Datos Tecnicos Kia PDF

2010
Table of Contents
Picanto
SA
Rio
JB
Cerato
LD
cee'd*
ED
All New Cerato / Forte*
TD
Magentis / Optima
MG
Opirus
GH
Soul*
AM
Carens
UN
Sportage
KM
Sorento
BL
Mohave / Borrego*
HM
Carnival / Sedona
VQ
K2500 / K2700 / K3000
PU
General Information
GI
Picanto (SA)
SA-2
Engine Mechanical System
SA-9
Engine Electrical System
SA-10
Fuel System..
SA-10
Clutch.
SA-11
Manual Transaxle.
SA-12
Automatic Transaxle
SA-12
Driveshaft..
SA-13
Suspension System.
Steering System SA-14
RestraintsSA-15
SA-16
Brake System
Body (Interior & Exterior). SA-19
SA-21
Body Electrical System
Heating, Ventilation & Air Conditioning..SA-22
SA-1
General Specifications - Picanto

Engine
GSL 1.0
GSL 1.1
DSL U 1.1
Engine
In-line, SOHC
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
In-line, DOHC
3
66 (2.5984)
x 73 (2.8740)
67 (2.6378)
x 73 (2.8740)
75 (2.9528)
x 84.5 (3.3268)
999
9.7:1
1.086
10.0: 1
1-3-4-2
BTDC 7 5
750 100
750 100
800 100
800 100
1.120
17.8:1
1-2-3
890 100
890 100
890 100
890 100
3.3 (2.90)
3.0 (2.64)
0.3 (0.26)
Above SG
5.3 (5.10)
4.8 (4.22)
0.5 (0.44)
Above CH-4 or B4
78.45 (0.8)
147.1 (1.5) [at

1000rpm,100C(212F)]
SA-2
Valve timing
Intake valve
Exhaust valve
Opens (ATDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
Cylinder head
Flatness of gasket surface
Intake
Flatness of manifold
mounting surface
Exhaust
Camshaft
mm (in.)
mm (in.)
mm (in.)
5
35
43
5
13 ~ 21
10 ~ 18
19 ~ 27
(BTDC)16 ~ 24
Less than 0.03 (0.0012)

Less than 0.03 (0.0012)
Less than 0.15 (0.0059)
Less than 0.05 (0.0020)

Less than 0.025 (0.0010) for width
Less than 0.1(0.0039)
Intake
mm (in.) 33.941 ~ 34.141 (1.3363 ~ 1.3441)
Exhaust
mm (in.) 34.055 ~ 34.255 (1.3407 ~ 1.3486)
Cam height
Journal outer Diameter (Intake, Exhaust) mm (in.) 40.940 ~ 40.955 (1.6118 ~ 1.6124)
LH: 35.452 ~ 35.652 (1.3957 ~

1.4036)
RH:
35 537 ~
~ 35.900
35 737 (1.4055
(1 3991 ~
~
LH: 35.700
1.4134)
RH: 35 452 ~ 35 652 (1 3957 ~
20.944 ~ 20.960
(0.8246 ~ 0.8252)
Bearing oil clearance
mm (in.)
0.045 ~ 0.085 (0.0018 ~ 0.0033)
0.040 ~ 0.077
(0.0016 ~ 0.0030)
End play
mm (in.)
0.07 ~ 0.19 (0.0028 ~ 0.0075)
0.10 ~ 0.20
(0.0039-0.0079)
SA-3

Engine
Valve
Valve length
GSL 1.0
GSL 1.1
Intake
Exhaust
mm (in.)
mm (in.)
99.55 (3.9193)
99.05 (3.8996)
93.0 (3.6614)
93.7 (3.6890)
Intake
mm (in.)
5.465 ~ 5.480 (0.2152 ~ 0.2157)
5.455 ~ 5.470
(0.2148 ~ 0.2154)
Exhaust
mm (in.)
5.430 ~ 5.450 (0.2138 ~ 0.2146)
5.435 ~ 5.450
(0.2140 ~ 0.2146)
mm (in.)
mm (in.)
45 ~ 4530'
0.8 (0.0315)
1.2 (0.0472)
45.58 ~ 45.75
1.1 (0.0433)
1.2 (0.0472)
Intake
mm (in.)
0.020 ~ 0.047 (0.0008 ~ 0.0019)
0.030 ~ 0.057
(0.0012 ~ 0.0022)
Exhaust
mm (in.)
0.050 ~ 0.082 (0.0020 ~ 0.0032)
0.050 ~ 0.077
(0.0020 ~ 0.0030)
Intake
mm (in.)
5.500 ~ 5.512
(0.2165 ~ 0.2170)
Exhaust
mm (in.)
5.500 ~ 5.512
(0.2165 ~ 0.2170)
Intake
Exhaust
mm (in.)
mm (in.)
46.0 (1.8110)
48.0 (1.8898)
31.3 ~ 31.7
(1.2323 ~ 1.2480)
Stem outer diameter

Face angle
Thickness of valve head Intake
(margin)
Exhaust
Valve stem to valve
guide clearance
Valve guide
Inner diameter
Length
DSL U 1.1
SA-4
Valve seat
Intake
Exhaust
mm (in.)
mm (in.)
Seat angle
Valve spring
Free length
0.9 ~ 1.3 (0.0354 ~ 0.0512)

