ 0.0275)

0.2 ~ 0.45 (0.0079~0.0177)

mm (in.) 21.001 ~ 21.007(0.8268 ~ 0.8270) -

mm (in.) 21.014 ~ 21.023(0.8273 ~ 0.8277) -

mm (in.) 0.011 ~ 0.018(0.0004 ~ 0.0007) -

mm (in.) 20.974 ~ 20.985(0.8257 ~ 0.8262) -20.974 ~ 20.985 (0.8257 ~ 0.8262 )

Piston pin

No. 1 ring groove 0.15 ~ 0.30 (0.0059 ~ 0.0118)

0.30 ~ 0.45 (0.0118 ~ 0.0177)

0.20 ~ 0.70 (0.0078 ~ 0.0275)

1.22 ~ 1.24 (0.0006 ~ 0.0488)

21.001 ~ 21.006 (0.8268 ~ 0.8270 )

21.016 ~ 21.021 (0.8274~0.8276 )

0.010 ~ 0.020 (0.0004 ~ 0.0008 )

No. 1 ring groove

Side clearance

No. 1 ring groove

No. 2 ring groove

1.22 ~ 1.24 (0.0480 ~ 0.0488)

2.01 ~ 2.03 (0.0791 ~ 0.0799)

0.03 ~ 0.07 (0.0012~0.0028 )

0.03 ~ 0.07 (0.0012~0.0028 )

0.06 ~ 0.15 (0.0024 ~ 0.0059)

Piston ring



No. 2 ring groove

Oil ring groove


Oil ring groove

Oil ring groove

Ring groove width


End gap No. 2 ring groove

MG-7


mm (in.) 0.016 ~ 0.033(0.0006 ~ 0.0013) -

mm (in.) 51.000 ~ 51.018(2.0079 ~ 2.0086) -

mm (in.) 0.018 ~ 0.036(0.0007 ~ 0.0014)

0.024 ~ 0.042 (0.0009 ~ 0.0016)

mm (in.) 0.1 ~ 0.25 (0.0039 ~ 0.0098) -

mm (in.) 61.982 ~ 62.000(2.4402 ~ 2.4409)

60.002 ~ 60.020 (2.362 ~ 2.363)

mm (in.) 47.982 ~ 48.000(1.8891 ~ 1.8898)

50.008 ~ 50.026 (1.9688 ~ 1.9695)

mm (in.) 0.004 ~ 0.022(0.0002 ~ 0.0009)

0.024 ~ 0.042 (0.0009 ~ 0.0016)

mm (in.) 0.07 ~ 0.25(0.0028 ~ 0.0098)

0.09 ~ 0.32 (0.0035 ~ 0.0126)

kPa(kg/cm²)

490.33 ~ 588.40(5.0 ~ 6.0)

570 ± 50 (5.8 ± 0.5)

Engine

51.942 ~ 51.960 (2.0449 ~ 2.0456)


Oil pump

0.10 ~ 0.25 (0.0039 ~ 0.0098)

End play

0.026 ~ 0.049 (0.0010 ~0.0019)

0.007 ~ 0.25 (0.0027 ~ 0.0098)

-

47.954 ~ 47.972 (1.8879 ~ 1.8886)

0.028 ~ 0.046 (0.0011 ~ 0.0018)

Crankshaft

-

51.000 ~ 51.018 (2.0079 ~ 2.0086)

Connecting rod







End play

MG-8

ℓ(lmp.qt)

8.2~8.3 (7.22~7.30) 5 (4.4)

°C (°F) 82±2 (179 6±35 6) 85 (185)

°C (°F) 95 (203) 100 (212)

mm (in.) 10 (0.3937) or more -

kPa(kg/cm²)

93.16 ~ 122.58(0.95 ~ 1.25 )

107.9 ± 14.7 (1.1±0.15)

kPa(kg/cm²)

0.98 ~ 4.90 (0.01 ~ 0.05 )

-6.86(-0.07)

kΩkΩ


19.6 (2.0) + 90˚ 25 (2.5) + 90°- -

29.4 (3.0) + 90˚ -15.7 (1.6) + 90˚ -

- 28 ~ 35 (2.8 ~ 3.5) + 120°

- 33.7 ~ 37.7 (3.37 ~ 3.77)

Thermostat

2.31 ~ 2.59Thermister type

95 (201)


-

-

-


BoltsBolts (M10)Bolts (M8)

Coolant quantity

Cooling method

82±1.5 (179.6 ±34.7)

0,3222

Full opening temperature

Opening

Full lift

Type



Bolts (12mm)

Bolts (15mm)

93.16 ~ 122.58(0.95 ~ 1.25)

6.86 (0.07) or less

Cooling system

19.6 (2.0) + 90°26.46 (2.7) + 45°

Radiator cap

Resistance



20°C (68°F)80°C (176°F)

-

Crankshaft bedplate

Main moving system

6.4~6.9 (5.631~6.07)

-

MG-9


- 26.5 ~ 29.5 (2.65 ~ 2.95)

10.8 ~ 12.7 (1.1 ~ 1.3) -

20.6 ~ 25.5 (2.1 ~ 2.6) -

24.5 (2.5) + 60˚ + 45˚

50 (5.0) + 120° + 120°

- -

- 10 ~ 12 (1.0 ~ 1.2)

- -- -

34.3 ~ 44.1 (3.5 ~ 4.5)

35 ~ 45 (3.5 ~ 4.5)

9.8 ~ 11.8 (1.0 ~ 1.2) -

Engine

Cylinder head bolt

-

Cylinder head


26.46 ~ 30.38 (2.7 ~ 3.1)

34.3 (3.5) + 90° +90°

-

-

-

Oil pan nuts or boltsBolts

Bolts (M8)

Bolts

Bolts (M6)

Lubrication system11.76 ~ 15.68 (1.2 ~ 1.6)

9.8 ~ 11.76 (1.0 ~ 1.2)

Oil filter

Oil pan drain plug

Lower oil pan bolt

Bolts (M8)

10.78 ~ 12.74 (1.1 ~ 1.3)

27.44 ~ 31.36 (2.8 ~ 3.2)

Bolts (M6)

MG-10

Engine Electrical System12 V, 1.2 kW 12V, 2.0KW

V 11,5 11A 90, MAX 120, MAX

2,600 rpm, MIN 4,000rpm, MIN

13.5 V, 110A 12V, 120A1,000 ~18,000

rpm5,900 ~12,000

rpm

14.2 ~ 14.8V 14.4 ± 0.3VMF 60AH MF 68AH MF 68AH CMF 90 AH

550 A 600 A 600 A 720A

92 min 110 min 110 min 160min

1.280 ± 0.01 1.280 ± 0.01 1.280 ± 0.01 1.280 ± 0.01

Ω 0.715 ± 0.015 -

kΩ - -

ILFR5B11 --

mm(in.) 1.0 ~ 1.1 (0.0394 ~ 0.0433) -

BKR5ES-11RC 10YC4

12 V, 1.2 kW

90, MAX2,600 rpm, MIN

VoltageStarter No-load charasteristics

13.5 V, 110ABattery voltage sensing

7.0 ± 15 %

11,5

1,000 ~18,000 rpm

14.2 ~ 14.8VElectronic built-in type

0.62 ± 10 %

Battery


Reserve capacity

Amperage

Rated voltage


Generator Speed in use

Type

Ignition coil

Cold cranking amperage at -18°C (-0 4°F)

Regulator setting

Spark plugs

Primary resistanceSecondary resistanceUnleaded (NGK)Unleaded (CHAMPION)Unleaded (Gap) 1.0 ~ 1.1 (0.0394 ~ 0.0433)

Rated voltage

Speed

Type

MG-11


Fuel SystemDelphi Bosch

ℓ(lmp.qt) -

Return type

Built in engine room


Plunger Pumping Type

Drive BeltMPa

(kgf/cm²)

160 (1,632) kPa

(kgf/cm²)

375 ~ 385 (3.82 ~ 3.92) -

Fuel Pump Type

-

Electrical

In-tank type

Electric motor

Engine

Driven by

Fuel FilterType

Engine Management Manufacturer



Regulated Fuel Pressure 338~348 (3.45~3.55)

High pressure type

Installation location Built in Fuel Pump assembly

Fuel Tank Capacity 62 (54.55)Fuel Return System Type Returnless type

Siemens

MG-12

ClutchClutch operation - Hydraulic type

Clutch disc - Single dry with diaphragm

Clutch cover assembly Diaphragm spring strap

Self Adjusting Clutch - Self Adjusting

ClutchTightening torque [N.m(kgf-m)]Clutch cover assembly 25~36 (2.5~3.6) 12~15 (1.2~1.5) - 25~36 (2.5~3.6)Clutch pedal bracket mounting 17~26 (1.7~2.6) 17~26 (1.7~2.6) - 17~26 (1.7~2.6)Clutch master cylinder mounting 13~16 (1.3~1.6) 13~16 (1.3~1.6) - 13~16 (1.3~1.6)Clutch release cylinder 15~22 (1.5~2.2) - - -Service standardClutch pedal stroke mm (in.) - 145 (5.70)Clutch pedal free play mm (in.) - 6~13 (0.24~0.51)

Hydraulic type

145 (5.70)6~13 (0.24~0.51)

Single dry with diaphragm

MG-13


Manual TransaxleType M5GF1 M5GF2 - M6GF2

3,636 3,267 - 3,6152,056 1,794 - 1,7941,333 1,552 - 1,5420,971 1,176 - 1,1760,775 0,974 - 0,974

- - - 0,8293,455 3,416 - 3,4164,333 4.333/3.250 - 4.063/2.955

- SAE 75W/85, API GL-4

MT oil capacity ℓ(lmp.qt) 2.1 (1.85) 1.9 (1.67) - 1.9 (1.67)

Automatic TransaxleType F4A42-2 A5GF1 A5GF1 F4A51-3

2,842 3,789 3,789 2,8421,529 2,064 2,064 1,4951,000 1,421 1,421 1,0000,712 1,034 1,034 0,731

- 0,728 0,728 -2,480 3,808 3,808 2,7204,042 3,311 3,311 4,520

ℓ(lmp.qt) 7.8 (6.86) 9.5 (8.36) 9.5 (8.36) 8.5 (7.48)

SAE 75W/85, API GL-4

Engine

ATF quality Diamond ATF SP III or SK ATF SP IIIATF capacity

Gear ratio

1st2nd3rd4th5th

Rev.FGR

Rev.FGR

M/T oil quality

Gear ratio

1st2nd3rd4th5th6th

MG-14

Driveshaft - - - -

UTJ-II#25BJ#25

LubricantsBJ#24 BJ#25 UTJ-II#24 UTJ#25

g 130 160 160 200

Front caliper assembly to knuckle bolts 140 ~ 160 (14.0 ~ 16.0)Tie rod end castle nut 24 ~ 34 (2.4 ~ 3.4)

Inner shaft bearing bracket 50 ~ 65 (5.0 ~ 6.5)Wheel speed sensor bolt 7 ~ 10 (0.4 ~ 1.0)

Driveshaft nut (Castle nut) 200 ~ 280 (20.0 ~ 28.0)Lower arm ball joint assembly to knuckle bolts 100 ~ 120 (10.0 ~ 12.0)

Outer : On tire sideTightening torque [N.m (kgf-m)]Hub nut 90 ~ 110 (9.0 ~ 11.0)

Rear hub ＆ bearing assembly 1.5 (0.15)[NOTE]Inner: On transaxle side

QuantityStarting torque [N.m (kgf-m)]Front wheel bearing 1.8 (0.18)

BJ#24

Joint typeRecommended grease RBA

Max. permissible angle Inner 23˚Outer 46.5˚

CW-13TJ

Joint typeM/T Inner UTJ-II#24

Outer BJ#24

A/T Inner UTJ-II#24Outer

MG-15


mm (in.)

Engine

King-pin 13.1°±30' -

Wheel alignment

Camber -0.5°±30' -1°±30'Caster 4.74°±30' -Toe-in 0±2 (0±0.079) 2±2(0.079±0.079)

Tire size [Tire pressure] kgf/cm2

(psi)

205/65 HR15 [2.1 (30)]205/60 HR16 [2.3 (33)]215/50 VR17 [2.3 (33)]


6.0J × 15", 6.5J × 16"6.5J × 16", 6.5J × 17"

Suspension type MacPherson strut Multi linkShock absorber type Gas pressurized


Carrier assembly to rear hub assembly bolts 70 ~ 90 (7.0 ~ 9.0)

Assist arm to carrier assembly bolts 45 ~ 55 (4.5 ~ 5.5)Trailing arm to carrier assembly bolts 45 ~ 55 (4.5 ~ 5.5)

Rear caliper assembly to carrier assembly bolts 50 ~ 60 (5.0 ~ 6.0)Rear strut assembly to carrier assembly bolts 140 ~ 160 (14.0 ~ 16.0)

Rear lower arm to cross member 140 ~ 160 (14.0 ~ 16.0)Rear upper arm to carrier assembly bolts 100 ~ 120 (10.0 ~ 12.0)

Front strut assembly to knuckle bolts 100 ~ 120 (10.0 ~ 12.0)Rear lower arm to carrier assembly bolts 140 ~ 160 (14.0 ~ 16.0)

MG-16

Rear stabilizer link to trailing arm 45 ~ 55 (4.5 ~ 5.5)Rear stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)

Trailing arm to body 140 ~ 160 (14.0 ~ 16.0)Trailing arm to carrier 45 ~ 55 (4.5 ~ 5.5)

Rear assist arm to carrier 45 ~ 55 (4.5 ~ 5.5)Rear assist arm to rear cross member 80 ~ 100 (8.0 ~ 10.0)

Rear lower arm to carrier 140 ~ 160 (14.0 ~ 16.0)Rear lower arm to rear cross member 140 ~ 160 (14.0 ~ 16.0)

Rear upper arm to carrier 100 ~ 120 (10.0 ~ 12.0)Rear upper arm to rear cross member 100 ~ 120 (10.0 ~ 12.0)

Rear shock absorber bracket to body 45 ~ 55 (4.5 ~ 5.5)Rear shock absorber to carrier 140 ~ 160 (14.0 ~ 16.0)

Front stabilizer link to strut assembly 100 ~ 120 (10.0 ~ 12.0)Front stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)

Front lower arm to sub frame FR: 140 ~ 160 (14.0 ~ 16.0), RR: 100 ~ 120 (10.0 ~ 12.0) Front lower arm to knuckle 100 ~ 120 (10.0 ~ 12.0)




MG-17

GSL θ 2.0 GSL θ 2.4 GSL μ 2.7 DSL D 2.0 VGT

Type

ℓ(lmp.qt)mm (in.)

kPa(kgf/cm²

)

Engine

Pressure hose to power steering pump 55 ~ 65 (5.5 ~ 6.5)Steering gear box to sub frame 60 ~ 80 (6.0 ~ 8.0)

Tie rod end to knuckle 24 ~ 34 (2.4 ~ 3.4)Power steering pump to pump bracket 17 ~ 26 (1.7 ~ 2.6), GSL μ-2.7I: 35 ~ 50 (3.5 ~ 5.0)





1.0 (0.88)Rack stroke 140 (5.51)

Steering angleInner 39.52°±1°30'Outer 32.17°

General specifications - Magentis/Optima


Power steering fluid Quality PSF-4Quantity

MG-18

ΩΩΩΩΩ



Curtain Airbag (CAB) 10.9 ~ 14.7 (1.1 ~ 1.5)Side Airbag (SAB) 4.9 ~ 6.9 (0.5 ~ 0.7)

Passenger Airbag (PAB)

Bolt 18.6 ~ 26.5 (1.9 ~ 2.7)Nut 8.8 ~ 13.7 (0.9 ~ 1.4)

Seat Belt Pretensioner (BPT) 1.5 ~ 4.5Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB) 7.9 ~ 10.8 (0.8 ~ 1.1)

Side Airbag (SAB) 1.5 ~ 4.5Curtain Airbag (CAB) 1.5 ~ 4.5

ResistanceDriver Airbag (DAB) 1.5 ~ 6.0Passenger Airbag (PAB) 1.5 ~ 4.5


MG-19

GSL θ 2.0 GSL θ 2.4 GSL μ 2.7 DSL D 2.0 VGT

Brake System

mm (in.)mm (in.)

kPa(kgf/cm²

)


mm (in.)

Engine

Cylinder I.D. Ø57.2 (Ø2.25)


Disc I.D. 172 (6.77)Disc thickness 26 (1.02)

Front brake(Disc)Type Floating type with ventilated discDisc O.D. 280 (11.02)

Brake boosterType vacuumBoosting ratio 9 : 1

Proportioning valve(CBS)

3.43 (35)

Decompression ratio 0.32 : 1

Cut-in pressure(Split point)

Piston stroke 30 ~ 31 (1.18 ~ 1.22)Fluid level warning sensor Provided

Master cylinderType Tandem typeI.D. 23.81(0.937)

Brake fluidRecommended lubricant DOT 3Quantity As required

General specifications - Magentis/Optima

MG-20


mm (in.)

mm (in.)

O.D=Outer DiameterI.D=Inner DiameterCBS : Conventional Brake SystemAnti-lock Brake System(ABS)/ Electronic Stability Program(ESP)

mm(in.)teeth


Brake pedal stroke 128 (5.04)Adjust Brake pedal stroke 76.2 ± 2 (3.0 ± 0.08)

Brake pedal heightLHD 171 (6.73)RHD 189.2 (7.45)

HECU System 4 channel 4 sensor (Solenoid)Acitve wheel speed sensor

Air gap 0.4 ~ 1.5 (0.016 ~ 0.059)Tone wheel 48

Drum I.D. 186 (6.61)[NOTE]

Manufacturer and Name

Parking brakeType DIH(Drum in hat)Actuation Lever

Cylinder type Single pistonCylinder I.D 34 (1.34)


Disc O.D. 262 (10.31)Disc I.D. 185 (7.28)


MG-21


mm (in.)

mm (in.)

mm (in.)


Engine

Brake pedal member assembly bracket mounting nut (cowl side upper mounting)

16.7 ~ 25.5 (1.7 ~ 2.6)

Brake pedal mounting nut 24.5 ~ 34.3 (2.5 ~ 3.5)

Caliper mounting bolt 78.5 ~ 98.1 (8.0 ~ 10.0)Brake hose to front caliper 24.5 ~ 29.4 (2.5 ~ 3.0)

Brake tube nut, brake hose 13.7 ~ 16.6 (1.4 ~ 1.7)Caliper guide rod bolt 21.6 ~ 31.4 (2.2 ~ 3.2)

Brake booster mounting nut 12.7 ~ 15.7 (1.3 ~ 1.6)Bleeder screw 6.9 ~ 12.7 (0.7 ~ 1.3)

Tightening torque [N.m (kgf-m)]proportioning valve to master cylinder 34.3 ~ 53.9 (3.5 ~ 5.5)Master cylinder to booster mounting nut 7.9 ~ 11.8 (0.8 ~ 1.2)

Rear disc brake disc thickness 10 (0.39)Rear brake lining thickness 4.3 (0.17)

Front disc thickness 26 (1.02)Rear disc brake pad thickness 15 (0.59)

Booster push rod to master cylinder piston


8 clicke




0.5 ~ 1.0 (0.02 ~ 0.04)

Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)

MG-22


mm (in.)mm (in.)mm (in.)mm (in.)Rear window 3.5 (0.1378)

Seat beltsFront 3 point type with Emergency Locking Retractor (E.L.R)Rear 3 point type with Emergency Locking Retractor (E.L.R), 2pont type


Glass thickness

Windshield 5 (0.1969)Front door 4 (0.1575)Rear door glass 4 (0.1575)

Rear doorConstruction Front hinged, full door constructionRegulator system X-ARM typeLocking system Pin-fork system


Front doorConstruction Front hinged, full door constructionRegulator system X-ARM typeLocking system Pin-fork system

HECU bracket mounting nut 5.9 ~ 9.8 (0.6 ~ 1.0)Yaw rate ＆ Lateral G sensor mouning bolt 4.9 ~ 7.8 (0.5 ~ 0.8)

HECU mounting bracket bolt 16.7 ~ 25.5 (1.7 ~ 2.6)HECU union screw 11.8 ~ 15.7 (1.2 ~ 1.6)

Stop lamp switch mounting nut 7.9 ~ 9.8 (0.8 ~ 1.0)wheel speed sensor mounting bolt 6.9 ~ 10.8 (0.7 ~ 1.1)

MG-23

General specifications - Magentis/OptimaGSL θ 2.0 GSL θ 2.4 GSL μ 2.7 DSL D 2.0 VGTEngine

39.2~53.9 (4.0~5.5)Rear seat belt anchor 39.2~53.9 (4.0~5.5)Rear seat belt retractor 39.2~53.9 (4.0~5.5)

Seat belt

Front seat belt height 39.2~53.9 (4.0~5.5)Front seat belt buckle 39.2~53.9 (4.0~5.5)Front seat belt anchor 39.2~53.9 (4.0~5.5)Front seat belt lower 39.2~53.9 (4.0~5.5)Front seat belt upper

SeatFront seat mounting 34.3~53.9 (4.0~5.5)Front seat mounting nut 23.5~35.3 (2.4~3.6)Rear seat mounting 16.7~25.5 (1.7~2.6)


Checker to door 6.9~10.8 (0.7~1.1)Trunk lid Trunk lid latch 6.9~8.8 (0.7~0.9)



Door hinge to body 21.6~26.5 (2.2~2.7)Door hinge to door 21.6~26.5 (2.2~2.7)Striker 16.7~21.6 (1.7~2.2)Checker to body 16.7~21.6 (1.7~2.2)

MG-24

AM/FM/Cassette(M420/M440)


- -


FMAM

ItemsKeyless entry transmitter Power source

Transmitter(TX)Lithium 3V battery (1EA)

Transmissible distanceLife of battery

10m or more2 years or more (at 20 times per day)

Button

FMMWLW

Speaker impedance 4Ω x 4Antenna

External amp,woofer speaker

Tuning type

The others

Type

Power supplyRated output Max 43W x 4

87.5~108 MHz / 100KHz (General)


DC 14.4VMax 50W x 4

10Ω x 480PF 75Ω

PLL synthesized type


531 ~ 1602 KHz/9 KHz (General)87.5 ~ 108.0 MHz/50 KHz (Europe)

522 ~ 1620 KHz/9 KHz (Europe)153 ~ 279 KHz/1 KHz (Europe)


Transmission frequency3 (Door lock, Door unlock, Trunk lid open)

433.92 MHz

MG-25


Lighting systemWWWWWWWWWWWWWWWWWW

Other system

Engine

Rear parking assist system 3 channel

Door courtesy lamp55

ImmobilizerTypeManufacturer

SMARTRA systemBosch

High mounted stop lamp10 x 2

16Luggage lamp

Room lamp5

10Overhead console lamp

License plate lamp215

Side repeater

Rear turn signal lamp1621

Rear fog lamp - Europe

Rear tail lamp (Inner) - General21/5

8Back up lamp

Front fog lamp5

51Rear tail/stop lamp (Outside)

Front turn signal lampFront position lamp 5Side repeater lights

555521

Head lampHighLow

MG-26


oz.(g)




OFF : 3.0 ± 0.5 (37.4 ± 32.9)ON : 5.0 ± 0.5 (41 ± 32.9)

A/C ON/OFF ()


Heater


Actuator

Actuator

Blower Type SirocoSpeed step Auto + 8speed (Autometic) , 1~8 speed (Manual)Speed control Power mosfet (Autometic)



17.6 ± 0.88(500 ± 25)Capacity

APT(A/C pressure




180 cc/revCondeser Heat rejection 14800 - 5% Kcal/hr

Compressor

Type VSOil type & Capacity FD46XG (PAG) , 150 ± 10ccPulley type 6PK - TYPEDisplacement

Temperature operating method

MG-27

　Engine Mechanical System………………………GH-2　Engine Electrical System…………………………GH-9　Fuel System……………………………..…………GH-10　Automatic Transaxle………………………………GH-11　Driveshaft………………………………..…………GH-11　Suspension System…………………….…………GH-13　Steering System………………………………… GH-15　Brake System………………………………………GH-16　Body (Interior & Exterior)……………….……… GH-19　Body Electrical System……………………………GH-22　Heating, Ventilation & Air Conditioning..………GH-24

Opirus(GH)F/L

GH-1

General specifications - Opirus F/L

Engine

mm (in.)cc

rpmrpmrpmrpm


kPa(kg/cm²)

Engine GSL λ 3.8

Oil quantity

Oil pressure (Idle)


Compression ratio

Bore x StrokeTotal displacement

Neutral,N,P-D-range

Ignition Timing


Engine oil

Idle Speed

A/C OFF

Firing order

A/C ON

Neutral,N,P-D-range 650 ± 100

650 ± 100650 ± 100

Total

V-type, DOHC6

96 (3.7795) x 87.0 (3.425)3,778

10.4 : 11-2-3-4-5-6

BTDC 10˚± 5˚650 ± 100

6.0 (5.28)5.5 (4.84)0.4 (0.35)5.2 (4.58)

Above SJ or SL

130(1.32) [at 1000rpm, 110°C(230°F)]

Oil quality

GH-2


mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)

Intake

Opens (ATDC)Closes (ABDC)Opens (BBDC)

45.8 (1.8031)No.1 : 27.964 ~ 27.980 (1.1009 ~ 1.1016)

No.2,3,4 : 23.954 ~ 23.970 (0.9430 ~ 0.9437)No.1 : 0.020 ~ 0.057 (0.0008 ~ 0.0022)

No.2,3,4 : 0.030 ~ 0.067 (0.0012 ~ 0.0026)0.02 ~ 0.18 (0.0008 ~ 0.0071)

46.8 (1.8425)

Intake valve

Cam height



Exhaust valve Closes (ATDC)

Flatness of gasket surfaceIntake

Camshaft

Less than 0.1 (0.0039)Less than 0.1 (0.0039)Exhaust

Exhaust

End play


Valve timing10°62˚42˚6˚

Less than 0.05 (0.0019)Cylinder head

GH-3





mm (in.)mm (in.)

Engine GSL λ 3.8

Exhaust

IntakeExhaust

Intake

105.27 (4.1445)105.50 (4.1535)

Inner. diameter

Length

Intake

Face angle


Width of seat contact Intake

Exhaust


Valve seat

IntakeExhaust

1.73 ~ 2.03 (0.06811 ~ 0.07992)0.020~0.047 (0.00078 ~0.00185)

0.030 ~ 0.054 (0.00118 ~0.00212)

5.500 ~ 5.512 (0.2165 ~ 0.2170)Valve guide

5.465 ~ 5.480 (0.2151 ~ 0.2157)5.458 ~ 5.470 (0.2149 ~ 0.2153)

45.25° ~ 45.75°1.56 ~ 1.86 (0.06142 ~ 0.07323)

Exhaust

ValveIntake

Exhaust

IntakeExhaust

Stem outer diameter

Valve length

5.500 ~ 5.512 (0.2165 ~ 0.2170)41.8 ~ 42.2 (1.6457 ~ 1.6614)41.8 ~ 42.2 (1.6457 ~ 1.6614)

1.15 ~ 1.45 (0.05118~0.05709)1.35 ~ 1.65 (0.05315~0.06496)

44.75° ~ 45.20°Seat angle

GH-4

mm (in.)

mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

mm (in.)mm (in.)

mm (in.)mm (in.)

mm (in.)mm (in.)

Less than 0.05 (0.0019) [Less than 0.02 (0.0008) / 150x150]

95.96 ~ 95.99 (3.7779 ~ 3.7791)0.03 ~ 0.05 (0.0012 ~ 0.0020)

Piston

mm (in.)

IntakeExhaustIntake

MLA outer diameter

ExhaustMLA to tappet bore clearance

Cylinder head tappet bore inner diameter Exhaust

Intake

IntakeExhaust

Piston outer diameterPiston to cylinder clearance

Cylinder block


Load

Out of squareness Less than 1.5°

34.964 ~ 34.980 (1.3765 ~ 1.3772)MLA

43.86 (1.7267)Free lengthValve spring

19.3±0.8kg / 34.0(1.3386)42.3±1.3kg / 24.2 (0.9527)

34.964 ~ 34.980 (1.3765 ~ 1.3772)35.000 ~ 35.025 (1.3779 ~ 1.3789)35.000 ~ 35.025 (1.3779 ~ 1.3789)0.020 ~ 0.061 (0.0008 ~ 0.0024)0.020 ~ 0.061 (0.0008 ~ 0.0024)

0.17 ~ 0.23 (0.0067 ~ 0.0090)0.27 ~ 0.33 (0.0106 ~ 0.0129)

96.00 ~ 96.03 (3.7795 ~ 3.7807)

Valve clearance

Cylinder bore

GH-5

General specifications - Opirus F/Lmm (in.)mm (in.)mm (in.)



No. 2 ring grooveOil ring groove

Piston OSPiston ring

0.06 ~ 0.15 (0.0024 ~ 0.0059)

No. 2 ring groove1.22 ~ 1.24 (0.0480 ~ 0.0488)1.22 ~ 1.24 (0.0480 ~ 0.0488)

No. 1 ring grooveEngine GSL λ 3.8

No. 1 ring groove

Oil ring grooveRing groove width

No. 2 ring groove

Connecting rod small end inner diameterConnecting rod small end hole clearance

Piston pin hole inner diameterPiston pin hole clearance

Side clearanceNo. 1 ring groove

Oil ring grooveEnd gap

2.01 ~ 2.03 (0.0791 ~ 0.0799)-

0.03 ~ 0.07 (0.0012 ~ 0.0027)0.03 ~ 0.07 (0.0012 ~ 0.0027)

0.17 ~ 0.32 (0.0067 ~ 0.0126)0.32 ~ 0.47 (0.0126 ~ 0.0185)0.20 ~ 0.70 (0.0078 ~ 0.0275)

23.001 ~ 23.006 (0.9055 ~ 0.9057)23.016 ~ 23.021 (0.9061 ~ 0.9063)

Piston pin

0.01 ~ 0.02 (0.0039 ~ 0.0078)


22.974 ~ 22.985 (0.9045 ~ 0.9049)-0.032 ~ -0.016 (-0.0012~0.0006)

GH-6



kPa(kg/cm²)

ℓ(lmp.qt)°C (°F)°C (°F)

mm (in.)kPa

(kg/cm²)kPa

(kg/cm²)

0.022 ~ 0.040 (0.0008 ~ 0.0016)

Pull opening

0.98 ~ 4.90 (0.01 ~ 0.05)Radiator cap Vacuum valve

opening press.


Connecting rod big end inner diameterConnecting rod bearing oil clearance

Connecting rod


Oil pump

End play 0.1 ~ 0.25 (0.0039 ~ 0.0098)

68.942 ~ 68.960 (2.7142 ~ 2.7149)54.954 ~ 54.972 (2.1635 ~ 2.1642)Pin journal outer diameter


Main bearing oil clearanceEnd play

Crankshaft

Opening

Coolant quantity

Cooling method

ThermostatFull lift

58.000 ~ 58.018 (2.2834 ~2.2842)0.038 ~ 0.056 (0.0015 ~ 0.0022)

0.10 ~ 0.28 (0.0039 ~ 0.0110)

450 ~ 550 (4.59 ~ 5.61)


8.7 (7.66)

Cooling system

82 ± 2 (179.6 ± 35.6)95 (203)

10 (0.3937)

93.16 ~ 122.58 (0.95 ~ 1.25)

GH-7


kΩkΩ


29.40 ~ 31.36 (3.0 ~ 3.2)

Crankshaft main bearing cap

Cylinder head bolt Long boltsShort bolts

Inner bolt (M11)Out bolt (M8)Side bolt (M8)

Cylinder head


Type Thermister type2.31 ~ 2.59


Oil pan drain plugLower oil pan bolt

Engine GSL λ 3.8

19.60 (2.0) + 90˚ 49.00 (5.0) + 90˚

20°C (68°F)Resistance 0,322280°C (176°F)

19.60 (2.0) + 120˚

Main moving system

18.62 ~ 23.52 (1.9 ~ 2.4)

24.50 (2.5)Lubrication system


Oil filter cap

39.2 (4.0) + 120˚ + 90˚9.80 ~ 11.76 (1.0 ~ 1.2)

34.30 ~ 44.10 (3.5 ~ 4.5)9.80 ~ 11.76 (1.0 ~ 1.2)

GH-8


VA

Ω

kΩ

mm(in.)

Battery

Ignition coil

Spark plugs



Unleaded (NGK)

Reserve capacity

Unleaded (Gap)

Type


Rated voltage

Amperage

Cold cranking amparage at -18°C (-0 4°F)

Regulator setting

TypeRated voltage


Speed

Speed in useGeneratorIC regulator built-in type

14.2 ~ 14.8VCMF 80AH

630 A

130 min

1.280 ± 0.01

2,600 rpm, MINBattery voltage sensing

13.5V, 130A1,000 ~ 18,000 rpm

IFR5G-111.0 ~ 1.1 (0.0394 ~ 0.0433)

12 V, 1.2 kW11,5

Max. 85

0.62 ± 10 %

7.0 ± 15 %

GH-9



)

MPa(kgf/cm²

)kPa(kgf/cm²

)

Engine GSL λ 3.8

Fuel Tank Capacity 70 (61.59)Fuel Return System Type

Engine Management Manufacturer Delphi

Returnless type

Fuel Filter Type High pressure type Installation location Built in Fuel Pump assembly

Fuel Pump Type-


Driven by Electric motorFuel Pressure (Maximum) Pressure -


GH-10


ℓ(lmp.qt)

Driveshaft

Type

3,8402,0921,440

FGRATF qualityATF capacity

Gear ratio

1st2nd3rd4th5th

Rev.

10.9 (9.59)

Max. Permissible angle

Inner 26˚Outer 50˚

Joint type Inner AARiOuterDriveshaft

Front wheel bearing

Double row angular contact ball bearing

Dimension Inner 45 mm (1.77 in.)Outer 87 mm (3.43 in.)

UFi

Radial ball bearingCenter bearing Dimension Outer 62 mm (2.44 in.)

TypeInner 30 mm (1.18 in.)