0.9 ~ 1.3 (0.0354 ~ 0.0512)
4330' ~ 44
0.8~1.4 (0.0315~0.0551)
1.2~1.8 (0.0472~0.0709)
44.5 ~ 45
mm (in.)
40.50 (1.5945)
44.9 (1.7677)
Load
mm (in.)
15.60.9kg / 32.0 (1.2598)

33.31.8kg / 24.5 (0.9646)
17.50.9kg/ 32.0(1.2598)
31.01kg/ 23.5(0.9252)
Less than 1.5
Less than 1.5
Width of seat contact
Out of squareness
Rocker arm and rocker arm shaft
Rocker arm inner diameter
Rocker arm shaft outer diameter
Cylinder block
mm (in.) 17.010 ~ 17.028 (0.6697 ~ 0.6704)

mm (in.) 16.985 ~ 16.998 (0.6687 ~ 0.6692)
Cylinder bore
mm (in.) 67.000 ~ 67.030 (2.6378 ~ 2.6390)
75.00 ~ 75.03
(2.9528 ~ 2.9539)

Piston
mm (in.)
Less than 0.05 (0.002)
Less than 0.05 (0.0020)
Piston outer diameter
mm (in.)
66.000 ~ 67.030 66.970 ~ 67.000

(2.5984 ~ 2.5996) (2.6366 ~ 2.6378)
74.93 ~ 74.96
(2.9500 ~ 2.9512)
Piston to cylinder clearance
mm (in.)
0.020 ~ 0.040 (0.0008 ~ 0.0016)
0.060 ~ 0.080
(0.0024 ~ 0.0031)
No. 1 ring groovemm (in.)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.83 ~ 1.85
(0.0720 ~ 0.0728)
1.21 ~ 1.23 (0.0476 ~ 0.0484)
1.82 ~ 1.84
(0.0717 ~ 0.0724)
2.51 ~ 2.53
2.01 ~ 2.03
(0.0988 ~ 0.0996) (0.0791 ~ 0.0799)
3.02 ~ 3.04
(0.1189 ~ 0.1197)
Ring groove width
Oil ring groove
mm (in.)
SA-5

Engine
Piston ring
Side clearance
GSL 1.0
DSL U 1.1
0.03 ~ 0.07 (0.0012 ~ 0.0028)
0.09 ~ 0.13
(0.0035 ~ 0.0051)
0.02 ~ 0.06 (0.0008 ~ 0.0024)
0.08 ~ 0.12
(0.0031 ~ 0.0047)
Oil ring groove
End gap
GSL 1.1
0.01 ~ 0.13
mm (in.)
(0.0003 ~ 0.0011)
0.06 ~ 0.15
(0.0024 ~
0 0059)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.15 ~ 0.30 (0.0059 ~ 0.0118)
0.20 ~ 0.35
(0.0079 ~ 0.0138)
0.25 ~ 0.40
0.30 ~ 0.50
(0.0098 ~ 0.0157) (0.0098 ~ 0.0157)
0.35 ~ 0.50
(0.0138 ~ 0.0197)
0.20 ~ 0.70 (0.0079 ~ 0.0276)
0.20 ~ 0.40
(0.0079 ~ 0.0157)
Oil ring groove
mm (in.)
Piston pin
Piston pin outer diameter
mm (in.) 17.000 ~ 17.003 (0.6693 ~ 0.6694)
27.995 ~ 28.000
(1.1022 ~ 1.1024)
Piston pin hole inner diameter
mm (in.) 17.011 ~ 17.015 (0.6697 ~ 0.6699)
Piston pin hole clearance
0.008 ~ 0.014
0.008 ~ 0.015
(0.0003 ~ 0.0006
mm (in.)
(0.0003 ~ 0.0005)
)
28.004 ~ 28.010
(1.1025 ~ 1.1028)
0.004 ~ 0.015
(0.0002 ~ 0.0006)
Connecting rod small end inner diameter mm (in.) 16.974 ~ 16.985 (0.6683 ~ 0.6687)
28.022 ~ 28.034
(1.1032 ~ 1.1037)
Connecting rod small end hole clearance mm (in.) -0.029 ~ -0.015 (-0.0006 ~ -0.0003)
0.022 ~ 0.039
(0.0009 ~ 0.0015)
SA-6
Connecting rod
49.000 ~ 49.018
(1.9291 ~ 1.9298)
Connecting rod big end inner diameter
mm (in.) 41.000 ~ 41.015 (1.6142 ~ 1.6148)
Connecting rod bearing oil clearance
mm (in.)
0.012 ~ 0.041 (0.0005 ~ 0.0016)
0.025 ~ 0.043
(0.0010 ~ 0.0017)
End play
mm (in.)
0.10 ~ 0.25 (0.0039 ~ 0.0098)
0.050 ~ 0.302
(0.0020 ~ 0.0119)
Crankshaft
Main journal outer diameter
mm (in.) 41.982 ~ 42.000 (1.6528 ~ 1.6535)
53.972 ~ 53.990
(2.1249 ~ 2.1256)
Pin journal outer diameter
mm (in.) 37.980 ~ 38.000 (1.4953 ~ 1.4961)
45.997 ~ 46.015
(1.8109 ~ 1.8116)
Main bearing oil clearance
mm (in.)
0.020 ~ 0.038 (0.0008 ~ 0.0015)
0.024 ~ 0.042
(0.0009 ~ 0.0017)
End play
mm (in.)
0.05 ~ 0.25 (0.0020 ~ 0.0098)
0.08 ~ 0.28
(0.0031 ~ 0.110)
Flywheel
Runout
Oil pump
mm (in.)
0.13 (0.0051 )
Relief valve opening pressure
kPa
(kg/cm)
490.33 49.03 (5 0.5)
490.33 ~ 588.40
(5.0 ~ 6.0)
Cooling system
Cooling method
Coolant quantity
Forced circulation with cooling fan
(lmp.qt)
5.3 (4.66)
SA-7

Engine
C (F)
Opening
C (F)
Thermostat
Pull opening
mm (in.)
Full lift
Main valve
kPa
opening press. (kg/cm)
Radiator cap
Vacuum valve
kPa
(kg/cm)
opening press.
Water temperature sensor
Type
k
20C (68F)
Resistance
k
80C (176F)
Tightening torque [N.m(kgf-m)]
Main moving system
Connecting rod cap nuts or bolts
Bolts
Crankshaft
Long bolts
main bearing cap
Short bolts
Cylinder head
Camshaft bearing cap nuts or bolts
Cylinder head bolt
GSL 1.0
GSL 1.1
82 1.5 (177 2.7)
95 (203)
-
DSL U 1.1
85 1.5 (185.0 2.7)
100 (212)
8 (0.3150) or more
93.16 ~ 122.58 (0.95 ~ 1.25)

0.98 ~ 4.90 (0.01 ~ 0.05)
Thermister type
2.45 0.14
0,3222
2.45 0.14
0,3222
19.6 ~ 22.6 (2.0 ~ 2.3)

49.0 ~ 53.9 (5.0 ~ 5.5)
12.7 (1.3) + 90
-
22.6 ~ 26.5
(2.3~2.7) + 90~94
32.4 ~ 36.3 (3.3 ~ 3.7)
7.8 ~ 9.8 (0.8 ~ 1.0)

55.8 ~ 68.6 (6.0 ~ 7.0)
11.8 ~ 13.7 (1.2 ~ 1.4)

49.0 (5.0) + 90 + 120
SA-8
Lubrication system
Oil filter
Oil pan nuts
Oil pan drain plug
11.8 ~ 15.7 (1.2 ~ 1.6)

5.9 ~ 7.8 (0.6 ~ 0.8)
34.3 ~ 44.1 (3.5 ~ 4.5)
24.5 (2.5)
34.3 ~ 44.1 (3.5 ~ 4.6)
12 V, 0.9 kW
11.5 V
60A
5,500 rpm
Battery voltage sensing
13.5 V , 70A
1,000 ~ 18,000 rpm
Electronic built-in type
147 0.3V
MF 40AH
12 V, 1.7 kW
11 V
90A, MAX
2,600 rpm, MIN
12V, 90A
1,000 ~ 18,000 rpm
Built-in I.C. regulator
CMF 60AH
354 A
550A
55 min
92min

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
Spark plugs
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Voltage regulator type
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
resistance
Unleaded (NGK)
Unleaded (Gap) mm (in.)
1.280 0.01
0.87 10 %
13.0 15 %
BKR5ES-11
RC10YC4
SA-9

Engine
GSL 1.0
GSL 1.1
DSL U 1.1
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Installation location
Type
Driven by
MPa
(kgf/cm
)
kPa
Fuel Pressure
(Maximum)
Pressure
Fuel Pressure Regulator
Regulated Fuel
(kgf/cm
Pressure
)
Bosch
35 (30.80)
Returnless type
Return type
High pressure type

Built in Fuel Pump assembly
Built in engine room
-
High Pressure
Fuel Pump
Electrical
In-tank type
Electric motor
Mechanical
Plunger Pumping Type
Drive Belt
160 (1,632)
350 (3.5)
Cable type
Single dry with diaphragm
Diaphragm spring strap
Hydraulic type
Clutch
Clutch operation
Clutch disc
Clutch cover assembly
SA-10

Clutch pedal bracket mounting
Clutch master cylinder mounting
Clutch release cylinder
Clutch cable bracket mounting
Service standard
Clutch pedal stroke
Clutch pedal free play
mm (in.)
mm (in.)
15~22 (1.5~2.2)
20~27 (2.0~2.7)
15~22 (1.5~2.2)
25~35 (2.5~3.5)
9~14 (0.9~1.4)
15~22 (1.5~2.2)
-
145 (5.70)
15~20 (0.58~0.78)
145 (5.70)
6~13 (0.24~0.51)
M5EF2
3,545
1,894
1,192
1,000
0,719
3,636
4,800
M5CF1
3,615
1,950
1,286
0,943
0,733
3,583
3,650
SAE 75W/85, 75W/90
SAE 75W/85, API GL-4
1.90 (1.67)
1.90 (1.67)
Manual Transaxle
Type
Gear ratio
M/T oil quality