A5HF1

1,0480,7283,8593,333

Diamond ATF SP III or SK ATF SP III

GH-11

General specifications - Opirus F/LEngine GSL λ 3.8Starting torque [N.m (kgf-m)]Front wheel bearing 28 (0.18 )[NOTE]Inner: On transaxle side UFi : Under Cut Free improved (GKN) Outer : On tire side AARi : Angular Adjusted Roller improved (GKN)Tightening torque [N.m (kgf-m)]Wheel nut 90 ~ 110 (9 ~ 11)Driveshaft castle nut 200 ~ 280 (20 ~ 28)Front upper arm to self locking nut 35 ~ 45 (3.5 ~ 4.5)Front subframe mounting bolt 140 ~ 160 (14 ~ 16)Front shock absorber lower mounting to bolt 60 ~ 80 (6 ~ 8)Front lower arm connector nut (to fork) 140 ~ 160 (14 ~ 16)Lower arm and ball joint 100 ~ 120 (10 ~ 12)Lower arm ball joint self locking nut 75 ~ 90 (7.5 ~ 9.0)Tie rod end self locking nut 24 ~ 34 (2.4 ~ 3.4)Stabilizer link self locking nut 100 ~ 120 (10 ~ 12)Stabilizer link mouning nut 45 ~ 55 (4.5 ~ 5.5)Hub assembly 60 ~ 70 (6 ~7)Wheel speed sensor 7 ~11 (0.7 ~ 1.1)Brake caliper to knuckle 80 ~ 100 (8 ~ 10)Rear brake disc 5 ~ 6 (0.5 ~ 0.6)Rear lower arm to knuckle 140 ~ 160 (14 ~ 16)Rear Brake caliper to knuckle bolt 50 ~ 60 (5 ~ 6)Rear upper arm to carrier self locking nut 80 ~ 90 (8 ~ 9)

GH-12

mm (in.)

Rear axle mounting bolt 60 ~ 70 (6 ~ 7)Inner shaft heat cover mounting bolt 9 ~ 14 (0.9 ~ 1.4)Inner shaft bearing bracket mounting bolt 50 ~ 65 (5 ~ 6.5)


Suspension type Double wishbone Multi linkShock absorber type Gas pressurized


-6.5J × 17"


235/55 R172.1kgf/cm2, (30psi)

Caster 4°32'±45' -Toe-in 0±2 (0±0.079) 2±2 (0.079±0.079)King-pin 9°43' -


Wheel alignment

Camber -30'±30' -1°±30'

Hub nuts 90 ~ 110 (9.0 ~ 11.0)Front strut assembly to wheel housing panel 45 ~ 60 (4.5 ~ 6.0)Mounting fork to lower arm 140 ~ 160 (14.0 ~ 16.0)Front strut assembly to mounting fork 60 ~ 80 (6.0 ~ 8.0)Front stabilizer link to strut assembly 100 ~ 120 (10.0 ~ 12.0)Front strut assembly self-locking nut 20 ~ 25 (2.0 ~ 2.5)Front lower arm to knuckle 100 ~ 120 (10.0 ~ 12.0)Front lower arm to sub frame 140 ~ 160 (14.0 ~ 16.0)Front upper arm to body 55 ~ 65 (5.5 ~ 6.5)Front upper arm to knuckle 35 ~ 45 (3.5 ~ 4.5)

GH-13

General specifications - Opirus F/LEngine GSL λ 3.8Front stabilizer link to stabilizer bar 100 ~ 120 (10.0 ~ 12.0)Front stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)Rear shock absorber to wheel housing panel 50 ~ 65 (5.0 ~ 6.5)Rear shock absorber to carrier 140 ~ 160 (14.0 ~ 16.0)Rear shock absorber self-locking nut 20 ~ 25 (2.0 ~ 2.5)Rear upper arm to carrier 80 ~ 90 (8.0 ~ 9.0)Rear upper arm to cross member 100 ~ 120 (10.0 ~ 12.0)Rear lower arm to carrier 140 ~ 160 (14.0 ~ 16.0)Rear lower arm to cross member 100 ~ 120 (10.0 ~ 12.0)Assist arm to carrier 140 ~ 160 (14.0 ~ 16.0)Assist arm to cross member 100 ~ 120 (10.0 ~ 12.0)Trailing arm to carrier 140 ~ 160 (14.0 ~ 16.0)Trailing arm to body 140 ~ 160 (14.0 ~ 16.0)Rear stabilizer link to carrier 35 ~ 45 (3.5 ~ 4.5)Rear stabilizer link to stabilizer bar 35 ~ 45 (3.5 ~ 4.5)Rear stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)Rear cross member mounting bolts 140 ~ 160 (14.0 ~ 16.0)

GH-14

Type

mm (in.)

kPa(kgf/cm²

)


Power steering fluid PSF-4Rack stroke 144 (5.67)



Tightening Torque [N.m(kgf-m)]Steering wheel lock nut 40 ~ 50 (4.0 ~ 5.0)Steering column mounting bolt & nut 13 ~ 18 (1.3 ~ 1.8)Bolt connecting steering column to universal joint 15 ~ 20 (1.5 ~ 2.0)Bolt connecting universal joint to steering gear 30 ~ 35 (3.0 ~ 3.5)Tie rod end to knuckle 24 ~ 34 (2.4 ~ 3.4)Steering gear box to sub frame 60 ~ 80 (6.0 ~ 8.0)Pressure hose to power steering pump 55 ~ 65 (5.5 ~ 6.5)Power steering pump mounting bolts 35 ~ 55 (3.5 ~ 5.5)

GH-15


Brake System

mm (in.)mm (in.)


mm (in.)

Engine GSL λ 3.8


Master cylinderType Tandem typeI.D. 25.4 (1.0)Piston stroke 30 ~ 32 (1.18 ~ 1.26)Fluid level warning sensor ProvidedBrake boosterType vacuumBoosting ratio 9 : 1Front brake(Disc)Type Floating type with ventilated discDisc O.D. 303 (11.93)Disc thickness 28 (1.10)Pad thickness 11 (0.43)Cylinder type Single pistonCylinder I.D. 60 (2.36)

GH-16


mm (in.)

mm (in.)O.D=Outer DiameterI.D=Inner DiameterAnti-lock Brake System(ABS)/ Electronic Stability Program(ESP)

teeth


mm (in.)

Tone wheel

Adjust Brake pedal full stroke

Rear brake(Disc)Type Floating type with solid discDisc O.D. 284 (11.18)Disc thickness 10 (0.39)Pad thickness 10 (0.39)Cylinder type Single pistonCylinder I.D 34 (1.34)Parking brakeType Mechanical brake acting on rear wheelsActuation Foot TypeDrum I.D. 190 (7.48)


47

Brake pedal height 193.5 (7.62 )Brake pedal full stroke 126.7± 3 (4.99 ± 0.12)


63.6 ± 2 (2.50 ± 0.08)Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)Stop lamp switch outer case to pedal stopper clearance

1.2 ~ 1.8 (0.05 ~ 0.07)

GH-17


mm (in.)

mm (in.)



Front disc brake pad thickness

Rear disc brake disc thickness

Master cylinder to booster mounting nut

Brake tube nut, brake hose

Caliper guide rod bolt

Brake pedal mounting nut

0 (at 500 mmHg)

Engine GSL λ 3.8

Parking brake pedal stroke when stroke assembly is pushed with 196N (20kgf, 44lb force)

88 ~ 98 (3.46 ~ 3.86)

11 (0.43)Front disc thickness 28 (1.10)Rear disc brake pad thickness 10 (0.39)

10 (0.39)Rear parking brake liner thickness 4.3 (0.17)Tightening torque [N.m (kgf-m)]

8 ~ 12 (0.8 ~ 1.2)Brake booster mounting nut 13 ~ 16 (1.3 ~ 1.6)Bleeder screw 7 ~ 13 (0.7 ~ 1.3)

13 ~ 17 (1.3 ~ 1.7)Caliper assembly to knuckle 80 ~ 100 (8 ~ 10)Brake hose to front caliper 25 ~ 30 (2.5 ~ 3.0)

22 ~ 32 (2.2 ~ 3.2)Stop lamp switch mounting nut 8 ~ 10 (0.8 ~ 1.0)Brake pedal assembly bracket mounting nut 13 ~ 16 (1.3 ~ 1.6)

25 ~ 35 (2.5 ~ 3.5)Active wheel speed sensor mounting bolt on the brake plate

8 ~ 10 (0.8 ~ 1.0)

HECU mounting bolt 8 ~ 10 (0.8 ~ 1.0)

GH-18



HECU mounting bracket bolt 17 ~ 26 (1.7 ~ 2.6)HECU port 12.2 ~ 16.3 (1.22 ~ 1.63)Yaw rate ＆ lateral acceleration sensor bolt 8 ~ 10 (0.8 ~ 1.0)Master cylinder pressure sensor 26 ~ 30 (2.6 ~ 3.0)



Rear doorConstruction Front hinged, full door constructionRegulator system X-ARM typeLocking system Pin-fork system


Glass thickness

Windshield 5 (0.1969)Front door 5 (0.1969)Rear door glass 5 (0.1969)Rear door fixed 4 (0.1575)Rear window 3.5 (0.1378)

Seat belts Front 3 point type with Emergency Locking Retractor (E.L.R)

GH-19


Tightening Torque [N.m(Kgf-m)]Engine GSL λ 3.8

Front fender

Mounting bolts 7~9 (0.7~0.9)Hinge bolts(Body side) 22~27 (2.2~2.7)Hinge nuts(Body side) 22~27 (2.2~2.7)Hinge bolts(Hood side) 22~27 (2.2~2.7)Lifter bracket bolts(Body side)

22~27 (2.2~2.7)

Lifter stud ball(Hood side 22~27 (2.2~2.7)Safety hook & Release lever bolts

7~11 (0.7~1.1)

Safety hook catch bolts 7~11 (0.7~1.1)Hood latch bolts 7~11 (0.7~1.1)


Hinge bolts(Body side) 35~42 (3.5~4.2)Hinge bolts(Door side) 10~20 (1.0~2.0)Checker bolts(Body 17~22 (1.7~2.2)Checker nuts(Door side) 7~11 (0.7~1.1)Door module bolts 7~11 (0.7~1.1)Door module nuts 7~11 (0.7~1.1)Glass bolts 8~12 (0.8~1.2)Glass grip bolts 8~12 (0.8~1.2)Outer handle bolts 7~11 (0.7~1.1)Latch screws 7~11 (0.7~1.1)Striker screws 7~22 (0.7~2.2)Glass guide bolt 7~11 (0.7~1.1)

GH-20

Trunk lid

Hinge bolts(Body side) 22~27 (2.2~2.7)Latch bolts 7~11 (0.7~1.1)Striker bolts 7~11 (0.7~1.1)Outer handle bolts 7~11 (0.7~1.1)Hinge bolts(Trunk lid side 22~27 (2.2~2.7)

Outside rearview mirror Mounting bolts 7~11 (0.7~1.1)Crash pad Mounting bolts 7~11 (0.7~1.1)

Cowl cross barMounting bolts- 33~55 (3.3~5.5)Mounting bolts-Lower(M8)

17~26 (1.7~2.6)

Front bumper Reinforcement nuts 9~14 (0.9~1.4)Rear bumper Mounting bolts 35~55 (3.5~5.5)

Front seatMounting nuts 45~55 (4.5~5.5)Front seat mounting 45~55 (4.5~5.5)

Rear seat

Cushion bolts(Power seat)

17~26 (1.7~2.6)

Seatback bolts 17~26 (1.7~2.6)Frame bolts(Power 17~26 (1.7~2.6)Frame nuts(Power seat) 17~26 (1.7~2.6)

Sunroof Glass mounting screws 2~4 (0.2~0.4)Mounting bolts and nut 7~9 (0.7~0.9)

Seat beltUpper anchor bolt 40~55 (4.0~5.5)Lower anchor bolt 40~55 (4.0~5.5)

GH-21




Lighting systemWWW

Engine GSL λ 3.8

TypePower supplyRated output

DC 14.4VH285 H295

Max 20W x 4 Max 35W x 6

80PF 75ΩPLL synthesized type

4Ω x 4 2Ω x 6

LW

Speaker impedanceAntennaTuning type


153 ~ 279 KHz/1 KHz (Europe)



FMAMFMMW



Head lampHighLow

ButtonTransmission frequency


5535

14.5 (LED) / 5 (BULB)

87.5~108 MHz / 100KHz (General)531 ~ 1602 KHz/9 KHz (General)

87.5 ~ 108.0 MHz/50 KHz (Europe)531 ~ 1602 KHz/9 KHz (Europe)

3 (Door lock, Door unlock, Trunk lid open)433.92 MHz

GH-22

WWWWWWWWWWWWW

Other system

Front fog lampRear stop/tail lamp (Outside)

Front position lamp

Back up lampRear turn signal lamp

1828

Rear fog lampLicense plate lamp

55

Side repeaterRoom lamp

510

Overhead console lampHigh mounted stop lamp

52.5 (LED)


Glove box lampTrunk lamp

Smart keyTypeManufacturer

Touch sensor type (Front door)SIEMENS

Rear parking assist system Front 4 channel/ Rear 4 channel

SMARTRA systemBosch

555

27/8

55

GH-23



oz.(g)

Engine GSL λ 3.8

Compressor

Type VS16Oil type & Capacity FD46XG (PAG) , 150 ± 10ccPulley type 6PK - TYPEDisplacement 180 cc/rev

Condeser Heat rejection 15,000 - 5% Kcal/hrAPT(A/C pressure





22.9 ± 0.88 (650 ± 25)Capacity Blower unitFresh and recirculation Operating method Actuator

Blower Type Siroco fanSpeed step Auto + 8 speed (Autometic)Speed control Power mosfet


GH-24


Mode operating methodHeater


ActuatorActuatorTemperature operating

Evaporator

Type Laminated typeTemperature control type Evaporator sensor

OFF : 0.5 ± 0.5 (32.9 ± 32.9)ON : 3.0 ± 0.5 (37.4 ± 32.9)


GH-25

　Engine Mechanical System………………………AM-2　Engine Electrical System…………………………AM-9　Fuel System……………………………..…………AM-10　Clutch…………………………………….…………AM-10　Manual Transaxle……………………….…………AM-11　Automatic Transaxle………………………………AM-11　Driveshaft………………………………..…………AM-12　Suspension System…………………….…………AM-13　Steering System………………………………… AM-15　Restraints…………………………………………AM-16　Brake System………………………………………AM-17　Body (Interior & Exterior)……………….……… AM-21　Body Electrical System……………………………AM-22　Heating, Ventilation & Air Conditioning..………AM-26

Soul (AM)

AM-1

General specifications - SOULGSL γ 1.6 GSL β 2.0 DSL U 1.6

EngineIn-line, DOHC In-line, DOHC In-line, DOHC

4 4 4

mm (in.) 77 (3.0315)x 85.44 (3.3638)

82mm (3.228in)x 93.5mm (3.681in)

77.2 (3.0394)x 84.5 (3.3268)

cc 1.591 1975cc (120.52cu.in) 1.58210.5:1 10.1 : 1 17.3 : 11-3-4-2 1-3-4-2 1-3-4-2

BTDC 6˚ ± 10˚ BTDC 5° ± 10° -rpm 660 ± 100 660 ± 100 rpm 850 ± 100(830± 100 MT)rpm 660 ± 100 660 ± 100 rpm 850 ± 100rpm 660 ± 100 660 ± 100 rpm 850 ± 100(830± 100 MT)rpm 690 ± 100 660 ± 100 rpm 850 ± 100

ℓ (lmp.qt) 3.7 (3.26) 4.1 (3.60 ) 5.7 (5.02)ℓ (lmp.qt) 3.0 (2.64) 3.7 (3.26 ) 4.8 (4.22 )ℓ (lmp.qt) 3.3 (2.90) 4.0 (3.52) 5.3 (4.66)

API SL, SM or aboveILSAC GF3, GF4 or above

API SL, SM or aboveILSAC GF3, GF4 or above

With CPF: ACEA C3Without CPF: ACEA B4

kPa(kg/cm²)

107kPa (1.1kg/cm², 15.6psi)

or above

100kPa (1.0kg/cm², 14.5psi)/at 800rpm

78.45kPa (0.8kg/cm², 11.38psi)

or above

ATDC 10°/BTDC 40° ATDC 11° ~ BTDC 29° 17°5' ± 4°ABDC 63°/ABDC 13° ABDC 59° ~ ABDC 19° 14°6' ± 4°

BBDC 40° Opens (BBDC) 23°25' ± 4°ATDC 3° Closes (ATDC) 20° ± 4°

Ignition Timing

Engine


Compression ratio

Bore x Stroke

Total displacement


D-rangeEngine oil

Oil pressure


Drain and refill

Oil quality

Oil quantity

D-rangeNeutral,N,P-range

Intake valve

Exhaust valve

Idle Speed

Total

Valve timing

Oil pan

Firing order

A/C OFF

A/C ON

Neutral,N,P-range

AM-2

mm (in.) Less than 0.05 (0.0020)Max:0.03mm

(0.0012in)Limit:0.06mm(0.0024in)

0.05 (0.0020in) for all 0.03 (0.0012in) for each cylinder

mm (in.) - 0.025 (0.0010) for width0.160 (0.0063) for length

mm (in.) - 0.025 (0.0010) for width0.160 (0.0063) for length

mm (in.) 43.85 (1.7264) 44.618mm (1.7566in) Limit:44.518mm(1.7527in)

LH : 35.452 ~ 35.652(1.3957 ~ 1.4036)

RH : 35.537 ~ 35.737(1.3991 ~ 1.4070)

mm (in.) 42.85 (1.6870) 44.518mm (1.7527in) Limit:44.418mm (1.7487in)

LH : 35.700 ~ 35.900 (1.4055 ~ 1.4134)

RH : 35.452 ~ 35.652(1.3957 ~ 1.4036)

mm (in.) 22.964 ~ 22.980 (0.9041 ~ 0.9047) 28 (1.1023) 20.944 ~ 20.960

(0.8246 ~ 0.8252)

mm (in.) 0.027 ~ 0.058(0.0011 ~ 0.0023)

.027 ~ 0.061mm (0.0011 ~ 0.0024in)

0.040 ~ 0.077 (0.0016 ~ 0.0030)

mm (in.) 0.10 ~ 0.20 (0.0039 ~ 0.0079)

0.1 ~ 0.2 (0.0040 ~ 0.0079)

0.10 ~ 0.20 (0.0039-0.0079)

Exhaust


Intake


Camshaft

Cam height

Max:0.15mm (0.0059in)Limit:0.03mm(0.0

012in)


Exhaust

Intake


End play

Cylinder head

AM-3


mm (in.) 93.15 (3.6673) 114.34 (4.5016) 93.0 (3.6614)mm (in.) 92.6 (3.6457) 116.8 (4.598) 93.7 (3.6890)

mm (in.) 5.465 ~ 5.480 (0.2152 ~ 0.2157)

5.965 ~ 5.98 (0.2348 ~ 0.2354)

5.455 ~ 5.470 (0.2148 ~ 0.2154)

mm (in.) 5.458 ~ 5.470 (0.2149 ~ 0.2154)

5.950 ~ 5.965(0.2343 ~ 0.2348)

5.435 ~ 5.450(0.2140 ~ 0.2146)

45.25° ~ 45.75° 45° ~ 45°30' 45.5° ~ 45.75°

mm (in.) 1.1 (0.0433) 1.6±0.15(0.0630±0.0059) 1.1 (0.0433)

mm (in.) 1.26 (0.0496) 1.8±0.15(0.0709±0.0059) 1.2 (0.0472)

mm (in.) 0.020 ~ 0.047 (0.0008 ~ 0.0019)

0.02 ~ 0.05 (0.0008 ~ 0.0019)

0.030 ~ 0.057 (0.0012 ~ 0.0022)

mm (in.) 0.030 ~ 0.054 (0.0012 ~ 0.0021)

0.035 ~ 0.065 (0.0014 ~ 0.0026)

0.050 ~ 0.077 (0.0020 ~ 0.0030)

mm (in.) - - 5.500 ~ 5.512 (0.2165 ~ 0.2170)

mm (in.) - - 5.500 ~ 5.512 (0.2165 ~ 0.2170)

mm (in.) 40.3 ~ 40.7 (1.5866 ~ 1.6024)

45.8~46.2mm (1.8031~1.8189in)

31.3 ~ 31.7 (1.2323 ~ 1.2480)

mm (in.) 40.3 ~ 40.7(1.5866 ~ 1.6024)

52.8~53.2mm (2.0787~2.0945in)

31.3 ~ 31.7 (1.2323 ~ 1.2480)

Stem outer diameter

Thickness of valve head (margine)

Face angle

Intake

Exhaust

Intake

Exhaust

Valve guide

Length

Intake

Intake

Inner diameter

Valve stem to valve guide clearanceExhaust

Exhaust

Intake

Exhaust

ValveIntakeValve length

Exhaust

Engine

AM-4

mm (in.) 1.1 ~ 1.5 (0.043 ~ 0.059) 0.8 ~ 1.4(0.0315~0.0551)

mm (in.) - 1.3 ~ 1.7 (0.051 ~ 0.066) 1.2 ~ 1.8(0.0472~0.0709)

- - 45° ~ 45°30'

mm (in.) 44.0mm (1.7323) 48.86mm (1.9236) 44.9mm (1.7677)

mm (in.) -18.8±0.9kg/39.0(41.4±2.0lb/1.5

354in)41.0±1.5kg/30.5(90.4±3.3lb/1.2

008in)

17.5±0.9kg/32.0(1.2598)31.0±1.6kg/23.5(0.9252)

Less than 1.5° 1.5° or less Less than 1.5°

mm (in.) - 0.20 (0.0079) -mm (in.) - 0.29 (0.0114) -mm (in.) - 0.28 (0.0110) -mm (in.) - 0.34 (0.0134) -

mm (in.) 77.00 ~ 77.03 (3.0315 ~ 3.0327)

82.00 ~ 82.03(3.2283 ~ 3.2295)

77.200 ~ 77.230(3.0394 ~ 3.0405)

mm (in.) Less than 0.05 (0.0020) - Less than 0.05 (0.0020)

mm (in.) 76.97 ~ 77.00 (3.0303 ~ 3.0315)

81.97 ~ 82.00 (3.2271 ~ 3.2283)

77.130 ~ 77.160 (3.0366 ~ 3.0378)

mm (in.) 0.020 ~ 0.040 (0.0008 ~ 0.0016)

0.02 ~ 0.04 (0.0008 ~ 0.0016)

0.060 ~ 0.080 (0.0024 ~ 0.0031)

mm (in.) 1.22 ~ 1.24 (0.0480 ~ 0.0488) 1.23 ~ 1.25mm 1.83 ~ 1.85

(0.0720 ~ 0.0728)

mm (in.) 1.22 ~ 1.24 (0.0480 ~ 0.0488) 1.22 ~ 1.24mm 1.82 ~ 1.84

(0.0717 ~ 0.0724)

mm (in.) 2.01 ~ 2.03 (0.0791 ~ 0.0799) 2.01 ~ 2.03mm 3.02 ~ 3.04

(0.1189 ~ 0.1197)

- 0.25, 0.50mm (0.010, 0.020in) -

20°C[68°F]



Piston

No. 2 ring groov

Oil ring groove

Exhaust

No. 1 ring groov

Cylinder block


Cylinder bore

Valve seat


20°C[68°F]

Free lengthValve spring

Intake

80°C[176°F]

Valve clearance

Load

Exhaust

Piston OS

80°C[176°F]Intake

Out of squareness

Seat angle

Ring groove width

AM-5


mm (in.) 0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.04 ~ 0.08 (0.0015 ~ 0.0031)

0.09 ~ 0.13 (0.0035 ~ 0.0051)

mm (in.) 0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.03 ~ 0.07 (0.0012 ~ 0.0027)

0.08 ~ 0.12 (0.0031 ~ 0.0047)

mm (in.) 0.06 ~ 0.15 (0.0024 ~ 0.0059) - 0.03 ~ 0.07

(0.0012 ~ 0.0028)

mm (in.) 0.14 ~ 0.28 (0.0055 ~ 0.0110)

0.20 ~ 0.35 (0.0079 ~ 0.0138)

0.20 ~ 0.35 (0.0079 ~ 0.0138)

mm (in.) 0.30 ~ 0.45 (0.0118 ~ 0.0177)

0.37 ~ 0.52 (0.0146 ~ 0.0205)

0.35 ~ 0.50 (0.0138 ~ 0.0197)

mm (in.) 0.20 ~ 0.70 (0.0079 ~ 0.0276)

Unleaded : 0.20 ~ 0.70mm (0.0079 ~ 0.0276in)

Leaded : 0.20 ~ 0.60mm (0.0079 ~ 0.0236in)

0.20 ~ 0.40 (0.0079 ~ 0.0157)

mm (in.) 18.001 ~ 18.006 (0.7087 ~ 0.7089)

20.001 ~ 20.006 (0.7874 ~ 0.7876)

27.995 ~ 28.000 (1.1022 ~ 1.1024)

mm (in.) 18.016 ~ 18.021 (0.7093 ~ 0.7095)

20.016 ~ 20.021 (0.7880 ~ 0.7882)

28.004 ~ 28.010 (1.1025 ~ 1.1028)


Oil ring groove

No. 1 ring groov

No. 2 ring groov

Piston pin


Oil ring groove

Piston ring

End gap

No. 1 ring groov

No. 2 ring groov

Side clearance

Engine

AM-6

mm (in.) 0.010 ~ 0.020 (0.0004 ~ 0.0008)

0.010 ~ 0.020 (0.0004 ~ 0.0008)

0.004 ~ 0.015 (0.0002 ~ 0.0006)

mm (in.) 17.974 ~ 17.985 (0.7076 ~ 0.7081)

19.974 ~ 19.985 (0.7864 ~ 0.7868)

28.022 ~ 28.034 (1.1032 ~ 1.1037)

mm (in.) - - 0.022 ~ 0.039 (0.0009 ~ 0.0015)

mm (in.) 45.000 ~ 45.018 (1.7717 ~ 1.7724) 48.000 ~ 48.018mm 49.000 ~ 49.018

(1.9291 ~ 1.9298)

mm (in.) 0.018 ~ 0.036 (0.0007 ~ 0.0014)

0.024 ~ 0.042 (0.0009 ~ 0.0017)

0.025 ~ 0.043 (0.0010 ~ 0.0017)

mm (in.) 0.10 ~ 0.25 (0.0039 ~ 0.0098) 0.10 ~ 0.25mm 0.050 ~ 0.032

(0.0020 ~ 0.0119)

mm (in.) - 56.942 ~ 56.962 (2.2418 ~ 2.2426)

53.972 ~ 53.990 (2.1249 ~ 2.1256)

mm (in.) - 44.946 ~ 44.966 (1.7695 ~ 1.7703)

45.997 ~ 46.015 (1.8109 ~ 1.8116)

mm (in.) 0.006 ~ 0.024 (0.0002 ~ 0.0009)

0.028 ~ 0.046mm (0.0011 ~ 0.0018in)

0.024 ~ 0.042 (0.0009 ~ 0.0017)

mm (in.) 0.05 ~ 0.25 (0.0020 ~ 0.0098)

0.06 ~ 0.260 (0.0023 ~ 0.010)

0.08 ~ 0.28 (0.0031 ~ 0.0110)

mm (in.) - 0.1 (0.0039) 0.1 (0.0039)

kPa(kg/cm²) - - 490±49.0 (5±0.5)





Connecting rod


Side clearance

End play

Flywheel



Oil pumpRunout


Crankshaft


AM-7


Forced circulation with water pump



ℓ(lmp.qt)

6.5(5.71) 7.2liter (7.6U.S qts, 6.3lmp.qts) 7.2 (6.33)

°C (°F) 82 ± 1.5 (179.6 ± 2.7) 82°C (177°F) 85 ± 1.5 (185.0 ± 2.7)°C (°F) 95 (203) 95°C (201°F) 100 (212)

kPa(kg/cm²)

93.16 ~ 122.58(0.95 ~ 1.25)

93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51 ~

17.78psi)

93.16 ~ 122.58 (0.95 ~ 1.25)

kPa(kg/cm²) MAX. 6.86 (0.07) MAX. 6.86 (0.07) MAX. 6.86 (0.07)

Thermister type Heat-sensitive thermistor type Thermister type

kΩ 2.45 ± 0.14 2.31 ~ 2.59kΩ 2.45 ± 0.14 kΩ 0,3222 0.3222kΩ 0,3222


17.7~21.6+ 90˚±2˚ (1.8~2.2+90˚±2˚) 49.0 ~ 52.0 (5.0 ~ 5.3) 12.7 (1.3) + 90°

19.6+90˚(2.0+90˚) 27.5~31.4 (2.8~3.2) + 60°~64° -

- - (22.6~26.5) + (90~94°)- - 32.4 ~ 36.3 (3.3 ~ 3.7)

11.8 ~ 13.7(1.2 ~ 1.4) 13.7 ~ 14.7 (1.4 ~ 1.5)18.6 ~ 22.6(1.9 ~ 2.3)

Cylinder headM6Camshaft bearing

cap nuts or bolts M8mark 9/10 : 12.7 ~ 14.7

(1.3 ~ 1.5)

80°C (176°F)Resistance


Bolts



Main moving system

20°C (68°F)

Radiator cap

Pull opening Thermostat

Coolant quantity

Cooling method

Cooling system


Type



Opening

Engine

AM-8

M12:27.5 ~ 31.4 (2.8 ~ 3.2)+ 60°~ 65° + 60°~ 65°

M10:22.6~26.5 (2.3 ~ 2.7)+ 60°~ 65° + 60° ~ 65°

11.8 ~ 15.7 (1.2 ~ 1.6) 11.8 ~ 15.7 (1.2 ~ 1.6) Oil filter upper cap : 25(2.5)

9.8 ~ 11.8 (1.0 ~ 1.2) 9.8 ~ 11.8 (1.0 ~ 1.2) 9.8 ~ 11.8 (1.0 ~ 1.2) 34.3 ~ 44.1 (3.5 ~ 4.5) 39.2 ~ 44.1(4.0 ~ 4.5) 34.3 ~ 44.1 (3.5 ~ 4.5)

Engine Electrical System12.V, 0.9 kW 12 V, 1.2 Kw 12 V, 1.7 kW

V 11,5 11 11A 60 MAX 90 MAX 90 MAX

5.500 rpm, MIN 2,800 rpm, MIN 2,600 rpm, MINBattery voltage sensing -

13.5 V, 90A 13.5 V, 90A 12 V, 120A1,000 ~ 18,000 rpm 1,000 ~ 18,000 rpm 1,000 ~ 18,000 rpm

IC Regulator built-in type - IC Regulator built-in type14.55 ± 0.2 V 14.55 ± 0.2 V 14.55 ± 0.2 V

36-20GL 48-23GL 56-26 FL

410 A 550 A 600 A

80 min 92 min 113 min

1.280 ± 0.01(at 20(68)) 1.280 ± 0.01(at 20°C(68°F))

1.280 ± 0.01(at 20(68))

Ω 0.7 ± 15 % 0.58 ± 10 % -kΩ - 8.8 ± 15 % -

RER8MC BKR5ES-11, RC10YC4 -

mm(in.) 1.0 ~ 1.1(0.0394 ~ 0.0433) 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.) -

Oil filter

Voltage

Reserve capacity


Oil pan bolts

Lubrication system

Ignition coil

Battery

Specific gravity

Spark plugs

Primary Secondary

Unleaded (Gap)

Unleaded (NGK)

(47.1~51.0) + (88~92°) + (118~122°)Cylinder head bolt

Long bolts

Short bolts

Starter No-load charasteristics

Oil pan drain plug

SpeedAmperage

TypeRated voltage


Rated voltage

17.7 ~ 21.6 (1.8 ~ 2.2)+ 90 ~ 95˚ + 100 ~105˚

Generator

Regulator setting

AM-9


Fuel SystemBosch Siemens Bosch

ℓ(lmp.qt) 48(42) 48(42)Returnless type Return type

Paper type High pressure type Built in Fuel Pump

assembly Built in engine room

Type Mechanical,Plunger Pumping

Driven by Timing chain

Type Electrical,in tank Mechanical,Gear pumping

Driven by Electrical motor Involved in High Pressure

Fuel PumpMPa

(kgf/cm²) 1600 bar

KPa(kgf/cm²) 333 ~ 345 (3.4 ~ 3.5) -


Fuel Return System Type

Engine Management System ManufacturerFuel Tank Capacity

Fuel Pump

Fuel FilterType

Installation location

Type

HI

LOW




Engine

AM-10

Clutch cover assembly 15~22 (1.5~2.2) 15~22 (1.5~2.2) 12~15 (1.2~1.5)Clutch pedal bracket 17~26 (1.7~2.6) 25~35 (2.5~3.5) 17~26 (1.7~2.6)Clutch pedal support member to master cylinder 17 ~26(1.7~2.6) 17 ~26(1.7~2.6) 17 ~26(1.7~2.6)Clutch release cylinder 15~22 (1.5~2.2) 15~22 (1.5~2.2) 15~22 (1.5~2.2)Service standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)

Manual TransaxleType M5CF1-1 M5CF2 M5CF3

3,615 3,308 3,6361,962 1,962 1,9621,286 1,257 1,1890,971 0,976 0,8440,839 0,778 0,6603,545 3,583 3,583

4,267 4,188 3,941

MT oil capacity ℓ(lmp.qt) 1.90 (1.67) 2.0ℓ(1.76lmp qt) 2.0 (1.76)

Automatic TransaxleType A4CF1 A4CF2 A4CF2

2,919 2,919 2,9191,551 1,551 1,5511,000 1 1,0000,713 0,713 0,7132,480 2,48 2,4804,619 4,375 3,849

ℓ(lmp.qt) 6.8(5.98) 6.6 (5.81) 6.6 (5.81)

168.7 (6.64)6~13 (0.24~0.51)

Rev.FGR

1st2nd3rd4th5thRev.


SAE 75W/85, API GL-4,TGO-7(MS517-14)

Gear ratio

1st2nd3rd4th

FGR

ATF quality

Gear ratio

Diamond ATF SP III or SK ATF SP IIIATF capacity

M/T oil quality

AM-11


DriveshaftTJ TJ TJBJ BJ BJTJ TJ TJBJ BJ BJ

Nm Kgf.m lb-ft

90 ~ 110 9.0 ~ 11.0 65 ~ 80240.2 ~ 269.6 24.5 ~27.5 177.2 ~ 198.9

100 ~ 120 10.0 ~12.0 72 ~ 8760 ~ 72 6.0 ~ 7.2 43 ~ 5216 ~ 34 1.6 ~ 3.4 12 ~ 2565 ~ 75 6.5 ~ 7.5 47 ~ 5465 ~ 75 6.5 ~ 7.5 47 ~ 5470 ~ 90 7.0 ~ 9.0 51 ~ 65

Joint typeM/T

InnerOuter

A/TInnerOuter

Rear carrier to torsion axle

Max. permissible angleInner 21˚ Outer 43˚

[NOTE]BJ : Birfield Joint

Front caliper to knuckleRear caliper to carrier

TJ : Tripod JointUTJ-ll : U Type-ll Tri-pod JointTightening torque [N.m (kgf-m)]

Hub nutsDriveshaft lock nutStrut assembly to knuckleLower arm to knuckleTie rod end castle nut

Item

Engine

AM-12

Front Suspension

Rear Suspension

Wheel & Tire

General specifications - SOUL

205/55 R16

225/45 R18

Suspension System

6.5J x 16

7.0J x 18

6.0J x 15

195/65 R15

Tire

Tire pressure 2.3kg/cm² (33psi)

268.0mm (Red – 1)

Suspension type

WheelAluminum

Steel

Shock absorber

Coil spring

Type

Free Height [I.D. color]

Torsion Beam Axle

Gas

301.3mm (Blue - 1)

303.5mm (Yellow - 1)

MacPherson Strut

Gas

313.5mm (Yellow – Yellow)Free Height [I.D. color]

Type

290.3mm (Yellow – White)

Suspension type

Coil spring

Shock absorber

AM-13

GSL γ 1.6 GSL β 2.0 DSL U 1.6

Wheel Alignment

195/65 R15 205/55 R16 225/45 R18

-2.0 ± 2.0mm -2.0 ± 2.0mm -2.0 ± 2.0mm

-0°30' ± 30' -0°30' ± 30' -0°30' ± 30'

3°24' ± 30' 3°24' ± 30' 3°24' ± 30'

14°32' ± 30' 14°32' ± 30' 14°32' ± 30'

4.0 ± 2.0mm 4.0 ± 2.0mm 4.0 ± 2.0mm

-1°30' ± 30' -1°30' ± 30' -1°30' ± 30'

Tightening TorquesNm Kgf.m lb-ft

90 ~ 110 9 ~ 11 65 ~ 80160 ~ 180 /100 ~ 120 16 ~ 18 /10 ~ 12 115 ~ 130 /72 ~ 87

24 ~ 34 2.4 ~ 3.4 72 ~ 8760 ~ 80 6 ~ 8 43 ~ 58

100 ~ 120 10 ~ 12 72 ~ 8745 ~ 55 4.5 ~ 5.5 32 ~ 40

100 ~ 120 10 ~ 12 72 ~ 87140 ~ 160 14 ~ 16 101 ~ 11590 ~ 110 9.0 ~ 11.0 65 ~ 80100 ~ 120 10.0 ~12.0 72 ~ 87100 ~ 120 10.0 ~12.0 72 ~ 87100 ~ 120 10.0 ~ 12.0 72 ~ 87

Tie rod end castle nutLower arm to sub frame

Item

Rear Suspension

Torsion beam axle to Shock absorber to

Shock absorber to bodyHub nuts

Front

Toe-in

King-pin angle

Caster angle

Camber angle

RearCamber angle

Steering gear box to Front Suspension

Front strut assembly to Stabilizer bar to front Stabilizer bar to sub

Stabilizer bar to

Hub nutsItem

Engine

Toe-in

AM-14

Tightening Torques

N.m Kgf.m lb-ft

90 ~ 110 9.0 ~ 11.0 65 ~ 80

13 ~ 18 1.3 ~ 1.8 9.4 ~ 13.0

30 ~ 35 3.0 ~ 3.5 22 ~ 25

24 ~ 34 2.4 ~ 3.4 17 ~ 25

60 ~ 80 6.0 ~ 8.0 43 ~ 58

Steering SystemType

30.90°

32.33°

38.38°±2°

40.96°±2°

134mm

140mm

Rack & Pinion

Manual Steering System

Non 215 Tire

215 Tire

Non 215 TireOuter

215 Tire

Steering angle(Max.)

Inner

Bolt connecting steering column to universal joint

Tie rod end castle nut

Steering gear box mounting bolts

Tightening torqueItem

Hub nuts

Steering column mounting bolts and nuts

Steering gear

Type

Rack strokeNon 215 Tire

215 Tire

AM-15


Tightening Torques

Nm kgf.m lb-ft

7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0

7.8 ~ 8.8 0.8 ~ 0.9 5.8 ~ 6.5

10.8 ~ 14.7 1.1 ~ 1.5 8.0 ~ 10.8

5.9 ~ 7.8 0.6 ~ 0.8 4.3 ~ 5.8

39.2 ~53.9 4.0 ~ 5.5 28.9 ~ 39.8

7.8 ~ 9.8 0.8 ~ 1.0 5.7 ~ 7.3

7.8 ~ 9.8 0.8 ~ 1.0 5.7 ~ 7.3

7.8 ~ 9.8 0.8 ~ 1.0 5.7 ~ 7.3

Front Impact Sensor (FIS) Mounting nut

Side Impact Sensor (SIS) Mounting Bolt


Side Airbag (SAB)

Seat Belt Anchor Bolt (BPT)

SRSCM

Restraints

1.6 ~ 6.0

1.6 ~ 6.0

1.6 ~ 6.0

1.6 ~ 6.0

1.6 ~ 6.0

Item

Driver Airbag (DAB)


Seat Belt Retractor Pretensioner (BPT)

Anchor Pretensioner


Side Airbag (SAB)


Driver Airbag (DAB)

Resistance (Ω)

1.6 ~ 6.0

Item

Engine

AM-16

Brake System

Lubricant

Brake fluid DOT 3 or DOT 4

Brake pedal bushing and brake pedal bolt Chassis grease

Parking brake shoe and backing plate contact surfaces Bearing grease

Caliper guide rod bolt and boot AI-11P grease

Front brake(Disc)Type

Disc I.D.Disc thicknessPad thicknessCylinder typeCylinder I.D.

11 mm (0.43 in)Single piston

Ø57.0 mm (2.24 in)

Floating type with ventilated disc280 mm (11.02 in)172 mm (6.77 in)26 mm (1.02 in)

Vacuum

Tandem type45 mm (1.77 in)

Provided

Boosting ratio 9:01

TypeMaster cylinder

Fluid level warning sensorPiston stroke

Brake boosterType

Disc O.D.

AM-17


Rear brake(Disc)TypeDisc O.D.Disc I.D.Disc thicknessPad thicknessCylinder type

Rear brake(Drum)TypeDrum I.D.Brake lining thicknessClearance adjustment

Parking brake (Disc type)ActuationTypeDrum I.D.

[NOTE]O.D : Outer DiameterI.D : Inner DiameterCBS : Conventional Brake System

Lever168 mm(6.61 in)

Ø203.2 mm (8.00 in)5.14 mm (0.20 in)

Automatic

DIH (Drum in hat)

Single pistonØ30.0 mm (1.22 in) - Australia only

Ø34.0 mm (1.34 in) - Except Australia

Leading trailing

262 mm (10.31 in)185 mm (7.28 in)10 mm (0.39 in)10 mm (0.39 in)

Floating type with solid disc

Cylinder I.D.

Engine

AM-18

Specification(ABS)SystemTypeOperating VoltageOperating TemperatureMotor power

Specification (Total control-ABS, EBD, TCS, ESP)SystemTypeOperating VoltageOperating TemperatureMotor power

Service Standard

Brake pedal strokeStop lamp switch outer case to pedal stopper clearanceBrake pedal free playBooster push rod to master cylinder piston clearance

Front disc brake pad thicknessFront disc thicknessRear disc brake pad thicknessRear disc brake disc thickness

26 mm (1.02 in)10 mm (0.35 in)10 mm (0.39 in)

Disc Brake : 2.6 mm (0.10 in)

3 ~ 8 mm (0.08 ~ 0.20 in)0.6 ~ 1.4 mm (at 500 mmHg vacuum)

5 ~ 7 clicks

11 mm (0.43 in.)

LHD : 194 mm (7.64 in)RHD : 180 mm (7.09 in)

135 mm (5.31 in)1 ~ 2 mm (0.039 ~ 0.047 in)

Motor, valve relay intergrated type10 ~ 16V

-40 ~ 120°C(-40 ~ 248°F)270W

10 ~ 16 V-40 ~ 120 °C (-40 ~ 248°F)

210 W

4 Channel 4 Sensor (Solenoid)

4 Channel 4 Sensor (Solenoid)Motor, valve relay intergrated type

Brake pedal height

Rear brake lining thicknessDrum Brake : 5.14 mm (0.20 in)

Parking brake lever stroke when lever assembly is pulled with 196N (20Kg, 44lb force)

HECU

HECU

AM-19


Tightening TorquesN.m kgf.m lb-ft

Master cylinder to booster mounting nut 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3Brake booster mounting nut 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8Bleeder screw 6.9 ~ 12.7 0.7 ~ 1.3 5.1 ~ 9.4Brake tube to HECU-ABS 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3Brake tube to HECU-ESP 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6Caliper guide rod bolt 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1Caliper mounting bolt (Front) 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3Caliper mounting bolt (Rear) 63.7 ~ 73.6 6.5 ~ 7.5 47.0 ~ 54.3Brake hose to caliper 24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7Brake pedal member assembly bracket mounting nut 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8Stop lamp switch mounting nut 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8Wheel speed sensor mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0HECU mounting bracket bolt 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8HECU bracket mounting nut 10.8 ~ 13.7 1.1 ~ 1.4 8.0 ~ 10.1Yaw rate & Lateral G sensor mounting bolt 7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0

Engine

AM-20


Specifications

Tightening Torques

N.m Kgf.m Lb-ft

6.9~10.8 0.7~1.1 5.1~8.0

15.7~23.5 1.6~2.4 11.6~17.4

21.6~26.5 2.2~2.7 15.9~19.5

16.7~21.6 1.7~2.2 12.3~15.9

6.9~10.8 0.7~1.1 5.1~8.0

37.2~58.8 4.0~6.0 28.9~43.4


Front hinged, full door constructionConstruction

Front Door

Seat Belts

Locking system

Regulator system X-arm type


Pin-fork system

Tailgate Type Inner hinged, gas lifter

Rear Door

Construction Front hinged, full door construction

Regulator system X-arm type

Front 3 point type with Emergency Locking Retractor (E.L.R)

Rear 3 point type with Emergency Locking Retractor (E.L.R)

Hood Hood latch to body

Items

TailgateTailgate striker

Tailgate latch

Checker to body

Checker to doorFront and rear doors

Seat Front seat mounting bolts

AM-21


Tightening Torques

39.2~53.9 4.0~5.5 28.9~39.8

39.2~53.9 4.0~5.5 28.9~39.8

39.2~53.9 4.0~5.5 28.9~39.8

39.2~53.9 4.0~5.5 28.9~39.8

39.2~53.9 4.0~5.5 28.9~39.8

39.2~53.9 4.0~5.5 28.9~39.8

39.2~53.9 4.0~5.5 28.9~39.8

Body Electrical System

Audio

531 ~ 1602 KHz/9 KHz (for General)

87.5 ~ 108.0 MHz/100 KHz (for General)

PLL SYNTHESIZED TUNING

80PF 75ΩMin 14WDC 14.4V

Radio/CD/MP3(Internal Amp) Radio/CD/MP3(External Amp)

Tuning typeAntenna

Rated outputPower supply

Model

FM

AM

FM

Front seat belt buckle mounting boltFront seat belt anchor mounting bolt

Rear seat belt anchor attaching boltRear seat belt retractor mounting bolt

Frequency range / Channel space 87.5 ~ 108.0 MHz/50 KHz (for Europe)

Front seat belt height adjuster

Seat belt

Engine

Front seat belt lower anchor Front seat belt upper anchor

AM-22

Speaker

External Amplifier

20 (Max. 40)Front

Rear

Power Supply DC 14.4V

20 (Max. 40)

20 (Max. 40)

20 (Max. 40)Rear

Tweeter

4.0 ± 0.6, 2.0 ± 0.3 (External Amp)

Tweeter 4.0 ± 0.6

Center 2.0 ± 0.3

315W (45×7CH)

LOAD Impedance (Ω) 2

8

LW

Output Power (W)

MW

Speaker Number

153 ~ 279 KHz/1 KHz (for Europe)

522 ~ 1620 KHz/9 KHz (for Europe)

Woofer 2.0 ± 0.3

20 (Max. 40)

4.0 ± 0.6, 2.0 ± 0.3 (External Amp)

Woofer

Center

Speaker Impedance(Ω)

Input Power(W)

Front

AM-23



Lighting systemWWWWWWWWWWWWWW

10

55

215510

Overhead console lampHigh mounted stop lampLuggage room lamp

Rear fog lamp - EuropeLicense plate lampSide repeaterRoom lamp


21 / 51621

Rear stop/tail lamp

60 / 5521275

Head lamp (High/Low)Front turn signal lampFront fog lamp

Life of batteryButton

Position lamp


433.92 MHz4 (Door lock, Door unlock, Tailgate and Panic)

DC 2.5V ~ 3.2V-4°F ~ 140°F (-20°C ~ +60°C)

FSKCR2032 (Lithium 3V battery, 1EA)

DC 3V


Modulation method

Service voltage rangeTemperature range

Rated voltage

Engine

Keyless entry transmitterPower sourceTransmissible distance

AM-24


Immobilizer

MAX 60 mAOscillation frequency : 2.2±0.5 KHz

Sound level : MIN 70 dB (DC 13V /m)

4 (Right, center, Left)DC 12 V

DC 9 ~ 16 V-30°C ~ + 80°C

DC 9 ~ 16 VMAX 20 mA

-30°C ~ + 80°CHorizontal : 100±5°(70cm), Vertical : 50±5°(50cm)

Operation current

Sound, tone

DC 12VDC 9 ~ 16 V

-30°C ~ + 80°CMAX 600 mA40 ± 5 KHz

Direct and indirect detectionDC 8 V

40 cm ~ 120 cm

Piezo buzzer

Operation temperatureBeam widthNumber of sensorsVoltage ratingOperation voltageOperation temperature

Ultrasonic sensor

Detective methodVoltage ratingDetecting rangeOperation voltageOperation current

Rear parking assist system control unit

Voltage ratingOperation voltageOperation temperatureOperation currentOperation frequency

Immobilizer Type SMARTRA systemManufacturer Bosch

AM-25


Heating Ventilation & Air Conditioning

Air conditioner

4,500 - 5%Pin & Tube typeSpecificationItem

Heating capacity

ON : 3.0 ± 0.5 (37.4 ± 32.9), OFF: 1.0 ± 0.5 (33.8 ± 32.9)Evaporator temperature sensor

ActuatorActuator

A/C ON/OFF [°C(°F)]Temperature control

Temperature operating Mode operating method

Type

Particle filterBlower resistor(Manual)

0~4 (Manual)SiroccoActuator

SpecificationFresh and recirculation

Item

TypeSpeed controlSpeed step

TypeOperating method

Specification

19.4 ± 0.88 (550 ± 25)R-134aBlock

Voltage = 0.00878835 * Pressure + 0.37081095

12,300min126cc/rev5PK-TYPE

FD46XG(PAG) 100 ± 10ccVS12

Evaporator

Heater

Condenser


Air filter

Blower

Blower unit

APT(A/C pressure transducer)

Heat rejectionDisplacement

Compressor

Refrigerant

Expansion valve

Capacity [oz.(g)]TypeType


Pulley typeOil type & Capacity

TypeItem

Engine

AM-26

　Engine Mechanical System………………………UN-2　Engine Electrical System…………………………UN-8　Fuel System……………………………..…………UN-9　Clutch…………………………………….…………UN-10　Manual Transaxle……………………….…………UN-11　Automatic Transaxle………………………………UN-11　Driveshaft………………………………..…………UN-12　Suspension System…………………….…………UN-14　Steering System………………………………… UN-15　Restraints…………………………………………UN-16　Brake System………………………………………UN-17　Body (Interior & Exterior)……………….……… UN-20　Body Electrical System……………………………UN-22　Heating, Ventilation & Air Conditioning..………UN-23

Carens(UN)

UN-1

General specifications - Carens

Engine

mm (in.)cc

rpmrpm

rpm

rpm

ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt)ℓ (lmp.qt)

kPa(kg/cm²)Oil pressure (Idle) - -

Including oil filter -Oil quality ACEA : C3

1-3-4-2- BTDC 8˚ ± 15˚

Oil quantity

- 5.2 (4.58)- -

--

4 486 (3.3858) x 86 (3.3858)

1991 1.99883 (3.27) x 92 (3.62)

DSL D2.0 VGT GSL θ 2.0

In-line, SOHC In-line, DOHC

-

5W-20(SJ or SL above/GF-3)4.3 (3.78)

A/C OFF

A/C ON

17.3 : 1

790 ± 100

790 ± 100

10.5 : 11-3-4-2

Engine oil

4.0 (3.52)

Ignition Timing

650 ± 100

650 ± 100

790 ± 100 650 ± 100650 ± 100790 ± 100

Oil panOil filterExcluding oil filte

Engine


Compression ratio

Bore x StrokeTotal displacement

Idle Speed

Total

Firing order

Neutral,N,P-D-rangeNeutral,N,P-rangeD-range

UN-2

mm (in.)

mm (in.)mm (in.)

mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.) 105.89 (4.1689)95.4 (3.76)

End play 0.1 ~ 0.22 (0.0039 ~ 0.0086)Valve

113.18 (4.4559)Intake

No.1 : 30 (1.1811)No.2,3,4,5 : 24 (0.9449)

Exhaust No.1 : 40 (1.5748)No.2,3,4,5 : 24 (0.9449)

Bearing oil clearanceIntake

0.040 ~ 0.074(0.0020 ~ 0.0029)

No.1 : 0.020 ~ 0.057 (0.00078 ~ 0.00224)

No.2,3,4,5 : 0.045 ~ 0.082 (0.00177 ~ 0.00323)

Exhaust No.1,2,3,4,5 : 0.045 ~ 0.082 (0.00177 ~ 0.00323)

34.570 (1.361)

Journal outer DiameterIntake

28 (1.10)

Intake valve-11° ~ 34°22° ~ 67°

Exhaust valve34°

Closes (ATDC) 6° 10°

Opens (BTDC)Closes (ABDC)

Valve timing

43°52°

Camshaft

Cam height43.80 (1.7244)

Exhaust 45.00 (1.7716)34.697 (1.366)

7°

-


-

Cylinder head

Flatness of gasket surface Less than 0.05 (0.0020)


Less than 0.10 (0.0039)Exhaust Less than 0.10 (0.0039)

0.05 ~ 0.15 (0.002 ~ 0.006)

95.7 (3.77)Valve length

Opens (BBDC)

Exhaust

Intake

Intake

UN-3

General specifications - Carensmm (in.)mm (in.)



mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.)Cylinder head tappet bore inner diameter - 32.000 ~ 32.025 (1.2598 ~ 1.2608)

Out of squareness Less than 1.5°MLAMLA outer diameter 31.964 ~31.980 (1.2584 ~ 1.2591)-

Valve springFree length 47.44 (1.8677)

Load 19.0 ± 0.6kg / 35.0 (1.3779),39.8±1.2kg / 26.0 (1.0236 )

1.61 (0.0634) 1.35 ~ 1.65 (0.0531 ~ 0.0649)Seat angle 44° ~ 44.5° 44.75° ~ 45.10°

Valve guide

- 5.500 ~ 5.512 (0.2165 ~ 0.2170)

Length Intake36.5 (1.437) 43.8 ~ 44.2 (1.7244 ~ 1.7401)

IntakeExhaust

45.25° ~ 45.75°1.02 (0.0401)1.09 (0.0429)


Intake 0.022 ~ 0.067 (0.00086 ~ 0.00263) 0.020 ~ 0.047 (0.00078 ~ 0.00185)0.050 ~ 0.095 (0.0020 ~ 0.0037) 0.030 ~ 0.054 (0.00118 ~ 0.00212)Exhaust

Stem outer diameter Intake 5.465 ~ 5.480 (0.2151 ~ 0.2157)5.458 ~ 5.470 (0.2149 ~ 0.2153)

5.953 (0.234)Engine DSL D2.0 VGT GSL θ 2.0

1.21 (0.0477)

38.8 (1.527)

21.25kg / 32 (1.26)

-

Width of seat contact Intake 1.16 ~ 1.46 (0.0457 ~ 0.0575)Exhaust

Valve seat

5.925 (0.233)44.5°

1.6 (0.063)1.3 (0.0512)

IntakeThickness of valve head (margin) Exhaust

Face angle

Inner diameter

Exhaust

Exhaust

UN-4

mm (in.)

mm (in.)mm (in.)

mm (in.)mm (in.)



mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)Connecting rod small end hole clearance --

0.010 ~ 0.020 (0.0004 ~ 0.0008 )Connecting rod small end inner diameter - 20.974 ~ 20.985 (0.8257 ~ 0.8262 )

Piston pin outer diameterPiston pin hole inner diameterPiston pin hole clearance -

-

No. 2 ring grooveOil ring groove 0.2 ~ 0.45 (0.0079~0.0177) 0.20 ~ 0.70 (0.0078 ~ 0.0275)

Side clearanceNo. 1 ring groove 0.064 ~ 0.114 (0.00252~0.00449) 0.03 ~ 0.07 (0.0012~0.0028 )No. 2 ring groove 0.065 ~ 0.11 (0.00256~0.00433) 0.03 ~ 0.07 (0.0012~0.0028 )Oil ring groove 0.03 ~ 0.07 (0.00118~0.00275) 0.06 ~ 0.15 (0.0024 ~ 0.0059)

Oil ring groove 3.02 ~ 3.04 (0.119 ~ 0.1196) 2.01 ~ 2.03 (0.0791 ~ 0.0799)Piston ring

Piston to cylinder clearance 0.07 ~ 0.09 (0.0027 ~ 0.0036) 0.015 ~ 0.035 (0.0028 ~ 0.0014)

Ring groove widthNo. 1 ring groove 1.915 ~ 1.945 (0.075 ~ 0.076) 1.22 ~ 1.24 (0.0006 ~ 0.0488)No. 2 ring groove 2.06 ~ 2.08 (0.08 ~ 0.082) 1.22 ~ 1.24 (0.0480 ~ 0.0488)

0.096 (0.00378) for length Less than 0.05 (0.0020)PistonPiston outer diameter 82.92 ~ 82.95 (3.26 ~ 3.27) 85.975 ~ 86.005 (3.3848 ~ 3.3860 )


Cylinder blockCylinder bore 83 + 0.03 (3.27 + 0.0012) 86.00 ~ 86.03 (3.3858 ~ 3.3870)

0.020 ~ 0.061 (0.0008 ~ 0.0024)-

21.001 ~ 21.006 (0.8268 ~ 0.8270 )- 21.016 ~ 21.021 (0.8274~0.8276 )

0.3 ~ 0.45 (0.0118~0.0177) 0.30 ~ 0.45 (0.0118 ~ 0.0177)

Piston pin

End gapNo. 1 ring groove 0.2 ~ 0.3 (0.0079~0.0118) 0.15 ~ 0.30 (0.0059 ~ 0.0118)

Valve clearanceMLA to tappet bore clearance

Intake - 0.17 ~ 0.23 (0.0067 ~ 0.0090)Exhaust - 0.27 ~ 0.33 (0.0106 ~ 0.0129)

UN-5




kPa(kg/cm²)

ℓ(lmp.qt)

°C (°F)

°C (°F)

mm (in.)

Thermostat

Opening temperature 82±1.5 (179.6 ±34.7)

Full opening temperatureFull lift - -

95 (201)

Cooling method Forced circulation with electrical fan Forced circulation with cooling fan

6.7 (5.90)

00.07 ~ 0.25 (0.0027 ~ 0.0098)Oil pump

-

Cooling system

End play


Pin journal outer diameter 50.008 ~ 50.026 (1.9688 ~ 1.9695) 47.954 ~ 47.972 (1.8879 ~ 1.8886)0.020 ~ 0.038 (0.0008 ~0.0015)

Connecting rod bearing oil clearance 0.024 ~ 0.042 (0.0009 ~ 0.0016) 0.028 ~ 0.046 (0.0011 ~ 0.0018 )End play 0.10 ~ 0.25 (0.0039 ~ 0.0098 )-

Connecting rodConnecting rod big end inner diameter - 51.000 ~ 51.018 (2.0079 ~ 2.0086 )

Engine DSL D2.0 VGT GSL θ 2.0

0.024 ~ 0.042 (0.0009 ~ 0.0016)0.09 ~ 0.32 (0.0035 ~ 0.0126)

570 ± 50 (5.8 ± 0.5)

5 (4.4)

85 (185)

100 (212)

Coolant quantity

60.002 ~ 60.020 (2.362 ~ 2.363) 51.942 ~ 51.960 (2.0449 ~ 2.0456)CrankshaftMain journal outer diameter


UN-6

kPa(kg/cm²)

kPa(kg/cm²)

kΩkΩ


Oil pan drain plug 34.3 ~ 44.1 (3.5 ~ 4.5) -

Oil pan nuts or boltsBolts 7.8 ~ 9.8 (0.8 ~ 1.0) -

Bolts (M6) - 9.8 ~ 11.76 (1.0 ~ 1.2)Bolts (M8) - 26.46 ~ 30.38 (2.7 ~ 3.1)

Cylinder head bolt 63.7 (6.5) + 120° + 120°Lubrication systemOil filter - 11.76 ~ 15.68 (1.2 ~ 1.6)

34.3 (3.5) + 90° +90°

Cylinder head

Camshaft bearing cap nuts or bolBolts

Bolts (M6)Bolts (M8) - 27.44 ~ 31.36 (2.8 ~ 3.2)

-- 10.78 ~ 12.74 (1.1 ~ 1.3)

Crankshaft bedplate Bolts (15mm) 27.5 ~ 31.4 (2.8 ~ 3.2) + 90° -Bolts (12mm) 36.3 ~ 37.0 (3.7 ~ 3.8) -

25 (2.5) + 90° 19.6 (2.0) + 90°Crankshaftmain bearing cap Bolts 26.46 (2.7) + 45°-

Resistance2.31 ~ 2.59

80°C (176°F) 0,322220°C (68°F)

93.16 ~ 122.58 (0.95 ~ 1.25)

6.86 (0.07) or less

Water temperature sensorType Thermister type

6.86 (0.07)

107.9 ± 14.7 (1.1±0.15)


Radiator cap

Main moving systemConnecting rod cap nuts or bolts


26.5 ~ 29.4 (2.7 ~ 3.0)

UN-7



VA

MF 60AH MF 68AH

550 A 600 A

92 min 110 min

1.280 ± 0.01 1.280 ± 0.01

Ω

kΩ

mm(in.)Spark plugs

Unleaded (NGK) - BKR5ES-11Unleaded (CHAMPION) RC 10YC4Unleaded (Gap) - 1.0 ~ 1.1 (0.0394 ~ 0.0433)

Ignition coilPrimary 0.62 ± 10 %Secondary resistance 7.0 ± 15 % -

-

14.55 ± 0.2V

Battery Reserve capacity 160minSpecific gravity at 25°C (77°F)


720A

2,600 rpm, MIN

Generator

Battery voltage sensing12V, 120A 13.5 V, 110A

1,000 ~ 12,000 rpm 1,000 ~ 18,000 rpmVoltage regulator type Electronic built-in typeRegulator setting

Starter

Rated voltage 12 V, 1.2 kW


Voltage 11,5Amperage 120, MAX 90, MAX

4,000rpm, MIN



SpeedType

12V, 2.0KW11,5

1.280 ± 0.01

14.4 ± 0.3VCMF 90 AH

UN-8


)

- -

MPa(kgf/cm²

)- -

KPa(kgf/cm²

)Fuel Pressure Regulator Regulated Fuel

Pressure

Fuel Pump Type

Fuel Filter Installation location


Engine Management Manufacturer SiemensFuel Tank CapacityFuel Return System Return type

Camshaft

160 (1,632)

-

High Pressure Fuel PumpElectrical

In-tank typeElectric motor

338 ~ 348 (3.45 ~ 3.55)

MechanicalPlunger Pumping Type

Built in Fuel Pump assembly

Returnless type55 (48.39)

Bosch55 (48.39)

High pressure type Built in engine room

Driven by

TypeType

UN-9


ClutchManual transaxle typeClutch operationFaling diameter(Outer × inner)Clutch release cylinder inner diameterClutch discClutch cover assemblyManual transaxle typeClutch operationFaling diameter(Outer × inner)Clutch release cylinder inner diameterClutch discClutch cover assembly

Clutch cover assemblyClutch pedal bracket mountingClutch tube to clutch hoseClutch release cylinderService standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)

145 (5.70)

25~35 (2.5~3.5)

6~13 (0.24~0.51)

M6GF2(DSL 2.0L VGT) M5GF1Hydraulic type

240 × 155 mm(9.44×6.10in) 235 × 155 mm(9.25×6.10in)

Single dry with diaphragm

235 × 155 mm(9.25×6.10in) -

Tightening torque [N.m(kgf-m)]25~35 (2.5~3.5)

[3EA] 8 ~ 12 (0.8 ~ 1.2) / [1EA] 17 ~ 26 (0.8 ~ 1.2)13~17 (1.3~1.7)

-Single dry with diaphragm -Diaphragm spring strap -

C.S.C 32.2 × 44 mm(1.26×1.73in) 20.64 mm(0.812 in)

Diaphragm spring strapM5GF1(DSL 2.0L WGT) -

Hydraulic type -

20.64 mm(0.812 in)


UN-10


MT oil capacity ℓ(lmp.qt)Type


FGRM/T oil quality SAE 75W/85, API GL-4 -

4,553 -

Gear ratio

FGR 4.063 / 2.955 4,553M/T oil quality SAE 75W/85, API GL-4

-------

1st

Gear ratio

Rev. 3,455 -

3,6362nd 2,056

2.1 (0.46) -

-Rev. 3,416 3,455

0,9715th 0,974 0,775

2,0563rd 1,542 1,296

M5GF11st 3,615 3,636

1.9 (1.67) 2.1 (0.46)M5GF1(DSL 2.0L WGT)

M6GF2(DSL 2.0L VGT)

2nd 1,794

4th 1,176

6th 0,829

3rd 1,2964th 0,9715th 0,7756th -

UN-11

General specifications - CarensAutomatic Transaxle

Type

ℓ(lmp.qt)

Driveshaft

Lubricants

g

ATF quality Diamond ATF SP III or SK ATF SP IIIATF capacity 8.5 (7.5) 7.8 (6.9)

Rev. 2,720 2,480FGR 3,274 4,042

Quantity 160

BJ#24

Max. permissible angleM/T Inner 23˚

Outer 46.5˚

A/T Inner 23˚

Joint typeM/T Inner UTJ-II#24

Outer BJ#24

A/T Inner UTJ-II#24Outer

F4A42

Gear ratio

1st 2,842

3rd 1,000 1,0004th 0,731 0,712

2,8422nd 1,495 1,529

Engine DSL D2.0 VGT GSL θ 2.0F4A51-3

UTJ-II#25BJ#25

UTJ-II#25BJ#25

46.5˚Outer

130

Joint type BJ #24/#25 UTJ-II #24/#25Recommended grease RBA CW-13TJα

UN-12

Wheel nut 88.3 ~ 107.9 (9.0 ~ 11.0)

Front caliper assembly to knuckle bolts

Outer : On tire sideBJ : Birfield JointUTJ-ll : U Type Tri-pod JointTightening torque [N.m (kgf-m)]

Starting torque [N.m (kgf-m)]Front wheel bearing 1.8 (0.18 )

1.5 (0.15)Rear hub ＆ bearing assembly

Wheel speed sensor bolt 6.9 ~ 9.8 (0.7 ~ 1.0)

Driveshaft nut (castle nut) 196.1 ~ 274.6 (20 ~ 28)Front lower arm ball joint assembly to knuckle 98.1 ~ 117.7 (10.0 ~ 12.0)

[NOTE]Inner: On transaxle side

78.5 ~ 98.1 (8.0 ~ 10.0)Tie rod end castle nut 23.5 ~ 33.3 (2.4 ~ 3.4)Front strut assembly to knuckle bolts 137.3 ~ 156.9 (14.0 ~ 16.0)

Rear caliper assembly to carrier assembly bolts 49 ~ 58.8 (5.0 ~ 6.0)Rear upper arm to carrier assembly bolts 107.9 ~ 127.5 (11.0 ~ 13.0)

Rear lower arm to carrier assembly bolts 137.3 ~ 156.9 (14.0 ~ 16.0)Rear lower arm to cross member bolts 137.3 ~ 156.9 (14.0 ~ 16.0)

Rear strut assembly to carrier assembly bolts 137.3 ~ 156.9 (14.0 ~ 16.0)Assist arm to carrier assembly bolts 44.1 ~ 53.9 (4.5 ~ 5.5)Trailing arm to carrier assembly boltsCarrier assembly to rear hub assembly bolts 58.8 ~ 68.6 (6.0 ~ 7.0)

44.1 ~ 53.9 (4.5 ~ 5.6)

UN-13


mm (in.)