MT oil capacity
1st
2nd
3rd
4th
5th
Rev.
FGR
(lmp.qt)
SA-11

Engine
GSL 1.0
GSL 1.1
DSL U 1.1
Automatic Transaxle
Type
Gear ratio
FRA
2,914
1,526
1,000
0,726
2,643
3,977
1st
2nd
3rd
4th
Rev.
FGR
ATF quality
(lmp.qt)
ATF capacity
Matic D+ESSO JWS3314

Mixture
(Ratio=2:1)
5.2 (4.6)
Driveshaft
M/T
Joint type
A/T
M/T
Max. permissible angle
A/T
Hub end play
Inner
Outer
Inner
Outer
Inner
Outer
Inner
Outer
mm (in.)
TJ
BJ
TJ
BJ
23 or more
46 or more
23 or more
46 or more
0.08 (0.003) or less
SA-12
Starting torque [N.m (kgf-m)]

Wheel bearing
[NOTE]
Inner: On transaxle side
Outer: On tire side
Tightening torque [N.m (kgf-m)]
Hub nut
Driveshaft lock nut
Knuckle to strut assembly nut
Lower arm ball joint to knuckle nut
Tie rod end to knuckle
Brake caliper to knuckle
Wheel nut
Rear hub bearing flange bolt
1.3 (0.13 )
100 ~ 240 (10.0 ~ 24.0)

100 ~ 120 (10.0 ~ 12.0)
60 ~ 72 (6.0 ~ 7.2)
16 ~ 34 (1.6 ~ 3.4)
69 ~ 75 (6.9 ~ 7.5)
90 ~ 110 (9.0 ~ 11.0)
100 ~ 120 (10.0 ~ 12.0)
Suspension System
Front
MacPherson strut
Suspension type
Shock absorber type
Wheel size
Oil filled
5J 14", 4B 13"
4.5J 13", 5J 14", 5.5J 15"
Steel
Aluminum
155/70 R13, 165/60 R14

175/60 R14, 175/50 R15
Tire size
Tire pressure
Rear
Torsion beam
kgf/cm
(Psi)
2.1 (30)
SA-13

Wheel alignment
Camber
Caster
Toe-in
King-pin
mm (in.)
GSL
DSL
Tightening Torque [N.m(kgf-m)]

Hub nuts
Front strut assembly to knuckle
Front strut assembly self-locking nut
Front lower arm to sub frame
Front lower arm to knuckle
Front stabilizer link to strut assembly
Front stabilizer bar bracket mounting bolts
Rear shock absorber to torsion beam
Torsion beam to body
Front
030'
243'30'
02 (00.079)
1330'
1430'
Rear
-130'
22 (0.0790.079)
90 ~ 110 (9.0 ~ 11.0)
100 ~ 120 (10.0 ~ 12.0)
40 ~ 55 (4.0 ~ 5.5)
95 ~ 120 (9.5 ~ 12.0)
60 ~ 72 (6.0 ~ 7.2)
35 ~ 45 (3.5 ~ 4.5)
17 ~ 26 (1.7 ~ 2.6)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
Steering System
Type
Power steering fluid
Quality
Quantity
Power steering pump relief pressure
(lmp.qt)
kPa
(kgf/cm
)
Rack and Pinion, EPS (Electric Power Steering) System

PSF-3
0.75 ~ 0.8 (0.66 ~ 0.70)
6570 ~ 7159 (67 ~ 73)
SA-14

Steering wheel lock nut
Steering column mounting bolt & nut
Bolt connecting steering column to universal joint
Bolt connecting universal joint to steering gear
Power steering pump to pump bracket
Pressure hose to power steering pump
Steering gear box to sub frame
40 ~ 50 (4.0 ~ 5.0)
13 ~ 18 (1.3 ~ 1.8)
13 ~ 18 (1.3 ~ 1.8)
30 ~ 35 (3.0 ~ 3.5)
16 ~ 34 (1.6 ~ 3.4)
20 ~ 27 (2.0 ~ 2.7)
55 ~ 65 (5.5 ~ 6.5)
60 ~ 80 (6.0 ~ 8.0)
Restraints
Type
Resistance
Driver Airbag (DAB)
Passenger Airbag (PAB)
Side Airbag (SAB)
Seat Belt Pretensioner (BPT)
Driver Airbag (DAB)
Passenger Airbag (PAB) Nut
Seat Belt Anchor Bolt (BPT)
SRSCM Mounting Bolt
Depowered
1.6 ~ 6.1
1.6 ~ 6.1
1.6 ~ 6.1
1.6 ~ 6.1
7.8 ~ 17.7 (0.8 ~ 1.8)
5.9 ~ 9.8 (0.6 ~ 1.0)
39.2 ~ 53.9 (4.0 ~ 5.5)
7.8 ~ 9.8 (0.8 ~ 1.0)
SA-15

GSL 1.0
Engine
GSL 1.1
DSL U 1.1
Brake System
Brake fluid
Recommended lubricant
Quantity
DOT 3 or DOT 4
As required
Master cylinder
Type
I.D.
Fluid level warning sensor
Proportioning valve (CBS)
mm (in.)
Tandem type
20.64 (0.813)
Provided
Cut-in pressure (Split point)
kg/cm
(MPa)
26 (2.55)
Decompression ratio
Brake booster
Type
Effective diameter
Boosting ratio
Front brake (Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
0.27 : 1
Vacuum
Tandem type with 8 in
7.5 : 1
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Floating type with ventilated disc

241 (9.48)
18 (0.71)
10 (0.39)
Single piston
51.1 (2.01)
SA-16
Rear brake (Disc)

Floating type with solid disc
Type
234 (9.21)
mm (in.)
Disc O.D.
10 (0.39)
mm (in.)
Disc thickness
9 (0.35)
mm (in.)
Pad thickness
Single piston
Cylinder type
33.96 (1.34)
mm (in.)
Cylinder I.D.
Rear brake (Drum)
Leading trailing
Type
180 (7.09)
mm (in.)
Drum I.D.
4.5 (0.18)
mm (in.)
Brake lining thickness
Automatic
mm (in.)
Clearance adjustment
Parking brake
Mechanical brake acting on rear wheels
Type
Lever
Actuation
O.D = Outer Diameter
I.D = Inner Diameter
Anti-lock Brake System(ABS)/ Electronic Stability Program(ESP)
4 channel 4 sensor (MGH-25)
System
HECU
Service standard
189 (7.24 )
mm (in.)
Brake pedal height
122 ~ 127 (4.8 ~ 5.0)
mm (in.)
Brake pedal stroke
3 ~ 8 (0.11 ~ 0.31)
mm (in.)
Brake pedal free play
Stop lamp switch outer case to pedal
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
stopper clearance
Booster push rod to master cylinder
0.6 ~ 1.4 (0.023 ~ 0.055)(at 500 mmHg vacuum)
mm (in.)
piston clearance
SA-17

Engine
Parking brake lever stroke when lever assembly
is pulled with 196N (20kgf, 44lb force)
mm (in.)
Front disc brake pad thickness
mm (in.)
Front disc thickness (minimum)
mm (in.)
Front disc run out
mm (in.)
Front disc parallelism
mm (in.)
Rear drum brake lining thickness
mm (in.)
Rear drum brake drum I.D (maximum)
mm (in.)
Rear disc brake pad thickness
mm (in.)
Rear disc brake disc thickness
mm (in.)
Rear disc run out
mm (in.)
Rear disc parallelism
Master cylinder to booster mounting nut
Brake booster mounting nut
Bleeder screw
Brake tube nut, brake hose
Caliper guide rod bolt
Caliper assembly
Member assembly bracket mounting bolt
Brake hose to front caliper
Brake pedal mounting bolt
Stop lamp switch mounting nut
Brake hub flange nut
GSL 1.0
DSL U 1.1
GSL 1.1
8 ~ 9 clicks : Rear Disc type,
8 clicks : Rear Drum type
2.0 (0.079)
18 (0.708)
0.05 (0.002)
0.005 (0.0002)
1.0 (0.039)
182 (7.165)
2.0 (0.079)
8 (0.315)
0.03 (0.0012)
0.005 (0.0002)
8 ~ 12 (0.8 ~ 1.2)
13 ~ 16 (1.3 ~ 1.6)
7 ~ 9 (0.7 ~ 0.9)
13 ~ 17 (1.3 ~ 1.7)
22 ~ 32 (2.2 ~ 3.2)
69 ~ 85 (6.9 ~ 8.5)
8 ~ 12 (0.8 ~ 1.2)
25 ~ 30 (2.5 ~ 3.0)
25~ 35 (2.5 ~ 3.5)
8 ~ 10 (0.8 ~ 1.0)
200 ~ 260 (20 ~ 26)
SA-18
Wheel cylinder mounting bolt

Rear drum backing plate mounting bolt
proportioning valve to master cylinder
Front
Sensor mounting bolt
(ABS)
Rear
HECU mounting bolt (ABS)
HECU mounting bracket bolt (ABS)
Brake tube nut (ABS)
Bleeder screw (ABS)
5 ~ 11 (0.5 ~ 1.1)
50 ~ 60 (5.0 ~ 6.0)
35 ~ 55 (3.5 ~ 5.5)
8 ~ 9 (0.8 ~ 0.9)
8 ~ 9 (0.8 ~ 0.9)
11 ~ 14 (1.1 ~ 1.4)
17 ~ 26 (1.7 ~ 2.6)
13 ~ 17 (1.3 ~ 1.7)
7 ~ 13 (1.7 ~ 1.3)
Body (Interior & Exterior)

Hood
Front door
Rear door
Tailgate
Glass thickness
Seat belts
Type
Construction
Regulator system
Construction
Regulator system
Type
mm (in.)
Windshield
mm (in.)
Front door
Rear door glass mm (in.)
mm (in.)
Rear window
Driver's seat
Passenger's seat
Rear seat (center)
Rear hinged, front opening type (open stay rod type)

Front hinged, full door construction
Wire drum type
Single arm type
Inner hinged, gas lifter type
5.0 (0.1969)
3.2 (0.1260)
3.2 (0.1260)
3.5 (0.1378)
3 point type
3 point type
Fixed 2 point type
SA-19