6.0J × 15"6.0J × 15", 6.5J × 16", 6.5J × 17"

225/50 R17 [2.2 (32)]

Wheel alignment

Camber -0.5°±30' -1°±30'Caster 4.74°±30' -Toe-in 0±2 (0±0.079)


Aluminum

225/50 R17 [2.3 (33)]

Suspension typeShock absorber type

205/65 R15 [2.3 (33)] 205/65 R15 [2.2 (32)]205/60 R16 [2.4 (35)] 205/60 R16 [2.4 (35)]

2±2(0.079±0.079)13.1°±30'

140 ~ 160 (14.0 ~ 16.0)45 ~ 60 (4.5 ~ 6.0)Front strut assembly to wheel housing panel

-

90 ~ 110 (9.0 ~ 11.0)Tightening Torque [N.m(kgf-m)]Hub nuts

Front strut assembly to knuckle70 ~ 95 (7.0 ~ 9.5)

100 ~ 120 (10.0 ~ 12.0)45 ~ 55 (4.5 ~ 5.5)

Front lower arm to knuckle 100 ~ 120 (10.0 ~ 12.0)Front stabilizer link to strut assemblyFront stabilizer bar bracket mounting bolts

Front lower arm to sub frameFront strut assembly self-locking nut

FR: 140 ~ 160 (14.0 ~ 16.0), RR: 100 ~ 120 (10.0 ~ 12.0)

45 ~ 55 (4.5 ~ 5.5)140 ~ 160 (14.0 ~ 16.0)

Rear shock absorber bracket to bodyRear shock absorber to carrier

110 ~ 130 (11.0 ~ 13.0)Rear upper arm to carrier

MacPherson strut Multi linkGas pressurized

Wheel size Steel

Tire size [Tire pressure] kgf/cm2

(psi)

King-pin

UN-14

Type

ℓ(lmp.qt)

InnerOuterInnerOuterkPa

(kgf/cm²)

Steering wheel lock nutSteering column mounting bolt & nut

40 ~ 50 (4.0 ~ 5.0)13 ~ 18 (1.3 ~ 1.8)



39.52°±1.5°32.17°

8336 ~ 9022 (85 ~ 92)

Steering angle17" tire 31.23°

15", 16" tire

15", 16" tire

110 ~ 130 (11.0 ~ 13.0)Rear upper arm to rear cross memberRear lower arm to carrier 140 ~ 160 (14.0 ~ 16.0)Rear lower arm to rear cross memberRear assist arm to carrierRear assist arm to rear cross memberTrailing arm to body

45 ~ 55 (4.5 ~ 5.5)

140 ~ 160 (14.0 ~ 16.0)45 ~ 55 (4.5 ~ 5.5)

PSF-4

37.85°±1.5°

Power steering fluid QualityQuantity 1.0 (0.88)

Rack stroke136 (5.35)140 (5.51)

Rack and Pinion

45 ~ 55 (4.5 ~ 5.5)

17" tiremm (in.)

Rear stabilizer bar bracket mounting boltsSteering System

45 ~ 55 (4.5 ~ 5.5)Trailing arm to carrierRear stabilizer link to trailing arm

80 ~ 100 (8.0 ~ 10.0)140 ~ 160 (14.0 ~ 16.0)

18 ~ 27 (1.8 ~ 2.7)Bolt connecting steering column to universal joint

UN-15


ΩΩΩΩΩ

Bolt

Bolt connecting universal joint to steering gear

Driver Airbag (DAB)

55 ~ 65 (5.5 ~ 6.5)60 ~ 80 (6.0 ~ 8.0)

Pressure hose to power steering pumpSteering gear box to sub frame

1.6 ~ 5.8Resistance

Passenger Airbag (PAB)Side Airbag (SAB)

6.8 ~ 9.2 (0.7 ~ 0.9)

1.6 ~ 5.8

7.9 ~ 9.8 (0.8 ~ 1.0)

1.6 ~ 5.8

Side Airbag (SAB)

Driver Airbag (DAB)

Nut17.2 ~ 26.5 (1.8 ~ 2.7)

7.0 ~ 9.0 (0.7 ~ 0.9)

1.6 ~ 5.8

Seat Belt Anchor Bolt (BPT) 39.2 ~ 53.9 (4.0 ~ 5.5)

Seat Belt Pretensioner (BPT)Tightening Torque [N.m(kgf-m)]

2.45 ~ 3.73 (0.25 ~ 0.38)7.0 ~ 9.0 (0.7 ~ 0.9)

Passenger Airbag (PAB)Curtain Airbag (CAB)

7.0 ~ 9.0 (0.7 ~ 0.9)Front Impact Sensor (FIS) Mounting Bolt

6.8 ~ 9.2 (0.7 ~ 0.9)

30 ~ 35 (3.0 ~ 3.5)

SRSCM Mounting Bolt

RestraintsDepoweredType

1.6 ~ 5.8Curtain Airbag (CAB)

24 ~ 34 (2.4 ~ 3.4)17 ~ 26 (1.7 ~ 2.6)

Tie rod end to knucklePower steering pump to pump bracket



UN-16

Brake System

mm (in.)mm (in.)

MPa(kg/cm²)


mm (in.)

mm (in.)mm (in.)


Floating type with ventilated discDisc O.D. 280 (11.02)

DOT 3Brake fluid

Recommended lubricantQuantity As required

Master cylinderTandem type25.4 (1.00)

TypeI.D.

31 (1.22)Provided

Piston strokeFluid level warning sensor

Decompression ratio

Proportioning valve(CBS)

1.96 (20)

0.27 : 1

TypeBrake booster

vacuumBoosting ratio 9 : 1Front brake(Disc)Type

Disc thickness 26 (1.02)Disc I.D. 166 (6.54)


60.6 (2.39)Cylinder type Single pistonCylinder I.D.

Floating type with solid discRear brake(Disc)Type

275 (10.83)185 (7.28)

Disc O.D.Disc I.D.

UN-17


mm (in.)mm (in.)

mm (in.)

mm (in.)

O.D=Outer Diameter

I.D=Inner Diameter


mm(in.)teeth


mm (in.)

mm (in.)

10 (0.39)Engine DSL D2.0 VGT GSL θ 2.0

10 (0.39)Disc thicknessPad thickness

Single piston38.18 (1.50)

Cylinder typeCylinder I.D

DIH(Drum in hat)Parking brakeType

Lever168 (6.61)

ActuationDrum I.D.

CBS : Conventional Brake System

Manufacturer and Name4 channel 4 sensor (Solenoid)

0.4 ~ 1.5 (0.015 ~ 0.059)HECU SystemAcitve wheel speed sensor

Air gapTone wheel 48

Brake pedal height148.7 (5.85 )

RHD 173 (6.81 )LHD

Brake pedal strokeStop lamp switch outer case to pedal stopper clearanceBrake pedal free play

128 (5.04)

0.5 ~ 1.0 (0.02 ~ 0.04)

3 ~ 8 (0.11 ~ 0.31)

UN-18

mm (in.)

mm (in.)


mm (in.)

24.5 ~ 29.4 (2.5 ~ 3.0)

16.7 ~ 25.5 (1.7 ~ 2.6)12.0 ~ 16.0 (1.22 ~ 1.63)

16.7 ~ 25.5 (1.7 ~ 2.6)

12.7 ~ 15.7 (1.3 ~ 1.6)

6.9 ~ 10.8 (0.7 ~ 1.1)Stop lamp switch mounting nutWheel speed sensor mounting boltHECU mounting bracket bolt

Brake pedal mounting nut7.9 ~ 9.8 (0.8 ~ 1.0)


0 (at 500 mmHg)

Master cylinder to booster mounting nut 7.9 ~ 11.8 (0.8 ~ 1.2)

Parking brake pedal stroke when pedal is pushed with 196N (20kgf, 44lb force)Front disc brake pad thickness

3.3 (0.13)

Rear disc brake disc thickness

Rear brake liner thickness

proportioning valve to master cylinder 34.3 ~ 53.9 (3.5 ~ 5.5)

Caliper mounting boltFrontRear

Caliper guide rod bolt

Brake pedal assembly bracket mounting nut(cowl side upper mounting)

Front disc thickness

78.5 ~ 98.1 (8.0 ~ 10)

13.7 ~ 16.7 (1.4 ~ 1.7)21.6 ~ 31.4 (2.2 ~ 3.2)

49.0 ~ 58.8 (5.0 ~ 6.0)

Bleeder screw 6.9 ~ 12.7 (0.7 ~ 1.3)

HECU union screw

Brake tube nut, brake hose

Brake hose to front caliper

Brake booster mounting nut 12.7 ~ 15.7 (1.3 ~ 1.6)

26 (1.02)Rear disc brake pad thickness 10 (0.39)

88 ~ 98 (3.46 ~ 3.86)

10 (0.39)

Tightening torque [N.m (kgf-m)]

10 (0.39)

UN-19




mm (in.)

Tailgate hinge to body 21.6~26.5 (2.2~2.7)Tailgate hinge to 21.6~26.5 (2.2~2.7)

Seat beltsFrontRear

Tailgate

Door hinge to door

Front door Rear door glass

4.9 ~ 7.8 (0.5 ~ 0.8)Yaw rate ＆ Lateral G sensor mounting boltHECU bracket mounting nut 10.8 ~ 13.7 (1.1 ~ 1.4)Engine DSL D2.0 VGT

Rear hinged, gas lifter typeFront hinged, full door construction

Front doorConstructionRegulator system Wire drum typeLocking system Pin-fork system

Type

GSL θ 2.0

Hood


Tailgate

Glass thickness

Windshield

4 (0.1575)Rear window glass

3.5 (0.1378)

Type Inner hinged, gas lifter type5 (0.1969)4 (0.1575)

3 point type with Emergency Locking Retractor (E.L.R)3 point type with Emergency Locking Retractor (E.L.R), 2point type

Door hinge to body 12.7~25.5 (1.3~2.6)9.8~19.6 (1.0~2.0)


Front and rear doorsStriker 6.9~10.8 (0.7~1.1)

UN-20

34.3~53.9 (3.5~5.5)

21.6~26.5 (2.2~2.7)21.6~26.5 (2.2~2.7)6.9~8.8 (0.7~1.1)

34.3~53.9 (3.5~5.5)

Hood

SeatFront seat mounting nut

Hood hinge to bodyHood hinge to hoodHood latch to bodyFront seat mounting

Rear seat mounting 16.7~25.5 (1.7~2.6)Rear seat frame mounting bolts

16.7~25.5 (1.7~2.6)

Front seat belt height adjuster

39.2~53.9 (4.0~5.5)

Front seat belt buckle mounting bolt

39.2~53.9 (4.0~5.5)

39.2~53.9 (4.0~5.5)

39.2~53.9 (4.0~5.5)

Rear seat belt anchor attaching bolt

Seat belt

Front seat belt anchor mounting bolt

39.2~53.9 (4.0~5.5)

Front seat belt lower anchor

39.2~53.9 (4.0~5.5)

Rear seat belt retractor mounting bolt

39.2~53.9 (4.0~5.5)

Front seat belt upper anchor

UN-21



Radio / Tape (M420)

Radio / CD(M445) Radio / Tape / CD / MP3(M455)

Radio / CDC / MP3 (M466)

Max 43W x 4 Max 43W x 4 Max 43W x 4 3.2Vrms10kΩ x 4


Lighting systemWW

Button

Transmission frequency 433.92 MHz(EUR, AUS)315 MHz (GEN)

Head lampHighLow


FM 87.5~108 MHz/ 100KHz (General), 50KHz(Europe)AM 531~1602 KHz/ 9KHz (General)MWLW 153~279 KHz/ 1KHz (Europe)

522~1620 KHz/ 9KHz (Europe)

Rated outputSpeaker impedance

Tuning type PLL synthesized type80PF 75Ω

4Ω x 4Antenna

Transmitter(TX)Keyless entry transmitter Power source

2 years or more (at 10 times per day)

Lithium 3V battery (1EA)Transmissible distanceLife of battery

30m or more

5555

3 (Door lock, Door unlock, Tail gate unlock)

Items

DC 14.4V

Type

Power supply


UN-22

WWWWWWWWWWWWW

Other system



Heat rejectionAPT(A/C pressure transducer)


Voltage = 5 * (0.025 * pressure + 0.1) [Kgf/]Voltage = 5 * (0.001758 * pressure + 0.074612) [PSIA]

Condeser

Overhead console lampHigh mounted stop lamp


10LED10Rear map lamp

Room lampCenter 10Rear 5

Rear turn signal lampRear fog lamp - EuropeLicense plate lampSide repeater

Front turn signal lampFront fog lampRear tail/stop lampBack up lamp

5

28

1827

Block

180 cc/rev15,000 - 5% Kcal/hr

Compressor

TypeOil type & CapacityPulley typeDisplacement

SMARTRA system

PAG , 120 ± 10cc6PK - TYPE

VS18

Bosch

2728/8

55

UN-23


oz.(g)



CapacityRefrigerant

Type

OFF : 0.5 ± 0.5 (37.4 ± 32.9)


Temperature control type Evaporator temperture sensorON : 2.5 ± 0.5 (41 ± 32.9)

Heater

Pin & Tube type

A/C ON/OFF


SirocoAuto + 8speed (Autometic) , 1~8 speed (Manual)Blower

TypeSpeed stepSpeed control Power mosfet (Autometic)

R - 134a15.8 ± 0.88 (450 ± 25)

()

Actuator

Heating capacity

Evaporator

Temperature operatingmethod

Type


4,500 ± 5% Kcal/hrActuator

UN-24

　Engine Mechanical System………………………KM-2　Engine Electrical System…………………………KM-9　Fuel System……………………………..…………KM-10　Clutch…………………………………….…………KM-11　Manual Transaxle……………………….…………KM-11　Automatic Transaxle………………………………KM-12　Driveshaft………………………………..…………KM-12　Suspension System…………………….…………KM-15　Steering System………………………………… KM-16　Restraints…………………………………………KM-17　Brake System………………………………………KM-18　Body (Interior & Exterior)……………….……… KM-22　Body Electrical System……………………………KM-23　Heating, Ventilation & Air Conditioning..………KM-25

Sportage(KM)

KM-1

General specifications - SportageDSL D2.0 WGT DSL D2.0 VGT GSL β 2.0 GSL δ 2.7

EngineIn-line, SOHC In-line, SOHC In-line, DOHC V-type, DOHC

4 4 4 6

mm (in.) 82 (3.2283)x 93.5 (3.6811)

86.7 (3.4133)x 75 (2.9528)

cc 1.991 1.991 1.975 2.65617.7:1 17.3:1 10.1 : 1 10.1:1

1-3-4-2 1-2-3-4-5-6- - BTDC 8˚ ± 5˚ BTDC 12˚ ± 5˚

rpm 720 ± 40 790 ± 100 700 ± 100 700 ± 100rpm 720 ± 40 790 ± 100 700 ± 100 700 ± 100rpm 720 ± 40 790 ± 100 850 ± 100 750 ± 100rpm 720 ± 40 790 ± 100 850 ± 100 750 ± 100

ℓ (lmp.qt) - - 4.0 (3.52) 7.0 (6.1)ℓ (lmp.qt) - - 3.7 (3.26) -ℓ (lmp.qt) - - 0.3 (0.26) -ℓ (lmp.qt) - - - -

- - Above SL, SJ -kPa

(kg/cm²) - - 156.9 (1.6) -

(ATDC) 11° 6˚59° 46°

Idle Speed

Total

Firing order

Valve timing


Oil quality

Oil pressure (Idle)

Engine


Compression ratio

Bore x Stroke

Total displacement

Oil quantity



83 (3.27) x 92 (3.62)

1-3-4-2

Engine oil

Ignition Timing

Intake valve

A/C OFFA/C ON

7°43°

KM-2

42° 38˚6˚ 14˚

mm (in.)

mm (in.)mm (in.)

mm (in.)

CVVT:44.518 ~ 44.718

(1.7527 ~ 1.7605)Without CVVT:

44.720 ~ 44.920(1.7606 ~ 1.7685)

mm (in.)

CVVT:44.418 ~ 44.618

(1.7487 ~ 1.7566)Without CVVT:

44.620 ~ 44.820 (1.7567 ~ 1.7646)

mm (in.) 27.964 ~ 27.980(1.1009 ~ 1.1016)

25.964 ~ 25.980 (1.0222 ~ 1.0228)

mm (in.)

mm (in.) 0.10 ~ 0.20 (0.0039 ~ 0.0079)

0.1 ~ 0.15(0.0039 ~ 0.0059)

Intake 34.697 (1.366)

34.570 (1.361)

28 (1.10)



Exhaust valve

IntakeExhaust

Cylinder head

0.02 ~ 0.061 (0.0008 ~ 0.0024)

Camshaft

Exhaust


Cam height


0.040 ~ 0.074 (0.0020 ~ 0.0029)

End play 0.05 ~ 0.15 (0.002 ~ 0.006)



--

52°6°

0.03(0.0012) or less

0.15(0.0059) or less0.15(0.0059) or less

43.95 ~ 44.15 (1.7303 ~ 1.7382)

KM-3


mm (in.) 114.34 (4.5016) 96.1 (3.783)mm (in.) 116.8 (4.5984) 97.15 (3.825)mm (in.)mm (in.)

45˚ ~ 45˚ 30' 45° ~ 45.5°mm (in.) 1.15 (0.0453) 1.0 (0.0394)mm (in.) 1.35 (0.0531) 1.3 (0.0512)mm (in.)

mm (in.) 0.035 ~ 0.065 (0.0014 ~ 0.0026)

0.030 ~ 0.065 (0.0012 ~ 0.0026)

mm (in.) 45.8 ~ 46.2 (1.8031 ~ 1.8189) -

mm (in.) 54.3 ~ 54.6 (2.1378 ~ 2.1496) -

mm (in.) 1.1 ~ 1.5 (0.0433 ~ -

mm (in.) 1.3 ~ 1.7(0.0512 ~ 0.0669) -

45˚ ~ 45˚ 30' -

mm (in.) 48.86 (1.9236) 42.5 (1.6732)

5.95 ~ 5.965 (0.234 ~ 0.235)

Engine

ExhaustIntakeExhaust

Intake

5.925 (0.233)

Valve length

Intake

Free length

LengthIntake

Exhaust

Intake

Valve spring


Thickness of valve head (margin) Exhaust

Face angle

Intake

Seat angle

44.5°1.6 (0.063)

1.3 (0.0512)0.022 ~ 0.067 (0.00086 ~ 0.00263)

0.050 ~ 0.095 (0.0020~ 0.0037)

36.5 (1.437)

95.7 (3.77)95.4 (3.76)

5.953 (0.234)

Valve

Stem outer diameter5.965 ~ 5.98 (0.235 ~ 0.2354)

1.21 (0.0477)

1.61 (0.0634)

Valve seat

Width of seat contactExhaust

44° ~ 44.5°

38.8 (1.527)

0.02 ~ 0.05 (0.0008 ~ 0.0020)

Valve guide

36.5 (1.437)

KM-4

mm (in.) 18.8±0.9kg/ 39 (1.5354) 21kg / 35(1.3780)

Max. 1.5° Max. 1.5°

mm (in.) - - 0.20 (0.0079) -mm (in.) - - 0.28 (0.0110) -

mm (in.) 82.00 ~ 82.03 (3.2283 ~ 3.2295) 86.7 (3.4134)

mm (in.)

Total : Less than 0.05 (0.0020)Bore to bore : Less than 0.03

(0.0012)

Max. 0.03(0.0012)

mm (in.) 81.970 ~ 82.000 (3.2272 ~ 3.2283)

86.68 ~ 86.71 (3.413 ~ 3.414)

mm (in.) 0.020 ~ 0.040 (0.0008 ~ 0.0016)

0.01 ~ 0.03 (0.0004 ~ 0.0012)


- 0.25 (0.010),0.50 (0.020)

mm (in.)mm (in.)

mm (in.) 0.06 ~ 0.15 (0.0024 ~ 0.0059) -

Piston

Load


Cylinder bore

Out of squareness

No. 1 ring groove

IntakeExhaust



Cylinder block

0.03 ~ 0.07 (0.00118 ~ 0.00275)


Ring groove width

Side clearance

No. 1 ring grooveNo. 2 ring groove

Oil ring groove

1.915 ~ 1.945 (0.075 ~ 0.076)2.06 ~ 2.08 (0.08 ~ 0.082)

82.92 ~ 82.95 (3.26 ~ 3.27)

21.25kg / 32 (1.26)

-

83 + 0.03 (3.27 + 0.0012)


0.012 (0.00047) / 50×50mm

0.07 ~ 0.09 (0.0027 ~ 0.0036)

3.02 ~ 3.04 (0.119 ~ 0.1196)

0.064 ~ 0.114 (0.00252 ~ 0.00449)0.065 ~ 0.11 (0.00256 ~ 0.00433)

Piston ring

0.25 (0.010), 0.5 (0.020) Piston OS

0.04 ~ 0.08 (0.0016 ~ 0.0031)0.03 ~ 0.07 (0.0012 ~ 0.0028)

Valve clearance

1.23 ~ 1.25 (0.0484 ~ 0.0492)1.22 ~ 1.24 (0.0480 ~ 0.0488)2.51 ~ 2.53 (0.0988 ~ 0.0996)

KM-5


mm (in.) 0.23 ~ 0.38 (0.0091 ~ 0.0150)

0.20 ~ 0.35 (0.0079 ~ 0.0138)

mm (in.) 0.33 ~ 0.48 (0.0130 ~ 0.0189)

0.37 ~ 0.52 (0.0146 ~ 0.0205)

mm (in.) 0.20 ~ 0.60 (0.0079 ~

0.2 ~ 0.7 (0.0079 ~ 0.0276)

mm (in.) 20.001 ~ 20.006 (0.7874 ~ 0.7876) -

mm (in.) 20.016 ~ 20.021 (0.7880 ~ 0.7882) -

mm (in.) 0.010 ~ 0.020 (0.0004 ~ 0.0008) -

mm (in.) 19.974 ~ 19.985 (0.7864 ~ 0.7868) -

mm (in.)-0.032 ~ -0.016

(-0.0013 ~-0.0006)

-

mm (in.) 48.000 ~ 48.018 (1.8898 ~ 1.8905) -

mm (in.) 0.024 ~ 0.044 (0.0009 ~ 0.0017)

0.018 ~ 0.036 (0.0007 ~ 0.0014)

mm (in.)

mm (in.) 56.942 ~ 56.962 (2.2418 ~ 2.2426)

61.982 ~ 62.000 (2.4402 ~ 2.4409)Main journal outer diameter






Crankshaft

Oil ring groove

End play

End gap

Piston pin

-



60.002 ~ 60.020 (2.362 ~ 2.363)

0.25 ~ 0.3 (0.0079 ~ 0.0118)

0.3 ~ 0.45 (0.0118 ~ 0.0177)

Engine

No. 1 ring groove

No. 2 ring groove

-

-

0.2 ~ 0.45 (0.0079 ~ 0.0177)

-

-

Connecting rod

-

28.022 ~ 28.034 (1.103 ~ 1.104)

0.024 ~ 0.042 (0.0009 ~ 0.0016)

0.10 ~ 0.25 (0.0039 ~ 0.0098)

KM-6

mm (in.) 44.946 ~ 44.966 (1.7695 ~ 1.7703)

47.982 ~ 48.000 (1.8891 ~ 1.8898)

mm (in.) 0.028 ~ 0.048 (0.0011 ~ 0.0019)

0.004 ~ 0.022 (0.0002 ~ 0.0009)

mm (in.) 0.06 ~ 0.260 (0.0024 ~ 0.0102)

0.070 ~ 0.250 (0.0028 ~ 0.0098)

mm (in.) - -

kPa(kg/cm²)

490.33 ~ 588.40(5.0 ~ 6.0)

450 ~ 550(4.59 ~ 5.61)

ℓ(lmp.qt)

6.0 (5.28) 7.0 (6.1)

°C (°F) 82±1.5 (179.6±2.7)

82 ± 2(179.6± 3.6)

°C (°F)kPa

(kg/cm²)93.16 ~ 122.58(0.95 ~ 1.25)

107.9 ± 14.7(1.1±0.15)

kPa(kg/cm²)

0.98 ~ 4.90 (0.01 ~ 0.05) -6.86 (-0.07)

kΩkΩ

Cooling system

100 (212.0)

Coolant quantity

Type


20°C (68°F)80°C (176°F)Resistance 0,3222

2.45 ± 0.14



Opening temperaturePull opening

Thermostat95 (203)

End play

Radiator cap

Cooling method


Oil pumpRunout

50.008 ~ 50.026 (1.9688 ~ 1.9695)


0.13 / 238Flywheel

0.024 ~ 0.042 (0.0009 ~ 0.0016)

0.09 ~ 0.32 (0.0035 ~ 0.0126)

-


5 (4.4)

107.9 ± 14.7 (1.1±0.15)

-6.86 (-0.07)

2.45 ± 0.14

85 (185)

Thermister type

0,3222

KM-7



49.0 ~52.0 (5.0 ~5.3)

16~20 (1.6~2.0)+ 90°~94°

27.5~31.4

(2 8~3 2)+60°~64-

- - - 27~33 (2.7~3.0) + 90°~94°

- - - 13~19 (1.3~1.9) + 90°~94°

13.7 ~14.7 (1.4 ~1.5) -

27.5 ~ 31.4 ( 2.8 ~ 3.2)+ 60°~65° + 60°~65°

25 (2.5)+ 58°~62° + 43°~47°

22.6 ~ 26.5 (2.3 ~ 2.7) +

60°~65°+60°~65°-

34.3 ~ 44.1 (3.5 ~ 4.5)9.8 ~ 11.8 (1.0 ~ 1.2)

Cylinder head

Oil pan nuts


Main moving system

25 (2.5) +90°

34.3 ~ 44.1 (3.5 ~ 4.5)9.8 ~ 11.8 (1.0 ~ 1.2)

Oil pan drain plug

Oil filterLubrication system

11.8 ~ 15.7 ( 1.2 ~ 1.6)

26.5 ~ 29.5 (26.5 ~ 29.5)

50 (5.0) + 120° + 120°


Engine

-

11.8 ~ 15.7 (1.2 ~ 1.6)


Cylinder head bolt

Long bolts

Short bolts

Bolts

Long bolts (M10)

Short bolts (M8)

KM-8

VA

13.5 V, 90A 12V, 120A

14.4 ± 0.3V 14.55 ± 0.2VMF 60 AH MF 68 AH

550 A 600 A

92 min 113 min

Ω - - 0.58 ± 10% 0.74 ± 10%kΩ - - 8.8 ± 15% 13.3 ± 15%

- - BKR5ES-11 IFR5G-11PFR5N-11

mm(in.) - -

GeneratorRated voltage


Type

12V, 2.0KWVoltage

Rated voltage

Starter AmperageSpeed


14.4 ± 0.3V

Battery


Reserve capacity


Regulator setting Electronic built-in typeI.C regulator built-in type

12V, 120A1,000 ~ 18,000 rpm1,000 ~ 12,000 rpm

1111,5


12 V, 1.2 kW

Battery voltage sensing3,000 rpm, MIN

Max. 90Max. 1204,000rpm, MIN

1.0 ~ 1.1 (0.0394 ~ 0.0433)

MF 90 AH

720 A

160 min

1.280 ± 0.01

Ignition coil

Spark plugs

Primary Secondary

Unleaded (NGK)

Unleaded (Gap)


KM-9



) 58 (51.03) 65 (57.19)

- -

MPa(kgf/cm²

)135 (1,377) 160 (1,632) - -

kPa(kgf/cm²

)

Engine

SiemensFuel Tank Capacity 58 (51.03)Engine Management Manufacturer Bosch

Fuel Return System Type Return type Returnless type

Fuel Filter Type High pressure type Installation location Built in engine room Built in Fuel Pump assembly

Fuel Pump TypeHigh Pressure Fuel Pump

Mechanical ElectricalPlunger Pumping Type In-tank type

Driven by Camshaft Electric motor

- 343 (3.5)



KM-10


Clutch cover assemblyClutch pedal bracket mountingClutch master cylinder mountingClutch release cylinderService standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)Manual TransaxleType M5GF1 M6GF2 M5GF1 -

3,636 3,615 3,636 -

2,056 1,794 2,056 -

1,296 1,542 1,333 -

0,943 1,176 1,061 -

0,698 0,974 0,821 -- 0,829 - -

3,455 3,416 3,455 -

4,333 4.643 / 3.421 4,533 --

MT oil capacity ℓ(lmp.qt) 2.1 (1.8) 1.9 (1.67) 2.1 (1.8) -SAE 75W/85, API GL-4M/T oil quality

Gear ratio

1st2nd3rd4th5th6thRev.FGR

Single dry with diaphragmDiaphragm spring strap

15~22 (1.5~2.2)Tightening torque [N.m(kgf-m)]

25~35 (2.5~3.5)12~16 (1.2~1.6)25~35 (2.5~3.5)

Hydraulic type

6~13 (0.24~0.51)150 (5.91)

KM-11


Automatic TransaxleType F4A42 F4A51

2,842 2,842 2,842 2,8421,529 1,495 1,529 1,5291,000 1.000 1,000 1,0000,712 0,731 0,712 0,7122,480 2.720 2,480 2,480

2WD 4,042 3,735 4,626 4,0424WD 4,042 3,735 4,626 4,407

ℓ(lmp.qt)

UTJ-II#25 - UTJ-II#24 -BJ#25 - BJ#24 -

UTJ-II#24 - UTJ-II#24 UTJ-II#25BJ#24 - BJ#24 BJ#25

UTJ-II#25 - UTJ-II#24 -BJ#25 - BJ#24 -

UTJ-II#24 - UTJ-II#24 UTJ-II#25BJ#24 - BJ#24 BJ#25

Gear ratio

1st2nd3rd4thRev.

FGR

A/TInnerOuter

Front driveshaft

Joint type

2WDM/T

InnerOuter

4WD

Max. permissible angleInner 46.5˚Outer 23˚

M/TInnerOuter

A/TInnerOuter

7.8 (6.9)

Driveshaft

Engine


Diamond ATF SP III or SK ATF SP III

F4A42

KM-12

ℓ

BJ#24 BJ#25 UTJ-II#24 UTJ-II#25

g 130 +10 160 + 10 160 + 10 200 + 10

g

Front hub

Rear driveshaft

Joint type 4WDInner TJ#22Outer BJ#22

Max. permissible angleInner 46.5˚Outer 23˚

Rear differential carrierOil type Hypoid gear oil (GL-5, 80W/SAE90)Oil capacity Approx. 0.75 ~ 0.80Reduction gear type Hypoid gearReduction gear ratio 3,091LubricantsFront driveshaft (2WD/4WD)Joint typeRecommended grease RBA RTA-RQuantityRear driveshaft (4WD)Joint type BJ#22 TJ#22Recommended grease RBA RTA-RQuantity 100 + 10 110 + 10[NOTE]Inner: On transaxle sideOuter : On tire sideTightening torque [N.m (kgf-m)]

Wheel nut 90 ~ 110 (9 ~ 11)Driveshaft castle nut 200 ~ 280 (20 ~ 28)Break caliper mounting bolt 50 ~ 60 (6 ~ 6)

KM-13


2WD4WD2WD4WD

Suspension arm mounting nut

Lower arm mounting bolt 100 ~ 120 (10 ~ 12)Strut lower mounting blot 140 ~ 160 (14 ~ 16)Tie rod end ball joint mounting nut 45 ~ 60 (4.5 ~ 6)RearWheel nut 90 ~ 110 (9 ~ 11)Break caliper mounting bolt 50 ~ 60 (5 ~ 6)Break disc(drum) mounting screw 5 ~ 6 (0.5 ~ 0.6)Dust cover mounting bolt 50 ~ 60 (5 ~ 6)Strut lower mounting nut 140 ~ 160 (14 ~ 16)Trailing arm mounting bolt 100 ~ 120 (10 ~ 12)

160 ~ 180 (16 ~ 18)140 ~ 160 (14 ~ 16)

200 ~ 260 (20 ~ 26)200 ~ 280 (20 ~ 28)

Propeller shaftFront propeller shaft mounting bolt 50 ~ 60 (5 ~ 6)propeller shaft center bearing bracket mounting 40 ~ 50 (4 ~ 5)Rear propeller shaft mounting bolt 100 ~ 120 (10 ~ 12)DifferentialRear differential mounting bolt 90 ~ 120 (9 ~ 12)Differential cover mounting bolt 40 ~ 50 (4 ~ 5)

Engine

Hub bearing flange nutDriveshaft castle nut

KM-14

mm (in.)

100 ~ 120 (10.0 ~ 12.0)Rear stabilizer link to rear strut assembly


Suspension type MacPherson strut Dual linkShock absorber type Gas pressurized

3°36'±30' -

SteelAluminum

-6.5J × 16", 7.0J × 17"

King-pin 12°46'±30' -


215/65 R16, 235/60 R16, 235/55 R172.1kgf/cm2, (30psi)

0°±30' -55'±30'Caster

0±2 (0±0.079) 5.6±2 (0.220±0.079)

100 ~ 120 (10.0 ~ 12.0)

Front lower arm to sub frame FR: 140 ~ 160 (14.0 ~ 16.0), RR: 100 ~ 120 (10.0 ~ 120)Front lower arm to knuckle 100 ~ 120 (10.0 ~ 12.0)

40 ~ 55 (4.0 ~ 5.5)

Front stabilizer link to strut assembly

60 ~ 70 (6.0 ~ 7.0)

Hub nuts 90 ~ 110 (9.0 ~ 11.0)Front strut assembly to wheel housing panelFront strut assembly to knuckle

45 ~ 60 (4.5 ~ 6.0)

Rear strut assembly self-locking nut

Wheel alignment

Camber

Toe-in

Rear strut assembly to wheel housing panelRear strut assembly to carrier

Front stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)

Wheel size

140 ~ 160 (14.0 ~ 16.0)

140 ~ 160 (14.0 ~ 16.0)30 ~ 40 (3.0 ~ 4.0)


Front strut assembly self-locking nut

KM-15


Type

ℓ(lmp.qt)mm (in.)

Rear stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)Rear suspension arm tie rod nut 50 ~ 60 (5.0 ~ 6.0)Rear suspension arm mounting bolt 2WD: 160 ~ 180 (16.0 ~ 18.0), 4WD: 140 ~ 160 (14.0 ~ 16.0)Rear cross member mounting bolt 100 ~ 120 (10.0 ~ 12.0)Trailing arm to body 100 ~ 120 (10.0 ~ 12.0)Trailing arm to rear carrier 100 ~ 120 (10.0 ~ 12.0)


Power steering fluidQuality PSF-3 or PSF-4Quantity 0.75 ~ 0.8 (0.66 ~ 0.70)

Rack stroke 140 (5.51)




)

8630 ~ 9120 (88 ~ 93)Diesel 9120 ~ 9611 (93 ~ 98)

Tightening Torque [N.m(kgf-m)]Steering wheel lock nut 35 ~ 45 (3.5 ~ 4.5)Steering column mounting bolt & nut 13 ~ 18 (1.3 ~ 1.8)Bolt connecting steering column to universal joint 15 ~ 20 (1.5 ~ 2.0)Bolt connecting universal joint to steering gear 15 ~ 20 (1.5 ~ 2.0)Tie rod end to knuckle 45 ~ 60 (4.5 ~ 6.0)


Power steering pump to pump bracket DSL: 17 ~ 26 (1.7 ~ 2.6), GSL: 35 ~ 50 (3.5 ~ 5.0)Pressure hose to power steering pump 65 ~ 75 (6.5 ~ 7.5)

Engine

KM-16

ΩΩΩΩΩ

RestraintsType DepoweredResistanceDriver Airbag (DAB) 1.6 ~ 5.7Passenger Airbag (PAB) 1.6 ~ 5.7Side Airbag (SAB) 1.6 ~ 5.7Curtain Airbag (CAB) 1.6 ~ 5.7Seat Belt Pretensioner (BPT) 1.6 ~ 5.7Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB) 7.84 ~ 10.79 (0.8 ~ 1.1)Passenger Airbag Bolt 18.63 ~ 26.48 (1.9 ~ 2.7)Curtain Airbag (CAB) 6.86 ~ 8.83 (0.7 ~ 0.9)Side Airbag (SAB) 5.88 ~ 9.8 (0.6 ~ 1.0)



KM-17



MPa (kg/cm²)

mm (in.)


Brake SystemMaster cylinder

Tandem type

I.D.CBS 23.8 (0.937)ABS 25.4 (1.0)

Type

Decompression ratio2WD 0.27 : 14WD 0.32 : 1

Brake boosterType vacuumEffective diameter 8 + 9 in

9:01Front brake(Disc)Type Floating type with ventilated discDisc O.D. 280 (11.02)Disc O.D. 172 (6.77)Disc thickness 26 (1.02)Pad thickness 11 (0.43)


Engine

Fluid level warning sensor ProvidedProportioning valve

1.47 (15)

Output port 4 portPiston stroke 30 ~ 32 (1.18 ~ 1.26)

KM-18

mm (in.)



mm (in.)

O.D=Outer DiameterI.D=Inner DiameterCBS : Conventional Brake SystemABS : Anti-lock Brake System

Cylinder type Single pistonCylinder I.D. 60 (2.36)Rear brake(Drum)Type Leading trailing drumDrum I.D. 228.6 (9.0)Brake lining thickness 4.5 (0.17)Clearance adjustment Automatic



Disc O.D.2WD 262 (10.31)4WD 284 (11.18)

Parking brakeType Mechanical brake acting on rear wheels

Cylinder I.D 34 (1.34)


Parking Brake Drum I.D. 190 (7.48)

Actuation Lever

KM-19


CBS mm(in.)ABS mm(in.)ESP mm(in.)

teethService standard


mm (in.)

mm (in.)


HECU System 4 channel 4 sensor (MGH-25)


Air gap0.2 ~ 1.3 (0.008 ~ 0.051)0.5 ~ 1.5 (0.019 ~ 0.059)0.5 ~ 1.5 (0.019 ~ 0.059)

Tone wheel(ABS)

48

Brake pedal height 163 (6.42 )Brake pedal full stroke 128 (5.04)Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)Brake pedal floorboard clearance 82 (3.23)

7 ~ 8 clicks



0.5 ~ 1.0 (0.02 ~ 0.04)




Front disc thickness (minimum) 26 (1.02)Rear drum brake lining thickness 4.5 (0.177)Rear drum brake drum I.D. 228.6 (9)Rear disc brake pad thickness 10 (0.39)Rear disc brake disc thickness 10 (0.39)


EngineAnti-lock Brake System(ABS) / Electronic Stability Program(ESP)

KM-20

FrontRear

Tightening torque [N.m (kgf-m)]proportioning valve to master cylinder 35 ~ 55 (3.5 ~ 5.5)Master cylinder to booster mounting nut 8 ~ 12 (0.8 ~ 1.2)Brake booster mounting nut 13 ~ 16 (1.3 ~ 1.6)Brake booster vacuum hose fitting to surge tank 15 ~ 18 (1.5 ~ 1.8)Bleeder screw 7 ~ 13 (0.7 ~ 1.3)Brake tube nut, brake hose 13 ~ 17 (1.3 ~ 1.7)Caliper assembly to knuckle 85 ~ 100 (8.5 ~ 10)Brake hose to front caliper 25 ~ 30 (2.5 ~ 3.0)Brake hub flange nut 200 ~ 260 (20 ~ 26)

Tightening torque [N.m (kgf-m)] (ABS & TCS)8 ~ 9 (0.8 ~ 0.9)8 ~ 9 (0.8 ~ 0.9)

Push rod locking nut 16 ~ 22 (1.6 ~ 2.2)Caliper guide rod bolt 22 ~ 32 (2.2 ~ 3.2)

Active wheel speed sensor mounting bolt on the brake plateHECU mounting bolt 8 ~ 10 (0.8 ~ 1.0)HECU mounting bracket bolt 17 ~ 26 (1.7 ~ 2.6)Brake tubes nut 12 ~ 16 (1.2 ~ 1.6)Air bleeder screw 7 ~ 13 (0.7 ~ 1.3)Tightening torque [N.m (kgf-m)] (ESP)Yaw rate ＆ lateral acceleration sensor nut 4 ~ 6 (0.4 ~ 0.6)Steering wheel nut 40 ~ 50 (4.0 ~ 5.0)Master cylinder pressure sensor 22.4 ~ 26.5 (2.24 ~ 2.65)

KM-21





Engine




Glass thickness

Windshield 5 (0.1969)Front door 3.2 (0.1260)Rear door glass 3.2 (0.1260)Rear window 3.2 (0.1260)

Seat beltsFront 3 point type with Emergency Locking Retractor (E.L.R)Rear 3 point type with Emergency Locking Retractor (E.L.R), 2point type


Front and rear doorsDoor hinge to body 33.3~41.2 (3.4~4.2)Door hinge to door 21.6~26.5 (2.2~2.7)

TailgateTailgate hinge to body 6.9~10.8 (0.7~1.1)Tailgate latch to tailgate 6.9~10.8 (0.7~1.1)Tailgate hinge to 6.9~10.8 (0.7~1.1)


KM-22


AM/FM/Cassette(M420)

AM/FM/CD(M445)



Max 50W x 42Ω x 4

SeatFront seat mounting 43.1~64.7 (4.4~6.6)Front seat mounting nut 43.1~64.7 (4.4~6.6)

Seat belt

Front seat belt height 39.2~53.9 (4.0~5.5)Front seat belt buckle 39.2~53.9 (4.0~5.5)Front seat belt anchor 39.2~53.9 (4.0~5.5)Front seat belt lower 39.2~53.9 (4.0~5.5)Front seat belt upper 39.2~53.9 (4.0~5.5)Rear seat belt anchor 39.2~53.9 (4.0~5.5)Rear seat belt retractor 39.2~53.9 (4.0~5.5)

Type

Power supply DC 14.4VRated output Max 43W x 4Speaker impedance 4Ω x 4Antenna 80PF 75ΩTuning type PLL synthesized type


FM 87.5~108 MHz/ 100KHz (General), 50KHz(Europe)AM 531~1602 KHz/ 9KHz (General)MW 522~1620 KHz/ 9KHz (Europe)LW 153~279 KHz/ 1KHz (Europe)FM 76.0~90.0 MHz/ 100KHz (Japan)AM 522~1629KHz/ 9KHz (Japan)

KM-23



Lighting systemWWWWWWWWWWWWWWW

Items Transmitter(TX)Keyless entry transmitter Power source Lithium 3V battery (1EA)Transmissible distance 10m or moreLife of battery 2 years or more (at 20 times per day)Button Door lock/unlock/Tailgate open/Panic(option)

Transmission frequency 433.92 MHz (EUROPE)315.00 MHz (GENERAL)

21Front position lamp 5



Front fog lamp 35Rear tail/stop lamp 21/5

21License plate lamp 5

16Rear turn signal lamp 21Back up lamp

10 x 2High mounted stop lamp LED

5Room lamp 10

5

Engine

Glove box lamp

Side repeater

Overhead console lamp

Rear fog lamp - Europe

KM-24

WW

Other system


10PA15C (Swash plate)


ND-OIL8(PAG) 120~135cc

ND-OIL8(PAG) 200~215cc

4PK - type 6PK - type155.3 cc/rev 177.7 cc/rev

[oz.(g)]

SMARTRA systemManufacturer Bosch

Trunk room lamp 55

Immobilizer

ON : 220 ± 11.4 (15.5 ± 0.8)OFF : 164 ± 17.1 (11.5 ± 1.2)

ON : 370 ± 2.8 (26.0 ± 0.2)

psi (kg/cm²

OFF : 28.4 ± 2.8 (2.0 ± 0.2)ON : 28.6 ~ 36.3 (2.00 ~ 2.55)psi

(kg/cm²

High

Low

Heat rejection 13,500 ± 5% Kcal/hr

Type R - 134a18.0 ± 0.88 (510 ± 25)

psi (kg/cm²

6PK - typePulley type177.7 cc/revDisplacement


RefrigerantCapacity

Medium

Block

Triple switch

OFF : 455 ± 2.8 (32.0 ± 0.2)


Oil type & Capacity ND-OIL8(PAG) 200~215cc

Condeser

Compressor

Type

Door courtesy lamp

Type

KM-25




Auto + 8speed (Autometic) , 9 speed (Manual)

Engine

Speed control Power mosfet (Autometic)

Blower unit


Fresh and recirculation Operating method Actuator

Blower

ActuatorTemperature operating method


ON : 2.5 ± 0.5 (36.5 ± 32.9)OFF : 0.5 ± 0.5 (37.4 ± 32.9)

A/C ON/OFF ()

Heater Actuator

Type SirocoSpeed step

Type Pin & Tube typeHeating capacity 4,500 ± 5% Kcal/hrPTC capccity 9000W +5% / -10%

KM-26

　Engine Mechanical System………………………BL-2　Engine Electrical System…………………………BL-9　Fuel System……………………………..…………BL-10　Clutch…………………………………….…………BL-11　Manual Transaxle……………………….…………BL-11　Automatic Transaxle………………………………BL-12　Driveshaft………………………………..…………BL-13　Suspension System…………………….…………BL-16　Steering System………………………………… BL-18　Restraints…………………………………………BL-18　Brake System………………………………………BL-19　Body (Interior & Exterior)……………….……… BL-22　Body Electrical System……………………………BL-24　Heating, Ventilation & Air Conditioning..………BL-26

Sorento(BL) F/L

BL-1

General specifications - Sorento F/LDSL A2.5 WGT DSL A2.5 VGT GSL λ 3.3 GSL λ 3.8

Engine

mm (in.) 92 (3.6220) x 83.8 (3.2992)

96 (3.7795)x 87.0 (3.425)

cc 3.342 3,778

rpmrpmrpmrpm


kPa(kg/cm²)

Engine

Idle Speed

Total

Firing order

-5.5 (4.84)0.4 (0.35)

650 ± 100800 ± 100

650 ± 100

V-type, DOHC6

In-line, DOHC4


A/C ON

7.4 (6.51)

-Oil quality


Compression ratio

Bore x Stroke

Total displacement

Ignition Timing

91 (3.58 ) x 96 (3.78 )

A/C OFF

6.4 (5.63)

10.4 : 11-3-4-2 1-2-3-4-5-6

650 ± 100

800 ± 100 650 ± 100

5.2 (4.58)Oil filterDrain and refill

Oil quantity

Oil pressure (Idle)

Oil pan

2.49717.7 : 1

800 ± 100800 ± 100

CH - 4

8.2 (7.21)Engine oil

Above SJ or SL130(1.32)

[at 1000rpm, 110°C(230°F)]-

- BTDC 7˚ ± 5˚

BL-2

-14˚ -10°66˚ 66°52˚ 52°0˚ 0°


Intake mm (in.) 46.3 (1.8228) 46.8 (1.8425)Exhaust mm (in.)Intake mm (in.) 46.3 (1.8228) 46.8(1.8425)Exhaust mm (in.)

mm (in.)

mm (in.)

mm (in.)

Valve timing

Cylinder headLess than 0.05 (0.0019)Less than 0.1(0.0039)

45.8 (1.8031)

45.8 (1.8031)

0.02 ~ 0.18 (0.0008 ~ 0.0071)

No.1 : 27.964 ~ 27.978 (1.1009 ~ 1.1015)

No.2,3,4 : 23.954 ~ 23.970 (0.9430 ~ 0.9437)

40.163 (1.5812)

ExhaustFlatness of manifold mounting surfaceCamshaft

Less than 0.1(0.0039)0.15 (0.0059)

40.043 (1.5765)39.782 (1.5662)Cam height

LH

RH 40.456 (1.5928)

29.964 ~ 29.980 (1.1797 ~ 1.1803)


End play


Intake valve

Intake

Opens (BTDC)Closes (ABDC)Opens (BBDC)Closes (ATDC)


Exhaust valve

-

0.15 (0.0059)0.15 (0.0059)

8°

0.10 ~ 0.20 (0.0039 ~ 0.0079)

No.1: 0.027 ~ 0.057 (0.0011 ~ 0.0022)

No.2,3,4 : 0.030 ~ 0.067 (0.0012 ~ 0.0026)

8°38°52°

BL-3





mm (in.)mm (in.)

mm (in.)

mm (in.)

Engine

Load

1.15 ~ 1.45 (0.05118~0.05709)

48.2 (1.898)

Less than 1.5°

41.8 ~ 42.2 (1.6457 ~ 1.6614)

1.35 ~ 1.65 (0.05315~0.06496)

43.86 (1.7267)19.3 ± 0.8kg / 34.042.3 ± 1.3kg / 24.2

39.4 (1.551)

1.5 (0.059)

-

43.3 (1.705)

-

45.25° ~ 45.75°1.56 ~ 1.86 (0.06142 ~ 0.07323)1.73 ~ 2.03 (0.06811 ~ 0.07992)0.020~0.047 (0.00078 ~0.00185)

5.465 ~ 5.480 (0.2151 ~ 0.2157)5.458 ~ 5.470 (0.2149 ~ 0.2153)

Valve length

Stem outer diameter

0.020 ~ 0.050 (0.0008 ~ 0.0020)

Exhaust

Intake

105.27 (4.1445)105.50 (4.1535)

ValveIntakeExhaust

Inner diameter

Length

Intake

IntakeExhaust

Face angleThickness of valve head (margin)

Valve spring

Valve stem to valve guide clearanceValve guide

IntakeExhaust

Exhaust

1.7 (0.067)Seat angle

Free length

Exhaust

Out of squareness

Valve seat


44.75° ~ 45.20°

Intake- 5.500 ~ 5.512 (0.2165 ~ 0.2170)

0.030 ~ 0.054 (0.00118 ~0.00212)

5.500 ~ 5.512 (0.2165 ~ 0.2170)

0.050 ~ 0.080 (0.0020 ~ 0.0031)

41.8 ~ 42.2 (1.6457 ~ 1.6614)

110.55 (4.352)110.55 (4.352)

6.965 ~ 6.980 (0.2742 ~ 0.2748)6.935 ~ 6.950 (0.2730 ~ 0.2736)

45°1.8 ~ 2.0 (0.071 ~ 0.079)1.8 ~ 2.0 (0.071 ~ 0.079)

IntakeExhaust

45°

26.3 ± 1.2 kg / 3851.5 ± 2.4 kg / 28.8

BL-4


mm (in.)mm (in.)

mm (in.) 92.00 ~ 92.03 (3.6220 ~ 3.6232)

96.00 ~ 96.03 (3.7795 ~ 3.7807)

mm (in.)

mm (in.) 91.96 ~ 92.00(3.6205 ~ 3.6220)

95.96 ~ 95.99 (3.7779 ~ 3.7791)


0.27 ~ 0.33 (0.0106 ~ 0.0129)

0.020 ~ 0.061 (0.0008 ~ 0.0024)0.020 ~ 0.061 (0.0008 ~ 0.0024)

--

34.964 ~ 34.980 (1.3765 ~ 1.3772)

-

- 0.17 ~ 0.23 (0.0067 ~ 0.0090)

34.964 ~ 34.980 (1.3765 ~ 1.3772)

-

--

0.03 ~ 0.05 (0.0012 ~ 0.0020)

Exhaust


Less than 0.05 (0.0019)[Less than 0.02 (0.0008) / 150x150]

Cylinder bore

90.910 ~ 90.940 (3.5791 ~ 3.5803)

Piston

Cylinder block


91.000 ~ 91.030 (3.5827 ~ 3.5839)

0.05 (0.0020)

35.000 ~ 35.025 (1.3779 ~ 1.3789)Exhaust

IntakeMLA outer diameter

MLA

Exhaust



Intake

IntakeExhaust

Valve clearance

35.000 ~ 35.025 (1.3779 ~ 1.3789)-Intake

2.01 ~ 2.03 (0.0791 ~ 0.0799)Ring groove width

1.22 ~ 1.24 (0.0480 ~ 0.0488)1.22 ~ 1.24 (0.0480 ~ 0.0488)

No. 1 ring groove 2.378 ~ 2.398 (0.0936 ~ 0.0944)

3.03 ~ 3.05 (0.1193 ~ 0.1201)


2.04 ~ 2.06 (0.0803 ~ 0.0811)

0.080 ~ 0.100 (0.0031 ~ 0.0039)


BL-5






Engine

Piston pin hole clearanceConnecting rod small end inner diameterConnecting rod small end hole clearanceConnecting rod

0.1 ~ 0.25 (0.0039 ~ 0.0098)End play

60.000 ~ 60.018 (2.3622 ~ 2.3629)0.024 ~ 0.042 (0.0009 ~ 0.0016)

Crankshaft

End gap No. 2 ring grooveOil ring groove

No. 2 ring groove


Piston pin outer diameterPiston pin hole inner diameter

-


Piston pin

End play

No. 1 ring groove

0.03 ~ 0.07 (0.0012 ~ 0.0027)Piston ring

No. 1 ring grooveSide clearance 0.03 ~ 0.07 (0.0012 ~ 0.0027)


-

0.25 ~ 0.40 (0.0098 ~ 0.0157)0.50 ~ 0.70 (0.0197 ~ 0.0276)0.20 ~ 0.40 (0.0079 ~ 0.0157)

0.04 ~ 0.08 (0.0016 ~ 0.0031)

58.000 ~ 58.018 (2.2834 ~2.2842)0.038 ~ 0.056 (0.0015 ~ 0.0022)

0.030 ~ 0.054 (0.0012 ~ 0.0021)0.05 ~ 0.25 (0.0020 ~ 0.0098)

54.954 ~ 54.972 (2.1635 ~ 2.1642)0.022 ~ 0.040 (0.0008 ~ 0.0016)0.10 ~ 0.28 (0.0039 ~ 0.0110)


0.06 ~ 0.15 (0.0024 ~ 0.0059)Oil ring groove0.05 ~ 0.09 (0.0020 ~ 0.0035)

0.20 ~ 0.70 (0.0078 ~ 0.0275)

0.17 ~ 0.32 (0.0067 ~ 0.0126)0.32 ~ 0.47 (0.0126 ~ 0.0185)

0.022 ~ 0.040 (0.0009 ~ 0.0016)

0.01 ~ 0.02 (0.0039 ~ 0.0078)22.974 ~ 22.985 (0.9045 ~ 0.9049)-0.032 ~ -0.016 (-0.0012~0.0006)

32.993 ~ 32.998 (1.2989 ~ 1.2991)33.014 ~ 33.019 (12.998 ~ 1.3000)0.016 ~ 0.026 (0.0006 ~ 0.0010)

33.020 ~ 33.033 (1.3000 ~ 1.3005)

68.942 ~ 68.960 (2.7142 ~ 2.7149)

23.001 ~ 23.006 (0.9055 ~ 0.9057)23.016 ~ 23.021 (0.9061 ~ 0.9063)

56.982 ~ 57.000 (2.2434 ~ 2.2441)66.982 ~ 67.000 (2.6371 ~ 2.6378)

BL-6

kPa(kg/cm²)

ℓ(lmp.qt)°C (°F)°C (°F)

mm (in.)kPa

(kg/cm²)kPa

(kg/cm²)

kΩkΩ

Full lift

Cooling system


10 (0.3937)


Opening Full opening

Coolant quantity

Cooling method

Relief valve opening pressure 784.5 ± 78.4 (8 ± 0.8)

Type


Oil pump

450 ~ 550 (4.59 ~ 5.61)

Radiator cap


Thermostat-

82 ± 2 (179.6 ± 35.6)95 (203) 95 (203)


9.0 (7.83)10 (8.80)

82 (180)

Thermister type

93.16 ~ 122.58 (0.95 ~ 1.25 )

0.98 ~ 4.90 (0.01 ~ 0.05)

2.31 ~ 2.590,3222

BL-7



- -- -- -

Engine

Main moving system

Cylinder head

Oil pan nuts or boltsOil pan drain plugLower oil pan bolt


-



Cylinder head bolt Long boltsShort bolts

BoltsInner bolt (M11)

58.8 + 34.3 (6.0 + 3.5) + 60 ~ 64°

Out bolt (M8)Side bolt (M8)

13.7 ~ 14.7 (1.4 ~ 1.6)

24.5 (2.5)

19.60 (2.0) + 90˚-127.5 ~ 137.3 (13 ~ 14)

34.3 ~ 44.1 (3.5 ~ 4.5)9.80 ~ 11.76 (1.0 ~ 1.2)

49.00 (5.0) + 90˚19.60 (2.0) + 120˚

29.40 ~ 31.36 (3.0 ~ 3.2)

9.80 ~ 11.76 (1.0 ~ 1.2)

Lubrication system21.6 ~ 24.5 (2.2 ~ 2.5)Oil filter

Oil filter cap

39.2 (4.0) + 120˚ + 90˚18.62 ~ 23.52 (1.9 ~ 2.4)

49.0 (5.0) +120°+90°

-

-

34.3 ~ 44.1 (3.5 ~ 4.5)29.8 ~ 11.8 (1.0 ~ 1.2) -

BL-8


VA

CMF 70AH CMF 80AH600 A 660 A

120 min 145 min

Ω

kΩ

mm(in.)

Rated voltage

Speed

TypeCold cranking

Regulator setting

Amperage

TypeRated voltage

Voltage regulator typeGenerator

Gap


Speed in use

Battery

Ignition coil

Reserve capacity

Spark plugs

Primary resistanceSecondary


Unleaded (NGK)Leaded (CHAMPION)

IC regulator built-in typeI.C regulator built-in type

12V, 2.2KW 12 V, 1.4 kW

1,000 ~ 18,000 rpm

Battery voltage sensing2,600 rpm, MIN

130, MAX

1.0 ~ 1.1 (0.0394 ~ 0.0433)

MF 100 AH14.2 ~ 14.8 V (500 RPM, 10A, 25°C)

850A182min

11,51185, MAX

13.5 V, 130A

4,500rpm, MIN

13.5V, 110A

-


-

14.4 ± 0.3V

-

-

BKR5ES

0.62 ± 10 %

7.0 ± 15 %IFR5G-11

1.280 ± 0.01

--

BL-9



)

- -

MPa(kgf/cm²

)135 (1,377) 160 (1,632) - -

KPa(kgf/cm²

)

Engine

Engine Management

- 375 ~ 385 (3.82 ~ 3.92)



DelphiFuel Tank Capacity 80 (70.39)

BoschManufacturer

Fuel Return System Type Return type Returnless type



Mechanical ElectricalPlunger Pumping Type In-tank type

Driven by Drive Belt Electric motor

BL-10


Clutch cover assemblyClutch pedal bracket mountingClutch master cylinder mountingClutch release cylinderService standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.)

Type M5UR1 M5SR1 - -3,749 4,393 - -2,044 2,306 - -1,289 1,452 - -1,000 1,000 - -0,794 0,825 - -3,453 4,632 - -

3.2 (2.8)2.7 (2.38)

SAE 75W-90 (Fill-for-life)

SAE 75W/85 or API GL - 4 -

3.5 (3.07)

Manual Transaxle


Tightening torque [N.m(kgf-m)]15~22 (1.5~2.2)25~35 (2.5~3.5)18~27 ( 1.8~2.7)19~26 (1.9~2.6)

150 (5.91)7.3~13.9 (0.28~0.55)

Rev.

M/T oil quality

2WD ℓ(lmp.qt)

Gear ratio

1st2nd3rd4th5th

MT oil capacity 4WD

-

--

BL-11

General specifications - Sorento F/LEngine DSL A2.5 WGT DSL A2.5 VGT GSL λ 3.3 GSL λ 3.8

Automatic TransaxleType A5SR1 A5SR2 A5SR1 A5SR2

3,827 4,497 3,827 4,4972,368 2,442 2,368 2,4421,520 1,686 1,520 1,6861,000 1,233 1,000 1,2330,834 0,868 0,834 0,8682,613 4,586 2,613 4,586

ℓ(lmp.qt)

4th5th

ATF quality

Gear ratio

1st2nd3rd

Rev.

ATF capacityAPOLLOIL ATF RED-1

10 (8.8)

BL-12

Driveshaft

M/T mm (in.) 640.8 × 63.5(25.23 × 2.50)

A/T mm (in.) 675 × 63.5(26.57 × 2.50)

M/T mm (in.) 1156 × 76.2(45.51 × 3.00)

A/T mm (in.) 1123 × 76.2(44.21 × 3.00)

M/T mm (in.) 1496 × 76.2(58.90 × 3.00) -

A/T mm (in.) 1476 × 76.2(58.11 × 3.00)

1462.8 × 76.2(57.59 × 3.00)

mm (in.)

660.4 × 63.5(26.00 × 2.50)

UJ + UJUJ + UJ

1137 × 76.2(44.76 × 3.00)

O.D. : Outer Diameter

Length × O.D.

Rear(2WD)

Propeller shaft

Joint type FrontRear

Front(4WD)

Rear(4WD)

Run-out[NOTE]UJ : Universal Joint

0.3 (0.01)

-

625.5 × 63.5(24.63 × 2.52)

-

1172 × 76.2(46.14 × 3.00)

-

1531.6 × 76.2(60.30 × 3.00)

BL-13

General specifications - Sorento F/LEngine DSL A2.5 WGT DSL A2.5 VGT GSL λ 3.3 GSL λ 3.8

M/T 4,181 3,727A/T

M/T 4,181 3,727A/T

Double taper roller bearingFront axle and driveshaftFront axle hub bearing type

Rear axle and axle shaftAxle housing typeAxle shaft supporting type

TSJBJDriveshaft Joint type

InnerOuter

Differential (4WD)Reduction gear type

Reduction ratio 3,333 -

3,333

Hypoid gear

Banjo typeSemi-floating type

DifferentialReduction gear type

Reduction ratio 3,333

Hypoid gear -

3,333BJ : Birfield Joint TSJ : Three Spherical Joint

BL-14

Lubricants

g

ℓ

RBATSJ

DriveshaftJoint typeRecommended greaseQuantity 210

SAE90, API GL-5 (MOBIL : MOBIL LUBE HD, SHELL : SHELL SPIRRAX HD)

SAE 85W-90, API GL-5 (MOBIL : INFILREX 33, SK : G-LS)(Fill the reservoir to the plug hole)

Front : 1.3, Rear :1.6

150

Differential

hypoid gear oil

LSD Oii

Quantity

[NOTE]Inner: On transaxle sideOuter : On tire side

BJ

BL-15

General specifications - Sorento F/L

mm (in.)


Suspension type Double wishbone 5 link coil springShock absorber type Gas pressurized


-7.0JJ × 16", 7.0JJ × 17"

Tire sizeTire pressure 2.4kgf/cm2 (35psi)

245/70 R16, 245/65 R17

Caster 3.89°±0.5° -Toe-in 0±2 (0±0.079) 0±2 (0±0.079)King-pin 12.13° -

Wheel alignment

Camber 0.00°±0.5° 0°±30'

BL-16

Tightening Torque [N.m(kgf-m)]Hub nuts 90 ~ 120 (9.0 ~ 12.0)Front strut assembly to frame 44 ~ 55 (4.4 ~ 5.5)Front strut assembly to lower arm 122 ~ 140 (12.2 ~ 14.0)Front stabilizer link to lower arm 100 ~ 120 (10.0 ~ 12.0)Front lower arm to knuckle 160 ~ 200 (16.0 ~ 20.0)Front lower arm to frame 145 ~ 165 (14.5 ~ 16.5)Front upper arm to knuckle 44 ~ 55 (4.4 ~ 5.5)Front upper arm to frame 76 ~ 95 (7.6 ~ 9.5)Front stabilizer link to stabilizer bar 100 ~ 120 (10.0 ~ 12.0)Front stabilizer bar bracket mounting bolts 44 ~ 55 (4.4 ~ 5.5)Rear shock absorber to frame 70 ~ 85 (7.0 ~ 8.5)Rear shock absorber to rear axle 122 ~ 140 (12.2 ~ 14.0)Rear upper arm to rear axle 122 ~ 140 (12.2 ~ 14.0)Rear upper arm to frame 122 ~ 140 (12.2 ~ 14.0)Rear lower arm to rear axle 140 ~ 160 (14.0 ~ 16.0)Rear lower arm to frame 140 ~ 160 (14.0 ~ 16.0)Rear stabilizer link to frame 100 ~ 120 (10.0 ~ 12.0)Rear stabilizer link to stabilizer bar 100 ~ 120 (10.0 ~ 12.0)Rear stabilizer bar bracket mounting bolts 45 ~ 55 (4.5 ~ 5.5)Lateral rod to rear axle 187 ~ 225 (18.7 ~ 22.5)Rear cross member mounting bolt 187 ~ 225 (18.7 ~ 22.5)

BL-17


Type

mm (in.)

ΩΩΩΩ

Rack and Pinion

Steering SystemEngine

Power steering fluid PSF-3Rack stroke 162 (6.38)

Power steering pump relief pressurekPa

(kgf/cm²)

8336 ~ 9002 (85 ~ 92)

Tightening Torque [N.m(kgf-m)]Steering wheel lock nut 40 ~ 50 (4.0 ~ 5.0)Steering column mounting bolt & nut 16 ~ 23 (1.6 ~ 2.3)Bolt connecting steering column to universal joint 22 ~ 27 (2.2 ~ 2.7)Bolt connecting universal joint to steering gear 22 ~ 27 (2.2 ~ 2.7)Tie rod end to knuckle 60 ~ 80 (6.0 ~ 8.0)Power steering pump to pump bracket DSL: 20 ~ 30 (2.0 ~ 3.0), GSL: 35 ~ 50 (3.0 ~ 5.0)

Steering gear box mounting clamp bolt and nut 85 ~ 110 (8.5 ~ 11.0)

Restraints

Pressure hose to power steering pump 55 ~ 65 (5.5 ~ 6.5)Steering gear box mounting bolt 122 ~ 158 (12.2 ~ 15.8)

Type DepoweredResistanceDriver Airbag (DAB) 1.6 ~ 6.4Passenger Airbag (PAB) 1.8 ~ 6.4Curtain Airbag (CAB) 1.8 ~ 4.8Seat Belt Pretensioner (BPT) 1.8 ~ 6.4

BL-18

Brake System

mm (in.)

mm (in.)

Master cylinderTypeI.D.

Brake boosterType

Provided

Vacuum type with tandem boosterEffective diameterBoosting ratio

Tandem type26.99 (1.06)


Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB) 7.9 ~ 10.8 (0.8 ~ 1.1)Passenger Airbag (PAB)

Bolt 18.6 ~ 26.5 (1.9 ~ 2.7)Nut 8.8 ~ 13.7 (0.9 ~ 1.4)

Curtain Airbag (CAB) 7.8 ~ 11.8 (0.8 ~ 1.2)Seat Belt Anchor Bolt (BPT) 39.2 ~ 53.9 (4.0 ~ 5.5)SRSCM Mounting Bolt 10.2 ~ 13.8 (1.0 ~ 1.4)Front Impact Sensor (FIS) Mounting Bolt 10.2 ~ 13.8 (1.0 ~ 1.4)Side Impact Sensor (SIS) Mounting Bolt 10.2 ~ 13.8 (1.0 ~ 1.4)

Brake fluidRecommended lubricantQuantity

DOT 3 or equivalentAs required

8 + 9 in 7.5 : 1

BL-19



mm (in.)


mm (in.)

mm (in.)mm (in.)

O.D=Outer DiameterI.D=Inner Diameter

EngineFront brakeTypeDisc O.D.

Floating type with ventilated disc302 (11.89)

Disc thicknessPad thickness

28 (1.10)10.5 (0.41)

Rear brake(Disc)

Double piston46 (1.81)

TypeDisc O.D.

Cylinder typeCylinder I.D.