Engine
Tightening Torque [N.m(Kgf-m)]
Front fender
Mounting bolts
Hinge (body side)
Hinge (door side)
Checker bolt (body side)
Front and rear doors
Checker bolt (door side)
Latch screw
Striker screw
Outside handle bolt
Hinge nut (body side)
Hinge bolt (tail gate
Latch bolt
Striker bolt
Tailgate
Actuator nut
Lifter stud ball (body
Lifter bracket bolt
Outside handle
Side guide bumper
Hinge bolt (body side)
Hinge nut (body side)
Hood
Hinge bolt (Hood side)
Striker bolt
Latch bolt
Front seat
Mounting bolt
GSL 1.0
GSL 1.1
DSL U 1.1
7~9 (0.7~0.9)
33~41 (3.4~4.2)
10~20 (1.0~2.0)
22~32 (2.2~3.3)
7~11 (0.7~1.1)
8~11 (0.8~1.1)
17~22 (1.7~2.2)
8~12 (0.8~1.2)
21~30 (2.1~3.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
9~14 (0.9~1.4)
7~11 (0.7~1.1)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~9 (0.7~0.9)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
34~54 (3.5~5.5)
SA-20
Rear seat
Seat belt
Seat cushion nut

Seatback bolt
Seatback nut
Seatback striker nut
Anchor bolt
34~54 (3.5~5.5)
34~54 (3.5~5.5)
17~25 (1.7~2.6)
17~25 (1.7~2.6)
39~54 (4.0~5.5)

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
FM
Frequency range /
Channel space
AM
MW
LW
Keyless Entry And Burglar Alarm
Items
Keyless entry transmitter Power source
Transmissible distance
Life of battery
Button
Transmission frequency
AM/FM/Cassette/MP3
AM/FM/Cassette
DC 14.4V
Max 20W x 2
Max 20W x 4
4 x 4
4 x 2
80PF 75
PLL synthesized type
87.5~108.0 MHz/100KHz(General)
87.5~108.0 MHz/50KHz(Europe)
531~1602 KHz/9KHz(General)
531~1602 KHz/9KHz(Europe)
153~279 KHz/9KHz(Europe)
AM/FM
Transmitter(TX)
Lithium 3V battery (1EA)
10m or more
2 years or more (at 20 times per day)
Door lock, door unlock
313.85 MHz (General)
433.92 (Europe)
SA-21

GSL 1.0
Engine
Lighting system
Head lamp
High
Low
Front turn signal lamp

Front position lamp
Rear stop/tail lamp (Outside)
Back up lamp
Rear turn signal lamp
Rear fog lamp - Europe
License plate lamp
Side repeater
Room lamp
Other system
Type
Immobilizer
Manufacturer
W
W
W
W
W
W
W
W
W
W
W
GSL 1.1
DSL U 1.1
60
55
21(Europe), 27(General)
5
21/5 (Europe), 27/8 (General)
21
5
5
10
SMARTRA system
Bosch
Heating Ventilation & Air Conditioning

Air conditioner
Compressor
Condeser
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
HS - 11 (Swash plate)
FD46CG (PAG) , 120 10cc
4PK - TYPE
110 cc/rev
8,500 10% Kcal/hr
SA-22
Tripple switch
Expansion valve
Refrigerant
High
psi
(kg/cm)
Low
psi
(kg/cm)
Medium
psi
(kg/cm)
Type
Type
Capacity
oz.(g)
Blower unit
Fresh and recirculation Operating method
Type
Speed step
Blower
Speed control
Air filter
Type
Heater and evaporator unit
Type
Heating capacity
Heater
Mode operating method
Temperature
operating method
Type
Temperature control type
Evaporator
C (F)
A/C ON/OFF
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)
Block
R - 134a
15.87 0.88(450 25)
Cable
Siroco fan
4 speed
Resistor
Particle filter
Pin & Tube type
4,058 5% Kcal/hr
Cable
Cable
Drawn cup
Thermistor
Off : 1.9 0.4 (35.4 32.9)
ON : 3.0 0.5 (37.4 32.9)
SA-23
Rio (JB)
JB-2
JB-9
JB-10
Fuel System..
JB-11
Clutch.
JB-11
Manual Transaxle.
JB-12
Automatic Transaxle
JB-12
Driveshaft..
JB-14
Suspension System.
Steering System JB-15
RestraintsJB-16
JB-17
Brake System
Body (Interior & Exterior). JB-20
JB-22
Heating, Ventilation & Air Conditioning..JB-24
JB-1
General Specifications - Rio

Engine
GSL 1.4
GSL 1.6
DSL U1.5
In-line, DOHC
4
In-line, DOHC
4
In-line, DOHC
4
mm (in.)
75.5 (2.9724)
x 78.1 (3.0748)
76.5 (3.0118)
x 87 (3.4252)
75 (2.9528)
x 84.5 (3.3268)
cc
1.399
1.599
1.493
17.8 : 1
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
10.0 : 1
1-3-4-2
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
BTDC 5 5
720 100
660 100
720 100
660 100
700 100
700 100
750 100
750 100
3.3 (2.90)
3.0 (2.64)
0.3 (0.26)
Above SJ / SL
5.3 (4.66)
4.8 (4.22)
0.5 (0.44)
Above API CH-4, Above ACEA B4
78.4 (0.8)
107.8 (1.1)
78.4 (0.8)
JB-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
9
31
43
5
-8
60
46
10
6
34
46
4
Cylinder head
mm (in.)
Less than 0.03 (0.0012)
0.03 (0.0012) for width

0.09 (0.0035) for length
Intake
mm (in.)
Less than 0.15 (0.0059)
0.025 (0.0010) for width