20 (0.787)10 (0.39)

Cylinder typeCylinder I.D

Single piston42.9 (1.69)

Parking brakeTypeActuation

DIH(Drum in hat) typelever

Drum I.D.Lining thickness

190 (7.48)4 (0.157)

Floating type with solid disc315 (12.4)

BL-20


Front mm(in.)Rear mm(in.)


mm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)



Air gap

Tone wheel

0.15 ~ 1.5 (0.006 ~ 0.059)0.2 ~ 1.2 (0.008 ~ 0.047)

48

Brake pedal heightClearance between stop lamp switch outer case and pedal arm

200 (7.87 )

0.5 ~ 1.0 (0.02 ~ 0.04)

Brake pedal free playParking brake lever stroke

4 ~ 7 (0.157 ~ 0.275)4 ~ 6 clicke (When lever assembly is pulled with 10kgf)

Front disc brake pad thicknessFront disc thickness (minimum)

2.0 (0.0787)26 (1.02)

Front disc runoutFront disc thickness variation

0.03 (0.0012)0.005 (0.0002)

Rear disc brake pad thicknessRear disc thickness

2.0 (0.079)18.4 (0.724)

Parking brake drum I.D.Parking brake liner thickness

191 (7.52)1.5 (0.059)

Tightening torque [N.m (kgf-m)]Sensor mounting bolt on the brake plate

FrontRear

7 ~ 10 (0.7 ~ 1.0)7 ~ 10 (0.7 ~ 1.0)

HECU mounting nutHECU mounting bracket bolt

8 ~ 12 (0.8 ~ 1.2)19 ~ 26 (1.9 ~ 2.6)

Six brake tubes on the hydraulic unit 13 ~ 22 (1.3 ~ 2.2)

BL-21





Engine

Front doorConstruction Front hinged, full door constructionRegulator system X-arm typeLocking system Pin-fork system


Glass thickness

Windshield 5 (0.1969)Front door 3.5 (0.1378)Rear door glass 3.5 (0.1378)Quarter window 3.5 (0.1378)Tailgate glass 3.5 (0.1378)

Seat beltsFront 3 point type with Emergency Locking Retractor (E.L.R)Rear 3 point type with Emergency Locking Retractor (E.L.R)

BL-22

Front fender Mounting bolts 7~9 (0.7 ~ 0.9)

Front door

Checker (Body side) 22~27 (2.2~2.7)Checker (Door side) 9~13 (0.9~1.3)Hinge (Body side) 35~42 (3.5~4.2)Hinge (Door side) 18~30 (1.8~3.0)Glass grip boltGlass guide 8~12 (0.8~1.2)Regulator assembly 4~6 (0.4~0.6)Latch assembly 4~6 (0.4~0.6)Outside handle 7~11 (0.7~1.1)Striker 18~26 (1.8~2.6)Outside rearview mirror 5~7 (0.5~0.7)

Rear door

Checker (Body side) 22~27 (2.2~2.7)Checker (Door side) 9~13 (0.9~1.3)Hinge (Body side) 35~42 (3.5~4.2)Hinge (Door side) 18~30 (1.8~3.0)Glass grip boltRegulator assembly 4~6 (0.4~0.6)Latch assembly 4~6 (0.4~0.6)Outside handle 7~11 (0.7~1.1)Striker 18~26 (1.8~2.6)

Crash pad Cross bar mounting 17~26 (1.7~2.6)Seat Seat mounting bolt/nut 39 (3.9)

HoodHinge 22~27 (2.2~2.7)Latch assembly 7~11 (0.7~1.1)

8~12 (0.8~1.2)

8~12 (0.8~1.2)


BL-23



531~1602 KHz / 9KHz (General)522~1620 KHz / 9KHz (Europe)

Engine

Seat belt

Front seat belt height 39.2~53.9 (4.0~5.5)Front seat belt buckle 39.2~53.9 (4.0~5.5)Front seat belt anchor mounting bolt

39.2~53.9 (4.0~5.5)

Front seat belt lower 39.2~53.9 (4.0~5.5)Front seat belt upper Rear seat belt anchor 39.2~53.9 (4.0~5.5)Rear seat belt retractor 39.2~53.9 (4.0~5.5)

TypePower supplyRated output

RADIO/TAPE/CD/MP3 (M455)DC 14.4V

Max 43W x 4 3.2Vrms

RADIO/TAPE/6CDC (M465)

87.5~108 MHz / 100KHz (General), 50KHz(Europe)

Speaker impedanceAntennaTuning type



FMAMMWLW 153~279 KHz / 1KHz (Europe)

10Ω4Ω x 4

39.2~53.9 (4.0~5.5)

BL-24







Button


Door lock / unlock, rear hatch glass open, panic433MHz ± 250MHz (Except Middle east)

315MHz ± 250 MHz (Middle east)

Head lampHighLow

5555


215

Front fog lampRear tail/stop lamp

2721/5


1621

License plate lampRoom lamp

510 x 2

Overhead console lampLuggage lamp

10 x 25

Door courtesy lamp 5

BL-25


Other system


Bosch

Engine

4 channelButton type (Front door)

SIEMENS


SMARTRA system


SMART KEYTypeManufacturer

Compressor

Type HS - 18 (Swash plate)Oil type & Capacity FD46XG (PAG) , 150 ± 10ccPulley type 4PK - TYPEDisplacement 110 cc/rev

Condeser Heat rejection 8,500 ± 10% Kcal/hrAPT(A/C pressure


Voltage = 5 * (0.025 * pressure + 0.1) [Kgf/]Voltage = 5 * (0.001758 * pressure + 0.074612) [PSIA]


RefrigerantType R - 134aCapacity [oz.(g)] 18.25 ± 0.88 (540 ± 25)

BL-26




Blower Type Siroco fanSpeed step Auto + 8speed (Autometic) , 1~8 speed (Manual)Speed control Power mosfet


Heater



Evaporator

Type Drawn cupTemperature control type Thermistor

Off : 0 ± 0.5 (32 ± 32.9)ON : 2.5 ± 0.5 (36.5 ± 32.9)


BL-27

　Engine Mechanical System …………………… HM-2　Engine Electrical System ……………………… HM-9　Fuel System ……………………………..……… HM-10　Clutch …………………………………….……… HM-11　Manual Transaxle ……………………….………HM-11　Automatic Transaxle …………………………… HM-12　Driveshaft ………………………………..……… HM-13　Suspension System …………………….……… HM-16　Steering System …………………………………HM-18　Restraints …………………………………………HM-18　Brake System ……………………………………HM-19　Body (Interior & Exterior) ……………….………HM-22　Body Electrical System …………………………HM-24　Heating, Ventilation & Air Conditioning …………HM-26

Mohave/Borrego(HM)

BL-1

General specifications -MOHAVE / HMG 3.8 DOHC G 4.6 DOHC

Engine

mm (in.) 96 (3.7795) x 87 (3.4252)

92 (3.6220) x 87 (3.4252)

cc 3.778 4,627

rpmrpmrpmrpm


kPa(kg/cm²)

Engine

Idle Speed

Total

Firing order

D 3.0 TCI

6.4L(6.76US qt, 5.63imp qt)

V-type, DOHC8

V-type, DOHC6


0.4 (0.35)

570 ± 100

630 ± 100


Compression ratio

Bore x Stroke

Total displacement

Ignition Timing

A/C ON

84.0mm (3.3071in) x 89.0mm (3.5039in)

A/C OFF

6.0L(5.28)

10.4 : 11-2-3-4-5-6 1-2-3-4-5-6 1-2-7-8-4-5-6-

3

720 ± 100

720 ± 100

Oil quantity

5.2 (4.58)Oil filterDrain and refill

Oil pan

7.4L(7.82US qt,6.51imp qt)

5.5 (4.84)

Oil pressure (Idle)

2.95917.3± 0.5 : 1

680rpm

API CH - 4 , ACEA B4

7.8L(8.24US qt,6.86imp qt)Engine oil

Above SJ or SL,SAE5w-20Oil quality130(1.32)

[at 1000rpm, 110°C(230°F)]0.8kg/(7.85kpa , 1.14psi)

- BTDC 11± 5

BL-2

10˚ 8°66˚ 74°52˚ 62°0˚ 4°


Intake mm (in.) 46.3 (1.8228) 41.6mm(15.4in)Exhaustmm (in.)Intake mm (in.) 46.3 (1.8228) 41.6mm(15.4in)Exhaustmm (in.)

mm (in.)

mm (in.)

mm (in.)

Cylinder head

Valve timing

Less than 0.05mm 0.02mmLess than 0.1(0.0039)

45.8 (1.8031) 41 5mm(16 3in)

45.8 (1.8031) 41 5mm(16 3in)

0.02 ~ 0.18mm (0.0008 ~ 0 0071in )

No1: No127.964 ~27.978 35.964~35.980mmNo.2,3,4: No.2,3,423.954~23.970

36.000~40.152mm

24.947 ~ 24.960mm

Flatness of manifold mounting surfaceCamshaft

Less than 0.1(0.0039)0.016 (0.0006in)

36.000~40.477mm36.000~40.152mm

Cam heightLH

RH36.000~40.477mm


End play

0.040~0.074mm

Intake


Exhaust

Opens (BTDC)


Exhaust valve

Intake valve Closes (ABDC)Opens (BBDC)Closes (ATDC)

0.05 (0.0020in)0.016 (0.0006in)

15°

0.05 ~ 0.15mm

No.1: 0.027 ~ 0.057 No.2,3,4 : 0.030 ~ 0.067

13°34°55°

BL-3

General specifications - MOHAVE/HMG6DA 3.8DOHC GSL λ 3.8




mm (in.)mm (in.)

mm (in.)

Engine

48.2 (1.898) 43.86 (1.7267)

41.8 ~ 42.2 (1.6457 ~ 1.6614)41.8 ~ 42.2 (1.6457 ~ 1.6614)

44.5 ~ 45°

1.39 ~ 1.43mm1.35 ~ 1.65 (0.05315~0.06496)

45.25° ~ 45.75°1.56 ~ 1.86 (0.06142 ~ 0.07323)1.73 ~ 2.03 (0.06811 ~ 0.07992)0.020~0.047 (0.00078 ~0.00185)

5.465 ~ 5.480 (0.2151 ~ 0.2157)5.458 ~ 5.470 (0.2149 ~ 0.2153)

105.27 (4.1445)

0.025 ~ 0.052mm

Exhaust

Intake

Valve length105.50 (4.1535)

Valve

D 3.0 TCI

99.3mm99.3mm

Intake

Exhaust

Face angleThickness of valve head (margin)

IntakeExhaust

Stem outer diameter

Width of seat contact 1.15 ~ 1.45 (0.05118~0.05709)

Valve spring

1.39 ~ 1.43mmSeat angle

IntakeExhaust

IntakeValve stem to valve guide clearanceValve guide

IntakeExhaust

Exhaust 0.030 ~ 0.054 (0.00118 ~0.00212)

5.500 ~ 5.512 (0.2165 ~ 0.2170)

0.030 ~ 0.057mm

6.000 ~ 6.012mm

44.75° ~ 45.20°

Intake6.000 ~ 6.012mm 5.500 ~ 5.512 (0.2165 ~ 0.2170)

Free length

Exhaust

5.960 ~ 5.975mm5.960 ~ 5.970mm

45.00 ~ 45.25°

36.25 ~ 36.75mm36.25 ~ 36.75mm

Inner diameter

Length

Valve seat

1.5mm1.5mm

BL-4

mm (in.)


mm (in.)mm (in.)

mm (in.) 92.00 ~ 92.0396.00 ~ 96.03

mm (in.)

mm (in.) 91.96 ~ 91.9995.96 ~ 95.99


0.17 ~ 0.23 (0.0067 ~ 0.0090)-

-

-

Load

0.27 ~ 0.33 (0.0106 ~ 0.0129)

0.020 ~ 0.061 (0.0008 ~ 0.0024)

Less than 1.5°

34.964 ~ 34.980 (1.3765 ~ 1.3772)- 34.964 ~ 34.980 (1.3765 ~ 1.3772)

1.5°or less

-

19.3 ± 0.8kg / 34.041.5 ± 1.3kg / 24.2

175 ± 8N/33.5mm278 ± 20N/24.8mm

Less than 0.05 (0.0019)[Less than 0.02 (0.0008) / 150x150]

0.03 ~ 0.05 (0.0012 ~ 0.0020)

Cylinder bore

Piston outer diameter 83.926 ~ 83.956mm

Piston

-IntakeExhaust

Cylinder block


84.000 ~ 84.030mmLess than 0.42mm (W), 0.096mm

(L)Less than 0 012(50mm x 50mm)

35.000 ~ 35.025 (1.3779 ~ 1.3789)Exhaust

Intake

Exhaust

MLA outer diameter

MLA


Out of squareness



Intake

IntakeExhaust

Valve clearance

35.000 ~ 35.025 (1.3779 ~ 1.3789)

0.020 ~ 0.061 (0.0008 ~ 0.0024)--

No. 1 ring groov1.82 ~ 1.84mm

2.01 ~ 2.03 (0.0791 ~ 0.0799)

1.22 ~ 1.24 (0.0480 ~ 0.0488)1.22 ~ 1.24 (0.0480 ~ 0.0488)Ring groove width

0.064 ~ 0.084 mm

No. 2 ring groovOil ring groove

2.434 ~ 2.454mm

3.02 ~ 3.04 mm

BL-5

General specifications -MOHAVE/HMG6DA 3.8DOHC G8BA4.6DOHC





Engine

Connecting rod

0.1 ~ 0.25 (0.0039 ~ 0.0098)End play

66.500 ~ 66.518 mm0.024 ~ 0.058mm


58.000 ~ 58.018 (2.2834 ~2.2842)0.038 ~ 0.056 (0.0015 ~ 0.0022)


0.007 ~ 0.024mmCrankshaft


Piston pin hole inner diameterPiston pin hole clearanceConnecting rod small end inner diameter

No. 2 ring groov


D3.0TCI

End gap No. 2 ring groovOil ring groove

Main bearing oil clearance 0.030 ~ 0.048mm01 ~ 0.3mm

Piston pin

No. 1 ring groov0.40 ~ 0.60 mm

0.06 ~ 0.15 0.06 ~ 0 15Oil ring groove

0.03 ~ 0.07 0.04 ~ 0 08

0.03 ~ 0.07 0.04 ~ 0 08

Piston ringNo. 1 ring groov

0.08 ~ 0.12mmSide clearance

54.954 ~ 54.972 (2.1635 ~ 2.1642)0.022 ~ 0.040 (0.0008 ~ 0.0016)0.10 ~ 0.28 (0.0039 ~ 0.0110)


End play

68.942 ~ 68.960 (2.7142 ~ 2.7149)63.482 ~ 63.500mm

31.020 ~ 31.031mm

75.982 ~ 76.000mm

0.102 ~ 0.146mm

0.20 ~ 0.35mm

0.20 ~ 0.70 0.20 ~ 0 70

0.17 ~ 0.32 0.17 ~ 0 32 0.32 ~ 0.47 0.37 ~ 0 52

0.25 ~ 0.50 mm

0.03 ~ 0.35mm

30.994 ~ 31.000 mm31.014 ~ 31.021mm0.014 ~ 0.027mm

0.020 ~ 0.037mm

0.01 ~ 0.02 0.004 ~ 0.01522.974 ~ 22.985 22.007 ~ 22 0180.032 ~ 0.016 0.007 ~ 0.023

23.001 ~ 23.006 21.995 ~ 22 00023.016 ~ 23.021 22.004 ~ 22 010

BL-6

kPa(kg/cm²)

ℓ(lmp.qt)

Type

°C (°F)°C (°F)

mm (in.)kPa

(kg/cm²)kPa

(kg/cm²)

kΩkΩ

Opening

0 ~ 6.86kpa (0 ~ 0.07)

2.31 ~ 2.59

Cooling system

Thermister type

93.16 ~ 122.58 (0.95 ~ 1.25 )

10 (0.3937)

Type


11.4 (12.0)

82 ± 2 (179.6 ± 35.6)82 ± 2 °C


Coolant quantity

Cooling method


Full lift

Oil pump

450 ~ 550 (4.59 ~ 5.61)

Radiator cap


-95 (203)


14.7L

0,3222

Wax pellet type


Full opening


95 (203)Thermostat

BL-7

General specifications - MOHAVE/HMG6DA 3.8DOHC G8BA4.6DOHC


IntakeExhaustIntakeExhaust

Cylinder head

Upper Oil pan nuts or bolts1

36.000 ~ 40 477mm(1 4173~1 5936in )36.000 ~ 40 152mm(1 4173~1 5808in )36.000 ~ 40 477mm(1 4173~1 5936in )

LHCamshaftRHCamshaft

D3.0TCI

long bolt(LH/RH)flange bolt(LH/RH)

Engine

Upper Oil pan nuts or bolts2

Camshaft bearing ladder bolts

Cylinder head bolt

27.5 ~31.4 + 120 ~ 124° 19.60 (2.0) + 90˚46.3mm(1.8228in.) / 46 8mm(1 8425in )

36.000 ~ 40 152mm(1 4173~1 5808in )

9.8~11.8

24.5 (2.5)

34.3 ~ 44.1 (3.5 ~ 4.5)

Main moving system

-


Cam height

7.2 ~ 8.7

45.8mm (1.8031in.)46.3mm(1.8228in.) / 46 8mm(1 8425in )45.8mm (1.8031in.)

9.8~11.8 13.7 ~ 14.7

Lubrication system9.8 ~ 11.8Oil gauge bracket

Oil filter cap

Lower oil pan bolt

39.2+120˚+90˚ 32.4~36.3

58.8+88°~92°+118°~122°

9.8 ~11.8

24,5

29.4 ~ 33.39.8 ~ 11.8 -

BL-8


VA

64-27AH CMF 80AH660 A 900 A

145 min 182 min

Ω

kΩ

mm(in.)

-

14.55 ± 0.2V

--

1000~18000rpm

Rated voltage

Speed

TypeCold cranking

Regulator setting

Amperage

TypeRated voltage


Gap


Speed in use

Battery

Ignition coil

Reserve capacity

Spark plugs

Primary resistanceSecondary


Unleaded (NGK)Leaded (CHAMPION)

IC regulator built-in typeI.C regulator built-in type

12V, 2.2KW 12 V, 1.4 kW

1,000 ~ 18,000 rpm


2,600 rpm, MIN 2660rpm MIN

130, MAX11,511

1.0 ~ 1.1 1.0 ~1.1

80-23FL

12.4 ~ 14.8 V 13.2V ~ 14 0V

900A182min

85A, MAX

13.5 V, 130A 13.5V ,180A

2.000rpm, MIN

12V, 150ABattery voltage sensing

0.62 ± 10 %

7.0 ± 15 %IFR5G-11 T40246P

1.280 ± 0.01

--

BL-9



)

MPa(kgf/cm²

)- -

KPa(kgf/cm²

)

Engine G6DA 3.8DOHC G8BA4.6DOHC

Automatic TransaxleType A5SR2 6HP26 (ZF)

RND 1↔2↔3↔4↔51st 3,827 4,171

2,368 2,3401,520 1,5211,000 1,1430,834 0,864

0,691 Rev

1ea [MV1]

ℓ(lmp.qt)

Neutral (Engine start allowed)Reverse

4,171

1,1431,5212,340

-

D3.0TCIEngine



Regulated Fuel Pressure

Fuel Tank Capacity 82 (21.6U.S.gal,86.6U.S.qt,72.1lmp.qt)BoschManufacturerEngine Management

Electrical In-tank type

Fuel Return System Type Return type


Fuel Pump

Type (High Pessere)Driven byType (Low Pessere)

Mechanical Plunger Pumping TypeTiming chain Electric motor

Electrical In-tank typeDriven by Electric motor

5th0,6910,864

380kpa(3.87kgf/ 55.0psi)

1600ber

6HP26 (ZF)Fix output axle (Engine start allowed)

D 3.0 TCI

Shift position

Gear ratio

P

2nd3rd

6th.

4th

ATF capacity

3.403 2.613 3.403

hell M-1375.4 10 (8.8) APOLLOIL ATF RED-1 Shell M-1375.4 10 (8

Solenoid 3-wayLinear

1ea [MV1]D3.0 G4.6 6ea[EDS1,EDS2,EDS3,EDS4,EDS5,EDS6]

BL-10

Driveshaft

20° 43° Inner side TSJ#25 Outer side BJ#25

Reduction gear type

Max. permissible angle

Front driveshaft

Propeller shaft

Rear driveshaft

TSJ210g130g

Quantity145g

150g

Rear differential

RBARBA

Reduction gear typeReduction gear ratio

Final drive gear

RBA

Oil capacity (L)

0.13 ~ 0.18

LubricantsBJ

Inner: On transaxle side

Rear driveshaftRBA

Outer : On tire side

[NOTE]

Oil capacity (L) About1.3~1.4Hypoid gear

Differential gear

Max. permissible angleJoint type

Joint type

Max : 0.1 (0.0039)

Inner side TSJ#25 Outer side BJ#25 20° 43°

ypoid gear oil(API GL-5, SAE 75W/90About1.7~1.9Hypoid gear

3,357

Hypoid gear oil(API GL-5, SAE 90)

Max : 0.1 (0.0039)

Front differential Reduction gear ratio 3,3570.13 ~ 0.18

Oil type

TSJBJ

LubricantsItems

Front driveshaft

Final drive gear

Differential gear

Oil type

BL-11

General specifications -MOHAVE/HM

mm (in.)


Suspension type Double wishbone Multi-linkShock absorber type Gas pressurized


-7.5JJ × 17", 7.5JJ × 18"

Tire sizeTire pressure 2.2kg/cm(32psi)

245/70 R16, 245/65 R17

Caster 0.50°±0.5° 1.00±0.5Toe-in 3.80°±0.5° 0±2 (0±0.079)King-pin 13.92° -


Wheel alignment

Camber 0±2mm (0±0.079in.) 2.1±2mm (0.082±0.079in.)

Front Wheel nut 88.3~107.9Nm (9~11Kgf.m)Driveshaft Lock nut 240.2~269.6Nm (24.5~27.5Kgf.m)Strut assembly lower mounting bolt 152.0~171.6Nm (15.5~17.5Kgf.m)Inner shaft bearing housing bolt 69.6~93.1Nm (7.1~9.5Kgf.m)Break caliper mounting bolt 88.3~98.1Nm (8.5~10Kgf.m)Wheel speed sensor mounting bolt 6.9~10.8 Nm (0.7~1.1Kgf.m)Break disc mounting screw 4.9~5.9 Nm (0.5~0.6Kgf.m)Lower arm assembly mounting bolt 137.2~156.9 Nm (14~16Kgf.m)

BL-12

Lower arm ball joint mounting bolt 98.1~117.7 Nm (10~12Kgf.m)Tie rod end ball joint mounting nut 58.8~78.4 Nm (6.0~8.0Kgf.m)Driveshaft lock nut 240.2~269.6Nm (24.5~27.5Kgf.m)Shock absorber upper mounting bolt 137.3~156.9 Nm (14~16Kgf.m)Shock absorber upper mounting nut 98.1~117.7 Nm (10~12Kgf.m)Break caliper mounting bolt 63.7~73.5 Nm (6.5~7.5Kgf.m)Wheel speed sensor mounting bolt 6.9~10.8 Nm (0.7~1.1Kgf.m)Break disc mounting screw 4.9~5.9 Nm (0.5~0.6Kgf.m)Hub assembly mounting bolt 78.5~88.3 Nm (8~9Kgf.m)Upper arm ball joint mounting nut 78.5~88.3 Nm (8~9Kgf.m)Lower arm mounting bolt 137.3~156.9 Nm (14~16Kgf.m)Assist arm ball joint mounting nut 98.1~117.7 Nm (10~12Kgf.m)Trailing arm mounting bolt 137.3~156.9 Nm (14~16Kgf.m)

BL-13


Type

mm (in.)

ΩΩΩΩΩ

Rack & Pinion

Steering SystemEngine D 3.0 TCI

Power steering fluid PSF-3Rack stroke 168mm

Power steering pump relief pressurekPa

(kgf/cm²)

90 ~ 95kgf/cm²(1280 ~ 1351 psi, 8.8 ~ 9.3MPa)

Tightening Torque [N.m(kgf-m)]Drive shaft nuts 245 ~ 275Steering wheel and column shaft 40 ~ 50Steering column assembly mounting bolts and nu 13 ~ 18Steering column assembly & universal joint 22 ~ 27 (2.2 ~ 2.7)Bolt connecting universal joint to steering gear pi 30 ~ 35Tie-rod end andknuckle 60 ~ 80

Power steering pump and Pump bracket 20 ~ 27

Restraints

Power steering gear box and frame LH122 ~ 158 RH90 ~ 110Pressure tube eye bolt and Power steering pump 55 ~ 65

ResistanceDriver Airbag (DAB) 1.5 ~ 5.7Passenger Airbag (PAB) 1.5 ~ 5.7

Curtain Airbag (CAB) 1.5 ~ 5.7Side Airbag (SAB) 1.5 ~ 5.7

Seat Belt Pretensioner (BPT) 1.5 ~ 5.7

BL-14

Brake System

mm (in.)

mm (in.)

Master cylinder

9:01

TypeI.D.

Brake boosterType

Provided

9" + 9" Tandem

26.99 mm (1.063 in)Fluid level warning sensor

Effective diameterBoosting ratio

Tandem type

Tightening Torque [N.m(kgf-m)]Driver Airbag (DAB) 7.8 ~ 10.8Passenger Airbag (PAB)

Bolt 18.6 ~ 26.5Nut 5.9 ~ 6.9

Curtain Airbag (CAB) 6.9 ~ 8.8Seat Belt Anchor Bolt (BPT) 39.2 ~ 53.9SRSCM Mounting Bolt 6.9 ~ 8.8Front Impact Sensor (FIS) Mounting Bolt 6.9 ~ 8.8Side Impact Sensor (SIS) Mounting Bolt 4.9 ~ 6.9

Brake fluidRecommended lubricantQuantity

DOT 3 or DOT 4As required

BL-15



mm (in.)


mm (in.)

mm (in.)mm (in.)

O.D=Outer DiameterI.D=Inner DiameterAnti-lock Brake System(ABS)/ Electronic Stability Program(ESP)


teeth

Engine D 3.0 TCI

Ventilated disc328 mm (12.91 in)

Front brake

Disc O.D.28 mm (1.10 in)

Type

Disc O.D.

Cylinder typeCylinder I.D.


Rear brake(Disc)

DoubleØ 48mm(1.89 in) X 2

Type

Pad thickness13 mm (0.51 in)

Cylinder type

Disc thickness

Cylinder I.DSingle piston

Parking brakeTypeActuation

DIH(Drum in hat) type

Drum I.D.Lining thickness

Ø 210 mm (7.48 in)

Manufacturer and NameHECU System 4 Channel 4 Sensor (Solenoid)


Air gap

Tone wheel

0.5 ~ 1.5 mm0.5 ~ 1.5 mm

48

Solid disc324 mm (12.76 in)

BL-16

Service standardmm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

Hub nutBrake tube flare nuts ABS ESP

88.3 ~ 107.912.7 ~ 16.718.6 ~ 22.6

Brake pedal free playBrake booster mounting nuts

3 ~ 8 mm (0.12 ~ 0.31 in)12.7 ~ 15.7

Front disc brake pad thicknessFront disc thickness (minimum)

10.5 mm (0.41 in)28 mm (1.10 in)

Master cylinder to brake boosterAir bleeding screw

12.7 ~ 16.76.9 ~ 12.7

Rear disc brake pad thicknessRear disc thickness

10.5 mm (0.41 in)13 mm (0.51 in)

Brake hose to caliperBrake pedal member bracket bolts

16.7 ~ 25.516.7 ~ 25.5

Tightening torque [N.m (kgf-m)]Stop lamp switch lock nut

Common pedalAdjustable pedal

7.8 ~ 9.811.8 ~ 14.7

HECU bracket mounting bolt and nutYaw rate&G sensor mounting bolts

16.7 ~ 25.54.9 ~ 6.7

BL-17



Rear DoorConstruction


Engine D 3.0 TCI


Locking system

Tailgate Type Inner hinged, gas lifterFront hinged, full door construction

Seat belts Front 3 point type with Emergency Locking Retractor (E.L.R)Rear 3 point type with Emergency Locking Retractor (E.L.R)

Glass Thicknes Front door glassRear door glass

3.56mm (0.1402in.)3.56mm (0.1402in.)

Wire drum typePin-fork system

Regulator system

BL-18

Front door

Checker (Body side) 16.7~21.6Checker (Door side) 6.9~10.8Hinge (Body side) 34.3~41.2Hinge (Door side) 34.3~41.2

Rear door

Checker (Body side) 16.7~21.6Checker (Door side) 6.9~10.8Hinge (Body side) 34.3~41.2Hinge (Door side) 34.3~41.2

Seat Seat mounting bolt/nut 39.2~53.9

HoodHood hinge to body 21.6~26.5

Hood latch to body 6.9~8.8

16.7~21.6

Hood hinge to hood 21.6~26.5

Striker

Striker 16.7~21.6


BL-19




Speaker impedance(Ω) Front

4 ± 0.6

Engine

Seat belt

Front seat belt height 39.2~53.9 (4.0~5.5)Front seat belt buckle 39.2~53.9 (4.0~5.5)Front seat belt anchor mounting bolt

39.2~53.9 (4.0~5.5)

Front seat belt lower 39.2~53.9 (4.0~5.5)Front seat belt upper Rear seat belt anchor 39.2~53.9 (4.0~5.5)Rear seat belt retractor 39.2~53.9 (4.0~5.5)

Type

Power supply DC 14.4VMax 43W x 4 (Power IC) 3.2Vrms

Radio/MP3/CD(PA710) Radio/MP3/CDC(PA760) Radio/MP3/6CDC(PA760 RSE)

Rated output

87.5~108.0 MHz / 100KHz

AntennaTuning type



FMLW 531~1602 KHz / 9KHz



Transmissible distanceLife of battery (General key , Smart key)

5m or more

2 year (10 times / day), 2 year (Active 20 times / day + Passive 10 times / day)

Button


Door lock / unlock, Panic, Tailgate unlock (for China)433MHz ± 250MHz (General and Middle east)

315MHz ± 250 MHz (China)

Min 1.64 ± 0.6

39.2~53.9 (4.0~5.5)

D 3.0 TCI

BL-20


Head lamp HighLow

5555


288

Front fog lampRear tail/stop lamp

2727/8 or LED


1621

License plate lampRoom lamp

510 x 2

Overhead console lampLuggage lamp

6 x 25

Front Side marker 5

BL-21


Other system




Bosch

Engine D 3.0 TCI

4 channelButton type (Front door)

Continental

Immobilizer TypeManufacturer

SMARTRA 3system


SMART KEYTypeManufacturer

Compressor

Type 10PA17 Oil type & Capacity PAG 200±15CC PAG

200 + 15CCPulley type 7PK-TYPEDisplacement 178cc/rev

Condeser Heat rejection 15,000-5% kcal/hr 17,000 kcal/hrAPT(A/C pressure

The method to measure

Voltage= 0.00878835 * Pressure (psig) + 0.5

Expansion valve Type Block type

Refrigerant Type R-134aCapacity [oz.(g)] 600±25(21.1±0.88) 750±25(26.4±0.88)


Speed control Power mosfetAir filter Type Particle filter

Blower Type SiroccoSpeed step Auto + 8 speed (Automatic), 1~8speed (Manual)

Heater

Type Pin & Tube typeHeating capacity 4,700 - 5% kcal/hr


Evaporator

Type Evaporator temperature sensorTemperature control type Thermistor

OFF: 1.0 ± 0.3 (33.8 ± 32.5)ON : 2.1 ± 0.3 (34.7 ± 32.5),


BL-22

　Engine Mechanical System………………………VQ-2　Engine Electrical System…………………………VQ-11　Fuel System……………………………..…………VQ-13　Clutch…………………………………….…………VQ-13　Manual Transaxle……………………….…………VQ-14　Automatic Transaxle………………………………VQ-14　Driveshaft………………………………..…………VQ-15　Suspension System…………………….…………VQ-17　Steering System………………………………… VQ-18　Restraints…………………………………………VQ-19　Brake System………………………………………VQ-20　Body (Interior & Exterior)……………….……… VQ-23　Body Electrical System……………………………VQ-25　Heating, Ventilation & Air Conditioning..………VQ-27

Carnival / Sedona(VQ)

VQ-1

General specifications - Carnival/SedonaDSL J2.9 WGT DSL J2.9 VGT GSL μ 2.7 GSL λ 3.8

EngineIn-line, DOHC In-line, DOHC V-type, DOHC V-type, DOHC

4 4 6 6

mm (in.) 86.7(3.4134)x 75 (2.9528)

96(3.7795)x 87.0 (3.425)

cc 2.902 2.902 2.656 3,778

2-3-4-5-6-1 1-2-3-4-5-6- - BTDC 7˚± 10˚ BTDC 10˚± 5˚

rpmrpmrpmrpm

ℓ (lmp.qt) 8.0 (7.0392) - 4.5 (3.96) 6.4 (5.63)ℓ (lmp.qt) 5.4 (4.75) 6.0 (5.28) 4.2 (3.70) 5.5 (4.84)ℓ (lmp.qt) 0.3 (0.26) 0.4 (0.35)ℓ (lmp.qt) 6.0 (5.28) 6.6 (5.81) - 5.2 (4.58)

Above API CH-4 Above API CH-4or ACEA B4

kPa(kg/cm²) 78.45 (0.8) 78.4 (0.8) 130 (1.32)

[at 1000rpm, 110°C(230°F)]

Above SJ or SL

101.5~101.526 (3.9961~3.9971)x 98 (8.8583)

18,4

800±100800±100

10,41-3-4-2

Oil quality

Oil quantity

Oil pressure (Idle)

650 ± 100650 ± 100

800±100 650 ± 100650 ± 100800±100


Engine oil

0.6 (0.53)


Compression ratio

Bore x Stroke

Total displacement

Ignition Timing

A/C ON


Firing order

Idle Speed

Total

A/C OFF

Engine

VQ-2

4° ~ -56° 10°60° ~ 0° 62˚

46° 42˚10° 6˚

mm (in.) 0.03 (0.0012)or less

Less than 0.05 (0.0019)

mm (in.) 0.15 (0.0059)or less

Less than 0.1 (0.0039)

mm (in.) 0.15 (0.0059)or less

Less than 0.1 (0.0039)

mm (in.) 46.8 (1.8425)mm (in.) 45.8 (1.8031)

mm (in.) 27.964 ~ 27.980(1.1009 ~ 1.1016)

No.1:27.964 ~ 27.980

(1.1009 ~ 1.1016)No.2,3,4:

23.954 ~ 23.970(0.9430 ~ 0.9437)

26°

39.397 ~ 39.597 (1.5511 ~ 1.5589)39.4932 ~ 39.6932 (1.5548 ~

1 5627)

27.941 ~ 27.960 (1.1000 ~ 1.1008)

Less than 0.05 (0.0020)

Less than 0.15 (0.0059)

Less than 0.15 (0.0059)

50°72°32°

Intake

Opens (ATDC)Closes (ABDC)Opens (BBDC)Closes (ATDC)



Intake

Exhaust

Exhaust


Camshaft

Cam height

Intake valve

Exhaust valve

Valve timing

Cylinder head

44.5 (1.7520)

VQ-3


mm (in.) 0.020 ~ 0.057(0.0008 ~ 0.0022)

No.1:0.020 ~ 0.057

(0.0008 ~ 0.0022)No.2,3,4:

0.030 ~ 0.067 (0.0012 ~ 0.0026)

mm (in.) 0.05 ~ 0.15(0.0020 ~ 0.0059)

0.02 ~ 0.18(0.0008 ~ 0.0071)

mm (in.) 110.1 (4.3346) 105.27 (4.1445)mm (in.) 111.1 (4.3740) 105.50 (4.1535)

mm (in.) 5.965 ~ 5.980(0.2348 ~ 0.2354)

5.465 ~ 5.480 (0.2151 ~ 0.2157)

mm (in.) 5.950 ~ 5.965(0.2343 ~ 0.2348)

5.458 ~ 5.470 (0.2149 ~ 0.2153)

45° ~ 45.5° 45.25° ~ 45.75°

mm (in.) 1.0 (0.0394)1.56 ~ 1.86(0.06142 ~ 0.07323)

mm (in.) 1.3 (0.0512)1.73 ~ 2.03(0.06811 ~ 0.07992)

0.08 ~ 0.17(0.0031 ~ 0.0067)

0.040 ~ 0.080 (0.0016 ~ 0.0031)

126.24 (4.9701)126.24 (4.9701)

6.965 ~ 6.980 (0.2742~0.2748)

6.945 ~ 6.960 (0.2734 ~ 0.2740)

45°

1.7 (0.0669)

1.6 (0.0630)

Exhaust

Intake

Exhaust


Face angle

Valve length


Valve

End play

IntakeExhaust


Engine

VQ-4

mm (in.) 0.020 ~ 0.050(0.0008 ~ 0.0020)

0.020~0.047 (0.00078

~0.00185)

mm (in.) 0.035 ~ 0.065(0.0014 ~ 0.0026)

0.030 ~ 0.054 (0.00118

~0.00212)

mm (in.) - - 6.000 ~ 6.015(2.2362 ~ 2.2368)

5.500 ~ 5.512 (0.2165 ~ 0.2170)

mm (in.) - - 6.000 ~ 6.015(2.2362 ~ 2.2368)

5.500 ~ 5.512 (0.2165 ~ 0.2170)

mm (in.) 45.8 ~ 46.2(1.8031 ~ 1.8189)

41.8 ~ 42.2(1.6457 ~ 1.6614)

mm (in.) 46.8 ~ 47.2(1.8425 ~ 1.8583)

41.8 ~ 42.2(1.6457 ~ 1.6614)

mm (in.) -1.15 ~ 1.45

(0.05118~0.05709)

mm (in.) -1.35 ~ 1.65

(0.05315~0.06496)

- 44.75° ~ 45.20°

0.030 ~ 0.065 (0.0012 ~ 0.0026)

0.050 ~ 0.085( 0.0020~ 0.0033)

Intake

Exhaust

45°

52.5 (2.0669)

52.5 (2.0669)

1.4 ~ 2.0(0.0551 ~ 0.0787)

0.9 ~ 1.5(0.0354 ~ 0.0591 )

Valve seat


Exhaust


Intake

Seat angle

Valve guide

Intake

Exhaust

Inner diameter

Length

Intake

Exhaust

VQ-5


mm (in.) 52.477 (2.0660) 52.477 (2.0660) 46.8 (1.8425) 43.86 (1.7267)mm (in.)mm (in.)

mm (in.)

mm (in.)

1.5° or less Less than 1.5°

mm (in.) - -mm (in.) - -

mm (in.) - - 29.964 ~ 29.980(1.1797 ~ 1.1803)

34.964 ~ 34.980 (1.3765 ~ 1.3772)

mm (in.) - - 29.964 ~ 29.980(1.1797 ~ 1.1803)

34.964 ~ 34.980 (1.3765 ~ 1.3772)

mm (in.) - - 30.000 ~ 30.025(1.1811 ~ 1.1821)

35.000 ~ 35.025 (1.3779 ~ 1.3789)

mm (in.) - - 30.000 ~ 30.025(1.1811 ~ 1.1821)

35.000 ~ 35.025 (1.3779 ~ 1.3789)

23.45±1.87kg/40.0

Exhaust


Intake

MLA outer diameter

MLA19.959 ~ 19.980 (0.7858 ~ 0.7866)20.000 ~ 20.027 (0.7874 ~ 0.7885)


Intake

Exhaust

Rocker arm inner diameterRocker arm and rocker arm shaft

Load(Intake)

Load(Exhaust)

Installed 180.5 ~ 199.5N(18.4 ~ 20.3Kgf) -

Height:35342 ~ 378N

(34.9 ~ 38.6Kgf) - Height: 26.539.43±3.15kg/31.50

Less than 2°

39.15±3.13kg/31.65

23.45±1.87kg/40.0

Valve spring

Valve opened

Installed

Valve opened

Engine

Free length

Out of squareness

19.3±0.8kg/34.042.3±1.3kg/24.2

VQ-6

mm (in.)- - 0.020 ~ 0.061

(0.0008 ~ 0.0024)0.020 ~ 0.061

(0.0008 ~ 0.0024)

mm (in.)- - 0.020 ~ 0.061

(0.0008 ~ 0.0024)0.020 ~ 0.061

(0.0008 ~ 0.0024)

mm (in.)- - 0.17 ~ 0.23

(0.0067 ~ 0.0090)0.17 ~ 0.23

(0.0067 ~ 0.0090)

mm (in.)- - 0.27 ~ 0.33

(0.0106 ~ 0.0129)0.27 ~ 0.33

(0.0106 ~ 0.0129)

mm (in.)

mm (in.) 97.100 ~ 97.126 (3.8228~ 3.8239) - - -

mm (in.) 101.480~101.526(3.9953~3.9971) - - -

mm (in.)


- - 0.25 (0.0098) -

2.05 ~ 2.07 ( 0.0807~ 0.0815) 1.22 ~ 1.24 (0.0480 ~ 0.0488)3.02 ~ 3.04 (0.1189 ~ 0.1197) 2.01 ~ 2.03 (0.0791 ~ 0.0799)

97.015 ~ 97.030 ( 3.8195~ 3.8201) 95.96 ~ 95.99 (3.7779 ~ 3.7791)

2.397 ~ 2.417 ( 0.0944~0.0952 ) 1.22 ~ 1.24 (0.0480 ~ 0.0488)0.070 ~ 0.098 (0.0028 ~ 0.0039) 0.03 ~ 0.05 (0.0012 ~ 0.0020)


Ring groove width

Piston OS

No. 1 ring groove

Intake

Exhaust

Piston outer diameterPiston to cylinder clearance

Cylinder block


96.00 ~ 96.03 (3.7795 ~ 3.7807)101.500~101.526 (3.9961~3.9971 )

Less than 0.05 (0.0020) Less than 0.05 (0.0019)[Less than 0.02 (0.0008.) / 150x150]

Intake

Exhaust


Cylinder bore

Liner outer diameter

Piston

Liner inner diameter

Valve clearance

VQ-7


mm (in.) 0.04 ~ 0.08(0.0016 ~ 0.0031)

0.03 ~ 0.07(0.0012 ~ 0.0027)

mm (in.)mm (in.)

mm (in.) 0.15 ~ 0.30(0.0059 ~ 0.0118)

0.17 ~ 0.32(0.0067 ~ 0.0126)

mm (in.) 0.30 ~ 0.45(0.0118 ~ 0.0177)

0.32 ~ 0.47(0.0126 ~ 0.0185)

mm (in.)

mm (in.) 21.001 ~ 21.007(0.8268 ~ 0.8270)

23.001 ~ 23.006 (0.9055 ~ 0.9057)

mm (in.) 21.014 ~ 21.023(0.8273 ~ 0.8277)

23.016 ~ 23.021 (0.9061 ~ 0.9063)

mm (in.) 0.007 ~ 0.022(0.0003 ~ 0.0009)

0.01 ~ 0.02(0.0039 ~ 0.0078)

mm (in.) 20.974 ~ 20.985(0.8257 ~ 0.8262)

22.974 ~ 22.985 (0.9045 ~ 0.9049)

mm (in.) 0.016 ~ 0.033(0.0006 ~ 0.0013)

-0.032 ~ -0.016(-0.0012~0.0006)

Engine

31.994 ~ 32.000 (1.2596 ~ 1.2598)

32.015 ~ 32.025 (1.2604 ~ 1.2608)

0.015 ~ 0.031 (0.0006 ~ 0.0012)

32.012 ~ 32.033 (1.2603 ~ 1.2611)

0.25 ~ 0.40 (0.0098~ 0.0157)

0.40 ~ 0.55 (0.0157~0.0217)

0.20 ~ 0.40 (0.0079 ~ 0.0157) 0.20 ~ 0.70 (0.0078 ~ 0.0275)

0.104 ~ 0.128(0.0041~0.0050 )

0.06 ~ 0.10 (0.0024~0.0039) 0.03 ~ 0.07 (0.0012 ~ 0.0027)0.03 ~ 0.07 (0.0012~0.0028) 0.06 ~ 0.15 (0.0024 ~ 0.0059)

0.012 ~ -0.039 (0.0005 ~ 0.0015)

Side clearanceNo. 1 ring groove


Piston ring

Piston pin

No. 1 ring groove

No. 2 ring groove

Oil ring groove

End gap






VQ-8

mm (in.) 51.000 ~ 51.018(2.0079 ~ 2.0086)

58.000 ~ 58.018(2.2834 ~2.2842)

mm (in.) 0.018 ~ 0.036(0.0007 ~ 0.0014)

0.038 ~ 0.056 (0.0015 ~ 0.0022)

mm (in.)

mm (in.)mm (in.)

mm (in.) 47.982 ~ 48.000(1.8891 ~ 1.8898)

54.954 ~ 54.972 (2.1635 ~ 2.1642)

mm (in.)mm (in.)

mm (in.) 0.07 ~ 0.25(0.0028 ~ 0.0098)

0.10 ~ 0.28(0.0039 ~ 0.0110)

mm (in.) 0.10 (0.0039) 0.10 (0.0039) - -

kPa(kg/cm²)

490.33 ~ 588.40(5.0 ~ 6.0)

450 ~ 550(4.59 ~ 5.61)

ℓ(lmp.qt)

- 9.7~10 (8.54 ~ 8.8)

8.2~8.3 (7.22~7.30) 8.6 (7.57)

0.022 ~ 0.040 (0.0008 ~ 0.0016)

61.982 ~ 62.000(2.4402 ~ 2.4409)

588.40±49.0(6.0±0.5)


Runout

0.067~0.101 (0.0026 ~0.0040 )0.14 ~ 0.39

(0.0055 ~0.0154 )

60.833 ~ 60.846 (2.3950 ~ 2.3955)

0.043 ~ 0.077 (0.0017 ~ 0.0030)

NO 1, 2, 4, 5

0.239~0.39 (0.0094 ~ 0.0154)



Connecting rod

0.1 ~ 0.25 (0.0039 ~ 0.0098)

69.995 ~ 70.015 (2.7557 ~2.7565 )

End play

68.942 ~ 68.960 (2.7142 ~ 2.7149)

End playCrankshaft

NO 1, 2, 4, 5

Cooling system

NO 3



Flywheel

0.045 ~ 0.079 (0.0018 ~0.0031 )

69.973~69.993 (2.7548 ~2.7556 )

57.106~57.124 (2.2483~2.2490 )

Coolant quantity

Cooling method


NO 3Main bearing oil clearance

Oil pump

0.004 ~ 0.022(0.0002 ~ 0.0009)

VQ-9


°C (°F)°C (°F)

mm (in.) - - 10 (0.3937) or more 10 (0.3937)

kPa(kg/cm²)


93.16 ~ 122.58(0.95 ~ 1.25)

kPa(kg/cm²) - -

kΩ 2.27 ~ 2.64 2.27 ~ 2.64 2.31 ~ 2.59 2.31 ~ 2.59kΩ


- 19.60(2.0) + 90˚- -

- - - 49.00(5.0) + 90˚- - - 19.60(2.0) + 120˚

- - - 29.40 ~ 31.36(3.0 ~ 3.2)

- - 29.4(3.0) + 90˚ -- - 15.7(1.6) + 90˚ -

Engine

Inner bolt (M11)

68.6(7.0)→Unfasten bolts→29.4+90°69.6~79.4(7.1~8.1) + 55°~65°

Out bolt (M8)

Side bolt (M8)Crankshaftmain bearing cap

0.98 ~ 4.90 (0.01 ~ 0.05)

0.31 ~ 0.33 0,3222

Thermister typeWater temperature sensorType

Radiator cap

Resistance

93.16 ~ 122.58(0.95 ~ 1.25)

82 ± 2 (179.6 ± 35.6)100 (212.0) 95 (203)

Thermostat

Bolts

Long bolts (M10)Short bolts (M8)

20°C (68°F)80°C (176°F)

88 ± 1.5 (190.4 ± 34.7 )


Opening

Main moving system

Full lift

Pull opening



VQ-10

- -22.6~26.5(2.3~2.

7) +(60˚±2°)+(45˚±2°

39.2(4.0) +120˚ + 90˚

- 18.62 ~ 23.52(1.9 ~ 2.4)

- -- -

34.3 ~ 44.1(3.5 ~ 4.5) -

- - 9.8 ~ 11.8(1.0 ~ 1.2)

9.80 ~ 11.76(1.0 ~ 1.2)


VA Max. 90 Max. 85

12V, 2.0KW 12 V, 1.2 kW

2,600 rpm, MINMax. 190

34.3 ~ 44.1 (3.5 ~ 4.5)

15.7 ~ 22.6 (1.6 ~ 2.3)

39.2(4.0) + 90°+ 90°

11,5

3,000rpm, MIN

Lubrication system21.6 ~ 24.5 (2.2 ~ 2.5)

17.7 ~ 26.5 (1.8 ~ 2.7)

39.2(4.0) + 90° + 120°


Oil pan drain plug

Oil filter


Short bolts


Lower oil pan bolt

Cylinder head

Oil pan nuts

Rated voltage

SpeedAmperage

VQ-11

General specifications - Carnival/SedonaDSL J2.9 WGT DSL J2.9 VGT GSL μ 2.7 GSL λ 3.8Battery voltage

sensing -

13.5 V, 110A 13.5V, 130A- -

14.4 ± 0.3V14.2 ~ 14.8V

(5000rpm, 10A, 25°C)

14.2 ~ 14.8V 14.2 ~ 14.8V

MF 68AH MF 80AH

600 A 630 A

110 min 130 min

Ω - - 0.715 ± 0.015 0.62 ± 10 %

kΩ - - - 7.0 ± 15 %

- - ILFR5B11 IFR5G-11mm(in.) - - 1.0 ~ 1.1 (0.0394 ~ 0.0433)

1) CMF 100 AH, 2) CMF 80 AH1) 900A - CMF 100 AH2) 660A - CMF 80 AH

1) 182min - CMF 100 AH2) 145min - CMF 80 AH

1.280 ± 0.01

Electronic built-in typeI.C regulator built-in type1,000 ~ 18,000 rpm


12V, 120A

Reserve capacity

Unleaded (Gap)


Spark plugs



Unleaded (NGK)

Battery

Ignition coil

Speed in useRated voltage

Engine


Regulator setting voltage

Type

VQ-12


)

- -

MPa(kgf/cm²

)- -

kPa(kgf/cm²

)- -


Clutch cover assemblyClutch pedal bracket mountingClutch master cylinder mountingClutch release cylinderService standardClutch pedal stroke mm (in.)Clutch pedal free play mm (in.) 6~13 (0.24~0.51)

12~16 (1.2~1.6)25~34 (2.5~3.4)

150 (5.91)

Engine Management Manufacturer DelphiFuel Tank Capacity 80 (70.39)Fuel Return System Type Return type Returnless type



Mechanical ElectricalVolume Metric-Blade Type In-tank type

Driven by Drive Belt Electric motorFuel Pressure (Maximum) Pressure 160 (1,632)


Tightening torque [N.m(kgf-m)]25~36 (2.5~3.6)19~26 (1.9~2.6)

Hydraulic typeSingle dry with diaphragm

Self Adjusting Clutch

VQ-13

General specifications - Carnival/SedonaEngine DSL J2.9 WGT DSL J2.9 VGT GSL μ 2.7 GSL λ 3.8

Manual TransaxleType M5GF2 -

3,615 -1,931 -1,969 -1,273 -0,974 -3,416 -

5.071 / 3.737 --

MT oil capacity ℓ(lmp.qt) 1.9 (1.67) -

Automatic TransaxleType F4A51 A5HF1

2,842 4,4971,495 2,4421.000 1,6860,731 1,233

- 0,8682.720 4,5864.520 3,333

ℓ(lmp.qt) 8.5 (7.5) 10.9 (9.6)

M5HF2

Gear ratio

1st 3,6002nd 1,8753rd 1,2054th 0,8185th 0,768Rev. 4,320FGR 4.500/3.706

M/T oil quality SAE 75W/85, API GL-41.85 (1.63)

A5HF1

Gear ratio

1st 4,4972nd 2,4423rd 1,6864th 1,2335th 0,868Rev. 4,586FGR 3,333

ATF quality Diamond ATF SP III or SK ATF SP IIIATF capacity 10.7 (9.4)

VQ-14

DriveshaftTSJ#26 -BJ#26 -

46.5˚ -23˚ -

LubricantsBJ#26 BJ#28 UTJ-II#25 TSJ#26

CK-2 RBAg 210 250 220 150

Joint typeM/T

Inner TSJ#26Outer BJ#28

A/TInner UTJ-II#25Outer BJ#26

Inner 46.5˚23˚

Max. permissible angleM/T

Inner 46.5˚Outer

A/TOuter 23˚

Joint typeRecommended grease RBA

Rear hub ＆ bearing assembly 1.97 (0.2)

QuantityStarting torque [N.m (kgf-m)]Front hub ＆ bearing assembly 1.97 (0.2)

[NOTE]Inner: On transaxle sideOuter : On tire side

VQ-15


Driveshaft lock nut 245 ~ 275 (24.5 ~ 27.5)

Tightening torque [N.m (kgf-m)]Hub nut 90 ~ 110 (9.0 ~ 11.0)

Tie rod end castle nut 60 ~ 80 (6.0 ~ 8.0)Front lower arm to knuckle bolt ＆ nut 90 ~ 120 (9.0 ~ 12.0)Inner shaft bearing ＆ bracket assembly boltsFront caliper assembly to knuckle bolts

43 ~ 63 (4.3 ~ 6.3) 50 ~ 65 (5.0 ~ 6.5)85 ~ 100 (8.5 ~ 10.0)

Front strut assembly to knuckle bolts 100 ~ 120 (10.0 ~ 12.0)Front hub ＆ bearing assembly to knuckle bolts 160 ~ 180 (16.0 ~ 18.0)Rear lower arm to carrier bolt ＆ nut 160 ~ 180 (16.0 ~ 18.0)Rear caliper assembly to carrier assembly bolts 50 ~ 60 (5.0 ~ 6.0)Rear hub lock nut 200 ~ 260 (20.0 ~ 26.0)Rear brake assembly to carrier assembly bolts 50 ~ 60 (5.0 ~ 6.0)

Carrier assembly to upper arm bolt 90 ~ 100 (9.0 ~ 10.0)

Carrier assembly to assist arm bolt 90 ~ 100 (9.0 ~ 10.0)Carrier assembly to upper arm bolt 90 ~ 100 (9.0 ~ 10.0)

VQ-16

mm (in.)

6.5J × 16"6.5J × 16", 6.5J × 17"

225/70 R16, 235/60 R172.4kgf.m/cm2, (35psi)

MacPherson strut Multi linkShock absorber type Gas pressurized

3°46'±30' -3°54'±30' -

0±2 (0±0.079) 2.6±2 (0.102±0.079)12°27'±30' -

Tightening Torque [N.m(kgf-m)]Hub nuts 90 ~ 110 (9.0 ~ 11.0)Front strut assembly to knuckle 100 ~ 120 (10.0 ~ 12.0)Front strut assembly self-locking nut 60 ~ 70 (6.0 ~ 7.0)Front lower arm to sub frame 160 ~ 180 (16.0 ~ 18.0)Front lower arm to knuckle 90 ~ 120 (9.0 ~ 12.0)Front stabilizer link to strut assembly 100 ~ 120 (10.0 ~ 12.0)Front stabilizer bar bracket mounting bolts 39 ~ 60 (3.9 ~ 6.0)Rear shock absorber to bracket 160 ~ 180 (16.0 ~ 18.0)Rear shock absorber to carrier 140 ~ 160 (14.0 ~ 16.0)Rear upper arm to carrier 90 ~ 110 (9.0 ~ 11.0)Rear upper arm to rear cross member 160 ~ 180 (16.0 ~ 18.0)Rear lower arm to carrier 160 ~ 180 (16.0 ~ 18.0)

0°±30' -6'±30'



Suspension type


Wheel alignmentCaster

Long bodyShort body

Toe-inKing-pin

Camber

VQ-17


Type

ℓ(lmp.qt)VRS on mm (in.)VRS off mm (in.)

InnerOuterInnerOuter

Rear assist arm to carrier 90 ~ 110 (9.0 ~ 11.0)Rear lower arm to rear cross member 200 ~ 270 (20.0 ~ 27.0)

Rear assist arm to rear cross member 90 ~ 120 (9.0 ~ 12.0)Trailing arm to bracket 160 ~ 180 (16.0 ~ 18.0)Trailing arm to carrier 80 ~ 100 (8.0 ~ 10.0)Rear stabilizer link to trailing arm 50 ~ 65 (5.0 ~ 6.5)

Rack and Pinion, VRS (Variable Rack Stroke) System PSF-3

Rear stabilizer bar bracket mounting bolts 39 ~ 60 (3.9 ~ 6.0)

Steering System

Power steering fluidQualityQuantity 1.1 (0.97)

148 (5.67)156 (6.14)

38.64°

33.54°

Steering angleVRS on

VRS off

31.78°41.91°



)

8630 ~ 9120 (88 ~ 93)Diesel 9611 ~ 10101 (98 ~ 103)

Rack stroke

VQ-18

ΩΩΩΩΩΩ


BoltNut

Side Airbag (SAB)Curtain Airbag (CAB)Seat Belt Pretensioner (BPT)Seat Belt Buckle Pretensioner (BUPT)

1.6 ~ 4.71.6 ~ 4.71.6 ~ 4.7

18.6 ~ 26.5 (1.9 ~ 2.7)

12.0 ~ 13.0 (1.2 ~ 1.3)7.0 ~ 8.0 (0.7 ~ 0.9)

1.6 ~ 4.7Tightening Torque [N.m(kgf-m)]


7.9 ~ 10.8 (0.8 ~ 1.1)

9.5 ~ 13.6 (1.0 ~ 1.4)

39.2 ~ 53.9 (4.0 ~ 5.5)39.2 ~ 53.9 (4.0 ~ 5.5)9.5 ~ 13.6 (1.0 ~ 1.4)9.5 ~ 13.6 (1.0 ~ 1.4)Front Impact Sensor (FIS) Mounting Bolt


Side Airbag (SAB)Seat Belt Anchor Bolt (BPT)Buckle Pretensioner (BUPT)SRSCM Mounting Bolt

Restraints

Resistance

18.6 ~ 26.5 (1.9 ~ 2.7)

Driver Airbag (DAB)


Type Depowered

1.6 ~ 4.71.6 ~ 4.7

Driver Airbag (DAB)


Tie rod end to knuckle 35 ~ 45 (3.5 ~ 4.5)




VQ-19


Brake System

mm (in.)mm (in.)


mm (in.)



Master cylinderType Tandem typeI.D. 26.99 (1.063)Piston stroke 30(1.18)Fluid level warning sensor ProvidedBrake boosterType 8 + 9 in TandemBoosting ratio 9Front brake(Disc)Type Floating type with ventilated discDisc O.D. 298 (11.73)Disc thickness 28 (1.10)Pad thickness 10.5 (0.41)Cylinder type Double pistonCylinder I.D. 48 (1.89)Rear brake(Disc)Type Floating type with solid discDisc O.D. 302 (11.89)Disc thickness 12 (0.47)Pad thickness 10 (0.39)

VQ-20

mm (in.)

mm (in.)O.D=Outer DiameterI.D=Inner DiameterAnti-lock Brake System(ABS)/ Electronic Stability Program(ESP)




mm (in.)

mm (in.)

mm (in.)

Cylinder type Single pistonCylinder I.D 42.9 (1.69)Parking brakeType DIH(Drum in hat)Actuation Foot brakeDrum 190 (7.48)



Air gap0.15 ~ 1.5 (0.006 ~ 0.059)0.2 ~ 1.2 (0.008 ~ 0.047)

Tone wheel 48

Brake pedal height 192.4 (7.57 )Brake pedal full stroke 122 (4.8)Adjust Brake pedal full stroke 60 (2.36)Brake pedal free play 3 ~ 8 (0.11 ~ 0.31)Stop lamp switch outer case to pedal stopper clearance

1.0 ~ 1.5 (0.04 ~ 0.06)


0.6 ~ 1.7 (0.02 ~ 0.07)(at 500 mmHg)

Parking brake pedal stroke when pedal assembly is depressed with 294N (30kgf, 66lb force)

above 145 (5.71)

VQ-21



Front disc brake pad thickness 10.5 (0.41)Front disc thickness 28 (1.10)Rear disc brake pad thickness 10 (0.39)Rear disc brake disc thickness 12 (0.47)Rear parking brake liner thickness 4 (0.16)

Brake booster mounting nut 13 ~ 16 (1.3 ~ 1.6)Bleeder screw 7 ~ 13 (0.7 ~ 1.3)

Rear 50 ~ 60 (5.0 ~ 6.0)25 ~ 30 (2.5 ~ 3.0)

Caliper assemblyto knuckleBrake hose to front caliper

Front 85 ~ 100 (8.5 ~ 10)

Brake pedal assembly bracket mounting nut 10 ~ 15 (1.0 ~ 1.5)Brake pedal mounting nut 13 ~ 16 (1.3 ~ 1.6)Stop lamp switch mounting nut 8 ~ 10 (0.8 ~ 1.0)Active wheel speed sensor mounting bolt on the brake plate

7 ~ 10 (0.7 ~ 1.0)

Yaw rate ＆ lateral acceleration sensor bolt 5 ~ 8 (0.5 ~ 0.8)

HECU mounting bracket bolt 17 ~ 26 (1.7 ~ 2.6)HECU mounting nut 6 ~ 10 (0.6 ~ 1.0)

Tightening torque [N.m (kgf-m)]Master cylinder to booster mounting nut 8 ~ 12 (0.8 ~ 1.2)

Caliper guide rod boltFrontRear 22 ~ 32 (2.2 ~ 3.2)

Brake tube nut, brake hose 13 ~ 17 (1.3 ~ 1.7)22 ~ 32 (2.2 ~ 3.2)

VQ-22





Rear doorConstruction Sliding door constructionRegulator system Wire drum typeLocking system Pin-fork system


Glass thickness

Windshield 5 (0.1969)Front door 4 (0.1575)Rear door glass 4 (0.1575)Rear window 3.5 (0.1378)

Seat beltsFront 3 point type with Emergency Locking Retractor (E.L.R)Rear 3 point type with Emergency Locking Retractor (E.L.R)



Door hinge to body 33.3~41.2 (3.4~4.2)Door hinge to door 21.6~26.5 (2.2~2.7)Striker 6.9~10.8 (0.7~1.1)Glass mounting bolt 7.8~11.8 (0.8~1.2)Outside handle 6.9~10.8 (0.7~1.1)Rear channel 7.8~11.8 (0.8~1.2)

VQ-23


Tailgate

Tailgate hinge to body 6.9~8.8 (0.7~0.9)Tailgate hinge to 6.9~8.8 (0.7~0.9)Tailgate lift mounting 6.9~8.8 (0.7~0.9)Key cylinder mounting 6.9~10.8 (0.7~1.1)


SeatFront seat mounting 43.1~64.7 (4.4~6.6)Rear seat mounting 43.1~64.7 (4.4~6.6)

Seat belt

Front seat belt height 39.2~53.9 (4.0~5.5)Front seat belt buckle 39.2~53.9 (4.0~5.5)Front seat belt anchor 39.2~53.9 (4.0~5.5)Front seat belt lower 39.2~53.9 (4.0~5.5)Front seat belt upper 39.2~53.9 (4.0~5.5)Rear seat belt anchor 39.2~53.9 (4.0~5.5)Rear seat belt retractor 39.2~53.9 (4.0~5.5)

VQ-24


RADIO/EQ/CD(M445)

RADIO/Cassette/EQ/CD/MP3

(M455)

Antenna 80PF 75ΩTuning type

87.5~108 MHz / 50KHz (Europe)

PLL synthesized type


FM

AM 531~160 KHz / 9KHz (General)

87.5~108 MHz / 100KHz (General)

Lithium 3V battery (1EA)Keyless entry transmitter Power source30m or more

2 years or more (at 10 times per day)

Tailgate open (option)

Button PTG(Power Tail Gate) open/close (option)Panic

447 MHz (Europe, Austrailia, Middle east)315.00 MHZ (General)





RADIO/Cassette/EQ/CDC/MP3(M465)

3.2VrmsSpeaker impedance 4Ω x 4 10Ω

Type

Power supplyRated output Max 43W x 4

DC 14.4V

Door lock/unlockPSD(Power Sliding Door) open/close (option)

VQ-25

General specifications - Carnival/SedonaEngine DSL J2.9 WGT DSL J2.9 VGT GSL μ 2.7 GSL λ 3.8Lighting system

WWWWWWWWWWWWWWWWWW

55288

Luggage room lampDoor courtesy lamp

55

High mounted stop lampGlove box lamp

LED5

Room lampOverhead console lamp

1010 x 2

License plate lampSide repeater

55

Rear turn signal lampRear fog lamp

2721

Rear stop/tail lampBack up lamp

12/516

Front fog lamp 35


5

LowHead lamp

Front side marker lamp

High 55

VQ-26

Other system


Power sliding door

Air conditioner

Kpa(kg/)

Kpa(kg/)

g

Body Network Communication type

Power tailgate

CAN4 channel

Electric type

SMARTRA systemBosch


Electric type

Fixed type (Swash plate)Oil type ＆ Capacity FD46XG(PAG), 180 ± 10cc FD46XG(PAG), 210 ± 10cc

Compressor

Type VS18 (Variable capacity)

Pulley type 4PK-TYPE 6PK-TYPEDisplacement 180cc/rev 214cc/rev

Condenser Heat rejection 14,000 ± 5% kcal/hr 19,500 ± 5% kcal/hrAPT(A/C pressue transducer)

Method to measure pressure

- Vout = 0.00878835 * pa + 0.37081095

Dual pressure switchHigh

ON : 26.0 ± 2.0, OFF : 32.0 ± 2.0(ON:2549.7±196.1, OFF:3138.1±196.1)

-

LowON : 2.0 ± 2.55, OFF : 2.0 ± 0.2

(ON: 196.1±250.1, OFF: 196 1±19 6)

-

Expansion valve Type Block(L-TYPE)

RefrigerantType R-134aCapacity 800 ± 25 900 ± 25

Heating, Ventilation & Air Conditioning

VQ-27

General specifications - Carnival/SedonaEngine DSL J2.9 WGT DSL J2.9 VGT GSL μ 2.7 GSL λ 3.8Blower unit



Blower

Type Sirocco

Speed stepAuto + 8 speed (Automatic)

1~8 speed (Manual)Speed control

Actuator

Power mosfetAir filter Type Particle filter

OFF: 1.3 ± 0.5 (34.34± 0.9) OFF: 1.1 ± 0.5 (34.0 ± 0.9)

Heater

Type Pin ＆ Tube typeHeating capacity 4,700 ± 5% kcal/hrMode operating ActuatorTemperature operating

EvaporatorTemperature control Evaporator temperature sensor

A/C ON/OFF °C (°F)ON : 2.3 ± 0.5 (36.14± 0.9) ON : 2.6 ± 0.5 (36.7 ± 0.9)

VQ-28

　Engine Mechanical System………………………PU-2　Engine Electrical System…………………………PU-8　Fuel System……………………………..…………PU-9　Clutch…………………………………….…………PU-9　Manual Transaxle……………………….…………PU-10　Driveshaft………………………………..…………PU-11　Suspension System…………………….…………PU-13　Steering System………………………………… PU-14　Brake System………………………………………PU-15　Body (Interior & Exterior)……………….……… PU-18　Body Electrical System……………………………PU-20　Heating, Ventilation & Air Conditioning..………PU-21

K2500 / K2700 /

PU-1

DSL 4D56-2.5 DSL J2-2.7 DSL JT-3.0 DSL JTA-3.0

In-line, OHC4 4

mm (in.) 91.1 (3.5866)x 95 (3.7401)

94.5 (3.7204) × 95 (3.7401)

cc 2.467 2.66520.5:1 21.5:1 22:1 21.5:1

ATDC 7˚ ATDC 7˚rpm - 750 ~ 790rpm - 700 ~ 750

ℓ (lmp.qt) 6.1 (5.3) 7.4 (6.5)ℓ (lmp.qt) 4.9 (4.2) 5.7 (5.0)

-kPa

(kg/cm²) -

20° 12˚48° 48°54° 50°22° 12°

Opens (BTDC)Closes (ABDC)

19˚47°

M/T

Oil quantity Total

Oil pressure

7.9 (6.9)Oil pan 6.2 (5.4)

Oil quality API Service CF-4 or CG-4

353~432 (3.6~4.4) / 3000rpm

Valve timing

Intake valve

4

2.957

Firing order 1-3-4-2

Number of cylinders

Total displacement

1-3-4-2

Bore x Stroke 98 (3.8583)× 98 (3.8583)

Compression ratio

Type

General specifications - K2500 / K2700 / K3000

Engine

Opens (BBDC)

In-line, Longitudinal

Ignition Timing ATDC 7˚

Idle Speed700 ~ 750

A/T 700 ~ 750Engine oil

52˚Exhaust valve Closes (ATDC) 14˚

Engine

PU-2

mm (in.) 0.05 (0.002)

mm (in.) 0.15 (0.0059)or less

mm (in.) 0.15 (0.0059)or less

mm (in.) 37.05 (1.4587) 44.133 (1.7375)mm (in.) 37.05 (1.4587) 44.133 (1.7375)

mm (in.) 29.94 ~ 29.95 (1.1787 ~ 1.1791)

mm (in.) 0.05 ~ 0.08 (0.002 ~ 0.0031)

mm (in.) 0.10 ~ 0.20 (0.0039 ~ 0.0079)

mm (in.) 130.15 (5.1240) - - -mm (in.) 129.85 (5.1122) - - -

mm (in.) 7.96 ~ 7.975 (0.3133~0.3140)

mm (in.) 7.93 ~ 7.975 (0.3122 ~ 0.3130)

45° ~ 45.5° -Face angle -

8.440~8.463 (0.3323~0.3332)

IntakeExhaust

Exhaust

44.116 (1.7369)Intake

0.15 (0.0059) or less

0.15 (0.0059) or less

Exhaust

0.25 (0.0098) / Longitudinal0.10 (0.0039) / Lateral


Intake


End play

Valve

Valve length


-

0.06~0.12 (0.0024~0.0047)

0.02~0.18 (0.0008~0.0070)

8.466~8.491 (0.3333~0.3343)

Cam height44.116 (1.7369)