0.160 (0.0063) for length
Exhaust
mm (in.)
Less than 0.15 (0.0059)
0.025 (0.0010) for width

0.160 (0.0063) for length

mounting surface
Camshaft
LH
Intake
RH
mm (in.) 43.3484~43.5484 43.7492~43.9492 35.452 ~ 35.652 (1.3957 ~ 1.4036)

(1.70663~1.7145 (1.72241~1.7302
0)
8)
35.537 ~ 35.737 (1.3991 ~ 1.4070)
mm (in.)
Cam height
LH
Exhaust
RH
Journal outer Diameter
(Intake, Exhaust) / (LH,RH)
End play
mm (in.) 43.5486~43.7486 44.1494~44.3494 35.700 ~ 35.900 (1.4055 ~ 1.4134)

(1.71451~1.7223 (1.73816~1.7460
8)
4)
35.452 ~ 35.652 (1.3957 ~ 1.4036)
mm (in.)
mm (in.) 26.964 ~ 26.980 (1.0616 ~ 1.0622)
mm (in.)
mm (in.)
0.02 ~ 0.061 (0.0008 ~ 0.0024)

0.10 ~ 0.20 (0.0039 ~ 0.0079)
20.944 ~ 20.960 (0.8246 ~ 0.8252)

0.040 ~ 0.077 (0.0016 ~ 0.0030)
0.10 ~ 0.20 (0.0039-0.0079)
JB-3

Engine
Valve
Valve length
Stem outer diameter
Face angle
Thickness of valve head
(margin)
Valve stem to valve
guide clearance
Valve guide
Inner diameter
Length
GSL 1.4
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Intake
Exhaust
Intake
Exhaust
GSL 1.6
DSL U1.5
mm (in.)
mm (in.)
mm (in.)
mm (in.)
91.8 (3.6142)
92.4 (3.6378)
5.955 ~ 5.970 (0.2344 ~ 0.2350)
5.935 ~ 5.950 (0.2337 ~ 0.2343)
45 ~ 45 30'
1.1 (0.0433)
1.3 (0.0512)
0.03 ~ 0.06 (0.0012 ~ 0.0024)
0.05 ~ 0.08 (0.0020 ~ 0.0031)
93.0 (3.6614)
93.7 (3.6890)
5.455 ~ 5.470 (0.2148 ~ 0.2154)
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)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
36.3 ~ 36.7 (1.4291 ~ 1.4449)

40.8 ~ 41.2 (1.6063 ~ 1.6220)
5.500 ~ 5.512 (0.2165 ~ 0.2170)

5.500 ~ 5.512 (0.2165 ~ 0.2170)
31.3 ~ 31.7 (1.2323 ~ 1.2480)
31.3 ~ 31.7 (1.2323 ~ 1.2480)
Intake
Exhaust
mm (in.)
mm (in.)
0.8 ~ 1.2 (0.0315 ~ 0.0472)

1.3 ~ 1.7 (0.0512 ~ 0.0669)
45 ~ 45 30'
0.8 ~ 1.4 (0.0315 ~ 0.0551)

1.2 ~ 1.8 (0.0472 ~ 0.0709)
45 ~ 4530'
Installed
Valve opened
mm (in.)
mm (in.)
mm (in.)
44.0 (1.7323)
21.61.1kg/35(1.3780)
45.12.2kg/27.2(1.0709)
Less than 1.5
44.9 (1.7677)
17.50.9kg/32.0(1.2598)
31.01.6kg/23.5(0.9252)
Less than 1.5
Valve seat
Seat angle
Valve spring
Free length
Load (Intake, Exhaust)
Out of squareness
JB-4
Cylinder block
Cylinder bore
Piston
No. 1
ring groove
Ring groove width
No. 2
ring groove
Oil ring groove
Piston ring
No. 1
ring groove
Side clearance
No. 2
ring groove
Oil ring groove
75.50 ~ 75.53
76.50 ~ 76.53
75.000 ~ 75.030 (2.9528 ~ 2.9539)
(2.9724 ~ 2.9736) (3.0118 ~ 3.0130)
Less than 0.05 (0.0020) (Overhaul)
Less than 0.05 (0.0020)
Less than 0.03 (0.0012) (Per I
mm (in.)
cylder)
mm (in.)
75.47 ~ 75.50
76.47 ~ 76.50
74.930 ~ 74.960 (2.9500 ~ 2.9512)
(2.9713 ~ 2.9724) (3.0106 ~ 3.0118)
0.060 ~ 0.080 (0.0024 ~ 0.0031)
mm (in.) 0.020 ~ 0.040 (0.0008 ~ 0.0016)
mm (in.)
mm (in.)
1.230 ~ 1.255 (0.0484 ~ 0.0494)
1.83 ~ 1.85 (0.0720 ~ 0.0728)
mm (in.)
1.230 ~ 1.255 (0.0484 ~ 0.0494)
1.82 ~ 1.84 (0.0717 ~ 0.0724)
mm (in.)
2.030 ~ 2.055 (0.0799 ~ 0.0809)
3.02 ~ 3.04 (0.1189 ~ 0.1197)
mm (in.)
0.04 ~ 0.085 (0.0016 ~ 0.0033)
0.09 ~ 0.13 (0.0035 ~ 0.0051)
mm (in.)
0.04 ~ 0.085 (0.0016 ~ 0.0033)
0.08 ~ 0.12 (0.0031 ~ 0.0047)
mm (in.)
0.08 ~ 0.175 (0.0031 ~ 0.0069)
0.03 ~ 0.07 (0.0012 ~ 0.0028)
JB-5