Exhaust

Cylinder head

Camshaft

PU-3

DSL 4D56-2.5 DSL J2-2.7 DSL JT-3.0 DSL JTA-3.0mm (in.) 2.0 (0.0787) 1.35 (0.05)mm (in.) 2.0 (0.0787)

mm (in.) 0.03 ~ 0.06(0.0012 ~ 0.0024)

mm (in.) 0.05 ~ 0.09( 0.0020~ 0.0035)

mm (in.) 8.0 ~ 8.02 (0.3150 - 0.3157)

mm (in.) 8.0 - 8.02 (0.3150 - 0.3157)

mm (in.) 71 (2.7953) - - -mm (in.) 74 (2.9134) - - -

mm (in.) 0.9 ~ 1.3 (0.0354 ~ 0.0512) 2.41(0.095)

mm (in.) 0.9 ~ 1.3 (0.0354 ~ 0.0512) 1.98 (0.078)

45°

mm (in.) 47.9 (1.5585)

mm (in.) 27.6 kg / 39.5 (1.5157)

mm (in.) Max. 2°

Valve guide

General specifications - K2500 / K2700 / K3000EngineThickness of valve head (margin)

Intake 1.5 (0.06)Exhaust 1.5 (0.06)

Out of squareness 1.63 (0.0641)

Inner diameter

Width of seat contactExhaust

Seat angle 45˚Valve spring

Load -

ExhaustValve seat

Intake 1.05~1.25 (0.041~0.049)

Intake8.518~8.540 (0.3354~0.3362)

Exhaust

Intake


0.027 ~ 0.074 (0.0010 ~ 0.0029)

Exhaust 0.055 ~ 0.10 (0.0021 ~ 0.0039)

Intake

49.5 (1.95)Free length

Length

0.90~1.10 (0.035~0.043)

PU-4

mm (in.) 18.910 ~ 18.928 (0.7445 ~ 0.7455)

mm (in.) 18.878 ~ 18.898 (0.7432 ~ 0.7440)

mm (in.) 0.15 (0.0059)mm (in.) 0.15 (0.0059)

mm (in.) 91.10 ~ 91.13(3.5866 ~ 3.5877)

X:97.513~97.526(3.8390 ~ 3.8396)Y:97.500~97.513(3.8385 ~ 3.8390)

mm (in.) 0.05 (0.0020) - - -

mm (in.) 91.05 ~ 91.08 (3.5846 ~ 3.5858)

94.468 ~ 94.488(3.7192 ~ 3.7200)

mm (in.) 0.04 ~ 0.06 (0.0016 ~ 0.0023)

0.047 ~ 0.072(0.0019 ~ 0.0028)

mm (in.)2.61 ~ 2.63 (0.1027 ~

0 1035)-

mm (in.) 2.10 ~ 2.12(0.0827 ~ 0.0835) -

mm (in.)4.01 ~ 4.035 (0.1579 ~

0 1589)-

0.25, 0.50,0.75, 1.00 -

Exhaust

Piston to cylinder clearance 0.045~0.071 (0.0018~0.0028)

Cylinder block


97.942~97.968 (3.8560~3.8570)

X: 101.5 ~ 101.513 (3.9960~3.9965)Y: 101.513~101.526

(3.9966~3.9971)

Piston

Cylinder bore

Rocker arm and rocker arm shaft

18.959~18.980 (0.746~0.747)

0.30 (0.0118)

Ring groove width

Oil ring groove

19.000~19.021 (0.748~0.749)


-

-

Piston OS

Rocker arm inner diameter

-

-

Intake Valve clearance

0.38 (0.0149)


No. 2 ring groove

No. 1 ring groove

PU-5


mm (in.) 0.056 ~ 0.076 (0.0022 ~ 0.0030)

mm (in.) 0.046 ~ 0.066 (0.0018 ~ 0.0026)

mm (in.) 0.02 ~ 0.065(0.0008 ~ 0.0026)

mm (in.) 0.30 ~ 0.43 (0.0118 ~ 0.0169)

mm (in.) 0.41 ~ 0.54(0.0161 ~ 0.0212)

mm (in.) 0.25 ~ 0.45(0.0098 ~ 0.0177)

mm (in.)28.994 ~ 29.000 (1.1415 ~ 1.1417

)

mm (in.) -mm (in.) -mm (in.) -

mm (in.) 66 (2.5984) - - -mm (in.) 53 (2.0866) - - -

General specifications - K2500 / K2700 / K3000Engine

0.20 ~ 0.40 (0.0078 ~ 0.0157)

29.994 ~ 30.000 (1.1809 ~ 1.1811)

0.239 ~ 0.390 (0.0094 ~ 0.0153)

30.012 ~ 30.033 (1.1816 ~ 1.1824)0.012 ~ 0.039 (0.0005 ~ 0.0015)

Connecting rod

Oil ring groove


No. 1 ring groove 0.26 ~ 0.36 (0.0102 ~ 0.0142)

No. 2 ring groove 0.30 ~ 0.45 (0.0118 ~ 0.0177)

Piston ring

Side clearance

No. 1 ring groove 0.06 ~ 0.10 (0.0023 ~0.0039)

No. 2 ring groove 0.04 ~ 0.08 (0.0015 ~ 0.0031)

Oil ring groove 0.03 ~ 0.07 (0.0012 ~ 0.0027)


Pin journal outer diameterMain journal outer diameter

End play

End gap

Piston pin

Crankshaft

PU-6

mm (in.) 0.02 ~ 0.05 (0.0008 ~ 0.0020)

mm (in.) 0.05 ~ 0.18 (0.0020 ~ 0.0071)

mm (in.) 0.13 (0.0051)

ℓ(lmp.qt)

8 (6.9)

°C (°F) 82 (179)°C (°F) 95 (203) 95 (203)

kΩ 2.45 ± 0.14kΩ 0,3222


45 ~ 48 ( 4.5 ~4.8) -

75 ~85 (7.5 ~ 8.5) -

19 ~ 21 (1.9 ~ 2.1) - - -

102.96 ~ 1152.77(10.5 ~ 11.5)


44 ~ 74 (4.5 ~7.5) + 90˚ + 90˚


Thermister type2.45 ± 0.14

0,3222

Thermostat Opening Pull opening 95 (203)

Cooling systemCooling method Forced circulation system Forced circulation with electrical fan

End play 0.14 ~ 0.30 (0.0055 ~ 0.0118)

FlywheelRunout -

82 ± 1.5 (179.6 ± 27)

0.038 ~ 0.071 (0.3726 ~ 0.6962)No 3 : 0.060 ~ 0.093 (0.5883 ~ 0.9120)


Coolant quantity

Type

9.5 (8.2) Without heater 8.5 (7.3)

80°C (176°F)Resistance 20°C (68°F)

Cylinder head bolt

Main moving systemConnecting rod cap nuts or bolts 68.6 (7.0) + 29.4 (3.0) + 90˚

Crankshaftmain bearing cap bolts 78.4 (8.0) + 44.1 (4.5) + 90˚

PU-7


11.8~15.7(1.2~1.6)

9.8 ~ 11.8 (1 ~ 1 2)

34.3~44.1(3.5~4.5

)Engine Electrical System

12V, 2.0KWV 11,5A 130

3600rpm

12V / 75A 12V /95A 12V / 95A 12V / 95A2.800

Electronic built - in type

14.4 ± 0.3VMF 100 AH

850A

122 min.

900A

Reserve capacity

Generator


182 min

-


Regulator setting PT80-33HL MF 100 AH

Cold cranking amperageat -18°C (-0 4°F)

14.4 ± 0.3V

I.C regulator built-in type

15.7 ~ 22.5 (1.6 ~ 2.3)

34.3 ~ 44.1 (3.5 ~ 4.5)

Voltage

Type

Oil pan drain plug

Starter

Rated voltage


Oil pan bolts



21.5 ~ 24.5 (2.2 ~ 2.5)

Amperage12

130Speed 4500 rpm


Battery

Type

Specific gravity at 25°C (77°F) 1.280 ± 0.01

Lubrication systemOil filter

12 V, 2.2 kW

PU-8

ZEXEL Electrical Injection Pump

ℓ(lmp.qt)

Service standardmm (in.)mm (in.)

Clutch cover assemblyClutch pedal bracket mountingClutch master cylinder mountingClutch release cylinder

Fuel System

Clutch

Clutch pedal stroke

Engine Management System Manufacturer Mechanical Injection Pump

Clutch operationClutch disc

Hydraulic SystemDry, single plate

Clutch pedal free play

15~22 (1.5~2.2)20~30 (2.0~3.0)10~15 (1.0~1.5)23~27 (2.3~2.7)

145~150(5.7~5.9)6~13 (0.24~0.51)

Type

Tightening torque [N.m(kgf-m)]Clutch cover assembly

Fuel Tank

Diaphragm spring type

Capacity 70 (61.59)Fuel Return System Return type

PU-9


- With PTO/Standard - -M5ZR14,270 4.186/4.1172,282 2.371/2.2721,414 1.432/1.4251,000 1,0000,813 0.806/0.8713,814 4.130/3.9583,727 4,444

2WD 2.4(2.1)/2.2(1.9)4WD 3.5(3.1)/3.3(2.9)


3.3(2.9)

FGRM/T oil quality SAE 75W-85, API GL-4

Gear ratio

1st

5th

3rd4th

Rev.

Manual Transaxle

1,5361,0000,8654,4324,111

MT oil capacity ℓ(lmp.qt) 2.4 (2.16)2.2(1.9)

Type

5,1922,621

RT-10

2nd

PU-10

mm (in.) 725.5 (28.56) 888.6 (34.98) - -mm (in.) 924 (36.38) 888.6 (34.98) - -mm (in.) - 1052.1 (41.42) - -mm (in.) - - 888.6 (34.98) 888.6 (34.98)mm (in.)mm (in.)

Lubricants

Li-COMPLEX(WBG-2)Outer bearing

Li-COMPLEX(WBG-2)Quantity (g) About 2

About 7

Oil sealQuality

About 7Grease cap inne

Quality Li-COMPLEX(WBG-2)

Front hub

Inner bearing

Quantity (g)

Li-COMPLEX(WBG-2)About 10

Run-out 0.3 (0.12)63.5 (2.5)

Differential Hypoid gearFull-floating type

Banjo typeRear axle housing typeSupporting type

Outer diameter

Propeller shafttotal length

Long wheelbaseHigh long wheelbase

1.4TON (2WD)Front (4WD)

Driveshaft

QualityQuantity (g)Quality

Reduction gear type

Quantity (g)

Hub innerQuality Li-COMPLEX(WBG-2)Quantity (g) About 45

Rear axle

PU-11


Gear oil

Quality Severe heat zone(30˚C Min.): API GL-#4, GS 90(SAE 140)Quantity (g) Fill the reservoir to the plug hold (About 1.7ℓ)Quality Severe frigid zone(-30˚C Max.): API GL-#5, GH 90(SAE 80)Quantity (g) Fill the reservoir to the plug hold (About 1.7ℓ)

ALVANIA EP #2Quantity (g) About 3.5

Differential carrier Quality General zone(-30~30˚C): API GL-#4, GS 90(SAE 90)Quantity (g) Fill the reservoir to the plug hold (About 1.7ℓ)

Inner/Outer oil seQuality Li-COMPLEX(WBG-2)Quantity (g) Required

General specifications - K2500 / K2700 / K3000Li-COMPLEX(WBG-2)

Quantity (g) Required

Outer bearing Quantity (g) Required

Universal joint Quality

Brake tube flare nut 22 ~ 30 (2.2 ~ 3)

Knuckle to upper arm ball joint mounting 140 ~ 180 (14 ~ 18)Knuckle to lower arm ball joint mounting 140 ~ 180 (14 ~ 18)

Disc brake mounting nut 65 ~ 87 (6.5 ~ 8.7)Knuckle to tie rod end mounting 34 ~ 45 (3.5 ~ 4.5)

Tightening torque [N.m (kgf-m)]Yoke flange mounting nut 50 ~ 60 (5 ~ 6)Caliper mounting bolt 120 ~ 140 ( 12 ~ 14)

Li-COMPLEX(WBG-2)Rear hub

Inner bearingQuality

Engine

Quality

PU-12

Rear

23 ~ 27 (2.3 ~ 2.7)Wheel sensor mounting 8 ~ 10 (0.8 ~ 1)

Suspension System

Differential carrier to rear axle housing mounting

Differential carrier gear oil supply plug 40 ~ 55 (4 ~ 5.5)Differential carrier gear oil drain plug 40 ~ 55 (4 ~ 5.5)

Rear axle shaft mounting bolt

Leaf spring

1.4ton

Shock absorber type

1ton 4WD

Wheel size1ton 2WD

1.4ton

Leaf springLeaf spring

Front wheel nut 190 ~ 220 (19 ~ 22)Rear wheel nut 190 ~ 220 (19 ~ 22)

Front

Suspension type1ton 2WD Torsion bar spring

60 ~ 75 (6 ~ 7.5)Rear axle housing mounting nut 80 ~ 110 (8 ~ 11)

Knuckle to dust cover mounting 16 ~ 23 (1.6 ~ 2.3)

Torsion bar springLeaf spring1.4ton

Gas pressurized5.0J × 14" 3.5J × 12" 4.0J × 13", 5.0J × 14"

1ton 4WD 5.0J × 14" 5.0J × 14"5.5J × 16"

195R14-6P [3.2 (45)]195R14-8P [3.2 (45)]

5.00R12-8P [4.0 (57)]145R13-8P [4.0 (57)]195R14-8P [4.0 (57)]

1ton 4WD kgf/cm2

(psi)6.70R14-8P [4.2 (60)]

6.70R14-10P [4.2 (60)]6.70R14-8P [4.4 (64)]

6.70R14-10P [4.8 (69)]

4.0J × 13"

1ton 2WD kgf/cm2

(psi)

kgf/cm2

(psi)6.50R16-10P [4.7 (67)] 5.50R13-8P [3.6 (52)]

5.50R13-10P [5.4 (77)]

Tire size [Tire pressure]

PU-13

CamberCasterToe-inKing-pin CamberCasterToe-inKing-pin CamberCasterToe-inKing-pin

mm (in.) 2WD: 176 (6.93) 4WD: 148 (5.83)2WD: 38.72° 4WD: 34.11°2WD: 35.35° 4WD: 31.00°

kPa(kgf/cm²

)

-0°±0.5°

Steering System1ton 1.4ton

3.7°±0.5° 0±2mm (0±0.079in.) -

9°53' -

1.4ton

--

Wheel alignment

7.85° -

-

--

1ton 4WD

1ton 2WD

0°±0.5°3.0°±0.5°

0±3mm (0±0.118in.)9°22'


0.67°±0.5° -1.5°±0.5° -

3±2mm (0.118±0.079in.) -

Rack stroke -

TypePower steering fluid

Rack and Pinion Ball & nutPSF-3 ←

Steering angle Inner 39.00°Outer 30.00°

Power steering pump relief pressure 8826 ~ 9316 (90 ~ 95) ←

Front Rear

PU-14

mm (in.)mm (in.)

MPa(kg/cm²)

MPa(kg/cm²)


Brake System

Type


0.2 : 1

ProvidedLSPV

0.98 (10)

5.49 (56)


As requiredMaster cylinder

Tandem type

I.D.K2500, K2700 26.99 (1.06)K3000S 28.57 (1.12)

Brake fluidRecommended lubricant

Without load

With load

Decompression ratio

Steering wheel lock nut 35 ~ 45 (3.5 ~ 4.5)Steering column mounting bolt & nut 17 ~ 26 (1.7 ~ 2.6)Bolt connecting universal joint to bevel gear 22 ~ 27 (2.2 ~ 2.7)

Knuckle arm to center link (1.4ton) 100 ~ 120 (10.0 ~ 12.0)

Bolt connecting universal joint to steering gear 22 ~ 27 (2.2 ~ 2.7)Pitman arm to drag link (1.4ton) 100 ~ 120 (10.0 ~ 12.0)

DOT 3 or DOT 4Quantity

Tie rod end to knuckle nut 60 ~ 80 (6.0 ~ 8.0)Steering gear box to frame 90 ~ 110 (9.0 ~ 11.0)

Drag link to knuckle arm (1.4ton) 100 ~ 120 (10.0 ~ 12.0)

PU-15



mm (in.)mm (in.)


Engine

Type


Brake lining thickness 4.5 (0.18)AutomaticClearance adjustment

Dual servo

Drum I.D.2WD 220 (0.87)4WD, K3000S 260 (1.02)

Type

46 (1.81) ×2K3000S 60.6 (2.39) ×2

Rear brake(Drum)

11 (0.43)K3000S 17.4 (0.69)

Double pistonCylinder type

278 (10.94)K3000S 294 (11.57)

Disc thicknessK2500, K2700 26 (1.02)K3000S 35 (1.38)

Tandem type with 8 + 9 in Tandem type with 9 + 10 in

Boosting ratio 8.0 : 1Front brake(Disc)

Floating type with ventilated disc

Disc O.D.K2500, K2700

Brake boosterType Vacuum

Pad thicknessK2500, K2700

Cylinder I.D.K2500, K2700

Effective diameterK2500, K2700K3000S

PU-16

mm (in.)mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)mm (in.)

Service standard

O.D=Outer Diameter

Mechanical brake acting on rear wheelsLever

I.D=Inner Diameter

221.5 (8.72)K3000S 261.5 (10.30)

0.02 (0.0008)Front disc parallelism 0.02 (0.0008)Rear drum brake lining thickness 1.0 (0.039)

1.0 (0.039)Front disc thickness (minimum)

K2500, K2700 24 (0.945)K3000S 33 (1.299)

0 ~ 3 (0 ~ 0.11)Booster push rod to master cylinder piston clearance

0.6 ~ 1.4 (0.023 ~ 0.055) (at 500 mmHg vacuum)


5 ~ 7 clicke

Front disc brake pad thickness (minimum)

K2500, K2700 2.0 (0.079)

185 (7.28)Brake pedal stroke 143 ~ 147 (5.63 ~ 5.79)Stop lamp switch outer case to pedal stopper clearance

0.5 ~ 1.0 (0.02 ~ 0.04)

TypeActuation

Parking brake

Brake pedal height

Brake pedal free play

K3000S

Front disc run out

Rear drum brakedrum I.D. (maximum)

K2500, K2700

PU-17


mm (in.)mm (in.)

Engine

Seat beltsDriver's seat 3 point typePassenger's seat 3 point type

Glass thicknessWindshield 5.0 (0.1969)Front door 3.2 (0.1260)

Front doorConstruction Front hinged, full door constructionRegulator system X-ARM type


Member assembly bracket mounting bolt 13.7~ 19.6 (1.4 ~ 2.0)Stop lamp switch mounting nut 7.8 ~ 9.8 (0.8 ~ 1.0)

Body(Interior & Exterior)Wheel cylinder mounting bolt 4.9 ~ 10.8 (0.5 ~ 1.1)

10 ~ 15 (1.0 ~ 1.5)

Caliper assemblyto knuckle

Front 117.7 ~ 137.3 (12 ~ 14)Rear

Brake hose to front caliper 24.5 ~ 29.4 (2.5 ~ 3.0)Brake pedal assembly bracket mounting nut

Caliper guide rod boltFront 21.6 ~ 31.4 (2.2 ~ 3.2)Rear

Bleeder screw 6.8 ~ 8.8 (0.7 ~ 0.9)Brake tube nut, brake hose 12.7 ~ 16.7 (1.3 ~ 1.7)

Master cylinder to booster mounting nut 9.8 ~ 15.7 (1.0 ~ 1.6)Brake booster mounting nut 12.7 ~ 15.7 (1.3 ~ 1.6)

Tightening torque [N.m (kgf-m)]


PU-18

Seat beltAnchor mounting bolt 39~54 (4.0~5.5)Retractor mounting bolt 39~54 (4.0~5.5)Buckle mounting bolt 39~54 (4.0~5.5)

Front seatMounting bolts 34~54 (3.5~5.5)Shutter lever mounting 7~11 (0.7~1.1)

Crash padCowl cross bar side 19~26 (1.9~2.6)Cowl cross bar center 19~26 (1.9~2.6)

Door glass screw 8~12 (0.8~1.2)Outside rearview mirror Mounting bolts 7~11 (0.7~1.1)

Front door

Hinge bolt(door side) 22~26 (2.2~2.7)Hinge bolt(body side) 33~41 (3.4~4.2)

Door channel nut 8~12 (0.8~1.2)Door window regulator 4~6 (0.4~0.6)

8~11 (0.8~1.1)Striker screw 17~22 (1.7~2.2)Outside handle bolt 7~11 (0.7~1.1)

Latch screw

Checker bolt(door side) 7~11 (0.7~1.1)Checker bolt(body side) 17~26 (1.7~2.6)


PU-19


WWWWWWWWWWWW

Engine

DC 13.2VAM/FM/ Cassette

Power supply

28/8Front turn signal lamp

HighLow

Lighting system6055

Overhead console lampRear fog lamp

10 x 221

License plate lampRoom lamp 10


2727

Rear tail/stop lamp27

27/8

10

AMMW

Head lamp

Front fog lamp

4Ω x 480PF 75Ω

4Ω x 2

Front position lamp 28/8

PLL synthesized type87.5~108 MHz / 100KHz (General), 50KHz(Europe)

531~1602 KHz / 9KHz (General)522~1620 KHz / 9KHz (Europe)


Rated outputSpeaker impedanceAntenna

FMTuning type

Max 25W x 2

AM/FM/Cassette (Logic deck)

Max 41W x 4

Type



PU-20

HS - 18 (Swash plate)

FD46XG(PAG)150

± 100cc5PK - TYPE

[oz.(g)]

Heating Ventilation & Air Conditioning

FD46XG(PAG)210 ± 100cc

1PK - TYPE

Air conditioner


Speed control ResistorBlower

Type Siroco fanSpeed step 4 speed

Type R - 134a15.87 ± 0.88(450 ± 25)Capacity

Blower unit

Dual pressure switch

ON : 370 ± 28(26.0 ± 0.2)OFF : 455 ± 28(32.0 ± 0.2)

ON : 28.6 ~ 34.8(2.00 ~ 2.45)OFF : 28.4 ± 2.8(0.0 ± 0.2)


Refrigerant

Condeser Heat rejection 10,000 ± 10% Kcal/hr

Compressor

Type

Oil type & Capacity

Pulley typeDisplacement 180 cc/rev


Low [psi

(kg/cm²)]

High [psi

(kg/cm²)]

PU-21


Cable

Evaporator

Type Drawn cupCooling capacity 4,000 -10% Kcal/hrTemperature control type Thermistor

Off : 1.0 ± 0.5 (33.8 ± 32.9)ON : 4.0 ± 0.5 (39.2 ± 32.9)

A/C ON/OFF


Heater

Type Pin & Tube typeHeating capacity 4,550 - 5% Kcal/hr

Actuator

Engine


[°C (°F)]

Temperature operating method


PU-22

GeneralInformation

GI-1

Terminal Terminal1 112 123 134 144 156 167 178 189 1910 20

CAN - Low

Chassis K-LineCAN - Hi

--

ON/START Input-CAN - Low

Body K-Line

GroundCAN - HiFLASHP/T K-Line

Diagnosis Plug

Feature Feature

B+

GroundMELCO TCU-

-Memory Power-

4 3

12 11 10 9 8 7 6 5

20 19 18 17 16 15 14 13

2 1

GI-2

Feature

8

56

OBD-II Plug

Terminal

34

12

CAN - Hi

1112

910

CAN - LowL-LineMemory Power-

-Body K-LineDoor Remote

-1615 J1850

1314

7

P/T K-LineChassis K-Line

J1850Vehicle Speed SensorGroundGround

12345678

910111213141516

GI-3

Error Code (Pending Code)

(P 0X X X X X

Error Number (00-99)

1 3 0)

1 - Fuel and Intake Air2 - Fuel and Exhaust Air (Injection Cycle)3 - Ignition System4 - Additional Emission Control5 - Speed and Idle System6 - ECU Output Side7 - Transmission8 - Transmission

0 - ISO1 - Manufacturer

B - BodyC - ChassisP - DrivelineU - Network

GI-4

GI-1

GI-2

GI-3

GI-4

Chassis Number

1 2 3 4 5 6 7 9 10 12 13 14 15 16 17

Transmission ModelYear

K N E J A 5 5 5 Y 1 2 3 4 5 6

Manufacturer Model ChassisK Korea SA Picanto 22 4 door Sendan N KIA JB Rio 24 5 door Hatchback

LD Cerato F/L 52 5 door Station WagonE Europe all MG Magentis / Optima 55 5 door SUVA PKW GH Opirus F/L 13 CoachC LKW UN Carens 23 Long CoachD MPV KM Sportage 01 Ultra long cargo box, Low deck, Standard cabin

BL Sorento F/L 03 Ultra long cargo box, Low deck, Super cabinVQ Carnival / Sedona 06 Ultra long cargo box, Low deck, Double cabinPU K2500 / K2700 / K3000 21 Standard cargo box, High deck, Standard cabin

26 Standard cargo box, High deck, Double cabin91 Standard cargo box, Low deck, Standard cabin96 Standard cargo box, Low deck, Double cabin

11ProductionLocation

5

Series Number

5

Manufacturer Model Code

Consecutive NumberModel Chassis

8

Motor

USA

GI-5

Motor Transmission Model year Production plant1 1.4 Gasoline (JB) 2 Manual (2WD) S 1995 5 Whasung

2.0 Gasoline (UN) 3 Automatic (2WD) T 1996 6 Soha2.0 Diesel (KM) 5 5 Speed Manual (4WD) V 1997 7 Kwang Ju2.5 Diesel (BL) 8 4 Speed Automatic (4WD) W 1998 T Donghee Auto2.7 Diesel (PU) X 19992.9 Diesel (VQ) Y 2000

2 1.6 Gasoline (JB, LD) 1 20012.0 Gasoline (MG, KM) 2 20022.4 Gasoline (BL) 3 20032.0 Diesel (UN) 4 20043.0 Diesel (PU) 5 2005

3 1.1 Gasoline (SA) 6 20062.0 Gasoline (LD) 7 20072.7 Gasoline (KM) 8 20083.5 Gasoline (BL)2.5 Diesel (PU)3.8 Gasoline (VQ)

4 1.5 Diesel (JB)2.0 Diesel (LD)2.7 Gasoline (MG)3.5 Gasoline (GH)2.5 Diesel (BL)

5 1.1 Diesel (SA)1.5 Diesel (LD)3.8 Gasoline (GH)

6 1.6 Diesel (LD)7 1.6 Gasoline (LD)

GI-6

GI-1

GI-2

GI-3

GI-4

GI-5

GI-6

Abbreviation English2WD 2 Wheel Drive4WD 4 Wheel Drive

A.P.I. American Petroleum InstituteA/C Air ConditioningA/T Automatic Transmission AAS Air Adjust ScrewABDC After Bottom Dead CenterABS Antilock Brake SystemACC AccessoriesACL Air CleanerACU Airbag Control ModuleADM Assist Door Module AFM Air Flow MeterALDL Assembly Line Diagnostic LinkAP Accelerator PedalAPS Accelerator Position Sensor AQS Air Quality Sensor AT(X) Automatic TransaxleATDC After Top Dead CenterATF Automatic Transaxle FluidATT Active Torque Transfer

B+ Battery Positive VoltageBAC Bypass Air ControlBARO Barometric PressureBBDC Before Bottom Dead CenterBCM Body Control Module BDC Bottom Dead CenterBPT Seat Belt Pretensioner BS Seat Belt Buckle Switch BTDC Before Top Dead CenterBTS Seat Belt Tension Sensor BUPT Seat Belt Buckle Pretensioner

A

B

Abbreviation Explanation

GI-7

Abbreviation English

CAB Curtain Air Bag CAC Charge Air CoolerCAN Controller Area NetworkCAS Crank Angle SensorCBS Conventional Brake System CFI Central Fuel InjectionCKPS Crankshaft Position SensorCLS Closed Loop SystemCM Control ModuleCMPS Camshaft Position SensorCO Carbon MonoxideCO2 Carbon DioxideCPP Clutch Pedal PositionCPU Central Processing UnitCSP Control Sleeve Position SensorCSS Control Sleeve SensorCTP Closed Throttle PositionCVVT Continuously Variable Valve Timing

D.O.T. Department of TransportDAB Driver AirbagDBV Diagonal Bracked VehicleDCC Damper Clutch Control DCL Data Communication LinkDCV Double Check ValveDDM Driver Door ModuleDI Distributer IgnitionDIS Driving Information SystemDLC Data Link ConnectorDLI Distributorless IgnitionDRL Daytime Running LightDOHC Double Overhead CamshaftDTC Diagnostic Trouble CodeDTM Diagnostic Test ModeDVC Driving Circle

C

D

GI-8


E/L Electric LoadEBD Electronic Brakeforce DistributionEC-AT Electronically Controlled Automatic TransaxleECM Engine Control ModuleECS Electronic Control Suspension ECTS Engine Coolant Temperature SensorECU Electronic Control UnitEEC Electronic Engine ControlEEPROM Electrically Eraseable Programable Read Only MemoryEFI Electronic Fuel InjectionEGR Exhaust Gas RecirculationELR Emergency Locking RetractorEPS Electric Power Steering ESC Electronic Stability Control ESP Electronic Stability Program EST Electric Shift TransferETACS Electronic Time & Alarm Control SystemETS Electronic Throttle System EVAP Evaporative EmissionEX Exhaust

FAM Front Area ModuleFC Fan ControlFCV Fuel Cut ValveFIP Fuel Injection PumpFIS Front Impact Sensor

GEN GeneratorGND Ground

HC HydrocarbonsHCU Hydraulic Control ModuleHECU Hydraulic & Electric Control Unit HFM Hot Film MeterHIVEC Hyundai Intelligent VehicleElectronic ControlHO2S Heated Oxygen Sensor

E

F

G

H

GI-9


IAC Idle Air ControlIATS Intake Air Temperature SensorICM Intergrated Circuit ModuleIG IgnitionIMS Integrated Memory System IN IntakeINT IntermittentIPM In-Panel ModuleISCA Idle Speed Control Actuator

KS Knock Sensor

LED Light Emitting DiodeLF Links FrontLH Left HandLHD Left Hand DriveLIN Local Interconnect NetworkLO LowLR Left RearLSD Limited Slip Differential

M/S Manual SteeringMAFS Mass Air Flow SensorMAPS Manifold Absolute Pressure SensorMAT Manifold Air TemperatureMCC Manifold Catalytic Converter MFL Multipoint Fuel InjectionMIL Malfunction Indicator LampMLA Mechanical Lash Adjuster MT(X) Manual Transaxle

NC Normal ClosedNO Normal OpenNOX Nitrogen of OxideNTC Negative Temperature Coefficient

K

I

J

L

M

N

GI-10


OBD On Board DiagnosisOC Oxidation Catalytic ConverterOCV Oil Control Valve OD OverdriveOHC Overhead CamshaftOL Open LoopOTS CVVT Oil Temperature Sensor

P/S Power SteeringP/W Power WindowPAB Passenger Air Bag PAD LAMP Passenger Air Bag Deactivation Lamp PCM Powertrain Control ModulePCSV Purge Control Solenoid ValvePCV Positive Crankcase VentilationPID Parameter Identification DataPNP Park / Neutral PositionPRC Pressure Regulator ControlPSD Power Sliding DoorPSP Power Steering PressurePTC Positive Temperature CoefficientPTC Pending Trouble CodePTG Power Tail Gate

QTY Quantity

RAM Rear Area ModuleRF Right FrontRH Right HandRHD Right Hand DriveRKE Remote Keyless Entry ROZ Research Octan valueRPM Rounds Per MinuteRR Right RearRSE Rear Seat Entertainment

Q

R

P

O

GI-11


SAB Side Airbag SAE Society of Automotive EngineersSAS Sophisticated Air Bag SensorSAS Start Adjust Screw SFI Sequential Fuel InjectionSIS Side Impact Sensor SRS Supplemental Restraint SystemSRSCM Supplemental Restraint System Control ModuleSST Special Service ToolST StartSTPS Seat Track Position Sensor SW Switch

TAS Throttle Adjusting ScrewTB Throttle BodyTBI Throttle Body InjectionTC TurbochargerTCC Torque Converter ClutchTCC Torque Converter Control TCI Turbo Charger Intercooler TCM Transmission Control ModuleTCS Traction Control SystemTCV Timer Control ValveTDC Top Dead CenterTFT Transaxle Fluid TemperatureTNS Tail Number SideTOD Torque On DemmandTPMS Tire Pressure Monitoring System TPS Throttle Position SensorTPS Timing Position SensorTR Transmission RangeTWC Three Way Catalytic Converter

UCC Underfloor Catalytic Converter

S

T

U

GI-12


V/P Vacuum PumpVAC VacuumVAF Volume Air FlowVAS Voice Alarm SystemVCM Vehicle Control ModuleVDC Vehicle Dynamic Control VFS Variable Force Solenoid VICS Variable Inertia Charging SystemVIM Vehicle Immobilizer ModuleVIN Vehicle Identification NumberVR Voltage RegulatorVREF Reference VoltageVSS Vehicle Speed SensorVSS Vehicle Speed Sensor

WCC Warm-up Catalytic Converter WOT Wide Open ThrottleWSS Wheel Speed Sensor

ZYX

V

W

GI-13

Unit ConversionUnit Multiplier Unit Unit Multiplier Unit

Length Accelerationin 25,4 mm ft/sec2 0,3048 m/s2ft 0,3048 m in/sec2 0,0254 m/s2

Yard 0,9144 mMeile 1,609 km

Surface Torquein2 645,2 mm2 in-lb 0,11298 Nmft2 0,0929 m2 ft-lb 1,3558 Nm

Yard 0,8361 m2 mkp 9,807 Nmkg.m 9,807 Nm

Volume Powerin3 16387 mm3 PS 0,746 Kwqt 0,9464 l

Gallone 3,7854 lYard 0,7646 m3

Weight Pressurelb 0,4536 kg psi 6,895 kPa

Ton 907,18 kg kp/cm2 9,807 barbar 100000 Pa

mmHg 1,333 mbarForce Energy

kg 9,807 N ft-lb 1,3558 Jkp 9,807 N kWh 3600000 Joz 0,278 Nlb 4,448 N

Speed Fuel consumptionmph 1,6093 km/h mpg 0,4251 km/l

°C = 5/9 × (°F - 32), °F = 9/5 × (°C + 32)

GI-1

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01 Foreword & Contentstoyotaux.berrios.cl/procedimientos/mecanica-dyp...9.7:1 10.0: 1 rpm rpm rpm rpm ℓ (lmp.qt) ℓ (lmp.qt) ℓ (lmp.qt) kPa (kg/cm²) In-line, SOHC 4 Engine DSL