Engine
End gap
GSL 1.4
No. 1
ring groove
No. 2
ring groove
Oil ring groove
Piston pin
Connecting rod small end inner diameter
Connecting rod small end hole clearance
Connecting rod
End play
Crankshaft
NO 1, 2, 4, 5
Main bearing oil
clearance
NO 3
End play
GSL 1.6
DSL U1.5
mm (in.)
0.20 ~ 0.35
0.15 ~ 0.30
(0.0079 ~ 0.0138) (0.0059 ~ 0.0118)
0.20 ~ 0.35 (0.0079 ~ 0.0138)
mm (in.)
0.37 ~ 0.52
0.35 ~ 0.50
(0.0146 ~ 0.0205) (0.0138 ~ 0.0197)
0.35 ~ 0.50 (0.0138 ~ 0.0197)
mm (in.)
0.20 ~ 0.70
0.20 ~ 0.70
(0.0079 ~ 0.0276) (0.0079 ~ 0.0276)
0.20 ~ 0.40 (0.0079 ~ 0.0157)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
18.001 ~ 18.007 (0.7087 ~ 0.7089)

18.016 ~ 18.021 (0.7093 ~ 0.7095)
0.011 ~ 0.018 (0.0004 ~ 0.0007)
17.974 ~ 17.985 (0.7076 ~ 0.7081)
-0.033 ~ -0.016 (-0.0013 ~ -0.0006)
27.995 ~ 28.000 (1.1022 ~ 1.1024)

28.004 ~ 28.010 (1.1025 ~ 1.1028)
0.004 ~ 0.015 (0.0002 ~ 0.0006)
28.022 ~ 28.034 (1.1032 ~ 1.1037)
0.022 ~ 0.039 (0.0009 ~ 0.0015)
mm (in.) 48.000 ~ 48.018 (1.8898 ~ 1.8905)

mm (in.) 0.018 ~ 0.036 (0.0007 ~ 0.0014)
0.10 ~ 0.25 (0.0039 ~ 0.0098)
mm (in.)
49.000 ~ 49.018 (1.9291 ~ 1.9298)

0.025 ~ 0.043 (0.0010 ~ 0.0017)
0.050 ~ 0.302 (0.0020 ~ 0.0119)
mm (in.) 49.950 ~ 49.968 (1.9665 ~ 1.9672)

mm (in.) 44.954 ~ 44.972 (1.7698 ~ 1.7705)
mm (in.) 0.022 ~ 0.040 (0.0009 ~ 0.0016)
mm (in.) 0.028 ~ 0.046 (0.0011 ~ 0.0018)
0.05 ~ 0.175 (0.0020 ~ 0.0069)
mm (in.)
53.972 ~ 53.990 (2.1249 ~ 2.1256)

45.997 ~ 46.015 (1.8109 ~ 1.8116)
0.024 ~ 0.042 (0.0009 ~ 0.0017)
0.08 ~ 0.28 (0.0031 ~ 0.110)
JB-6
Flywheel
Runout
Oil pump
mm (in.)
0.10 (0.0039)
0.10 (0.0039)
kPa
(kg/cm)
50049.0 (5.10.5)
49049.0 (50.5)
Forced circulation with electrical fan
5.5 ~ 5.8 (4.84 ~5.10)
5.3 ~ 5.5 (4.66 ~ 4.84)
821.5 (179.62.7)
851.5 (185.02.7)
[Lift : 0.35mm, (0.0138in)]
95 (203)
100 (212)
[Lift : 8mm, (0.3150 in)]
Cooling system
Cooling method
Coolant quantity
(lmp.qt)
Opening
C (F)
temperature
Thermostat
Full opening
C (F)
temperature
Main valve
kPa
Radiator cap
Vacuum valve
kPa
Type
k
20C (68F)
Resistance
k
80C (176F)
93.16 ~ 122.58 (0.95 ~ 1.25)

0.98 ~ 4.90 (0.01 ~ 0.05)
Thermister type
2.450.14
0,3222
JB-7

Engine
Main moving system
Bolts
Crankshaft
Long bolts
main bearing cap
Short bolts
Cylinder head
Cylinder head bolt
Lubrication system
Oil filter
Oil filter cap
Oil pan bolts or nuts
Oil pan drain plug
Oil pan and transaxle fixing bolt
GSL 1.4
GSL 1.6
DSL U1.5
31.4 ~ 34.3 (3.2 ~ 3.5)

53.9 ~ 58.8 (5.5 ~ 6.0)
-
12.7 (1.3) + 90
24.5 (2.5) + 90
32.4 ~ 36.3 (3.3 ~ 3.7)
11.8 ~ 13.7 (1.2 ~ 1.4)
12.7 ~ 13.7 (1.3 ~ 1.4)
34.3 (3.5) +90 29.4 (3.0) +90

Release all bolts Release all bolts
34.3 (3.5) + 90 29.4 (3.0) +90
49.0 (5.0)+90+120
11.8 ~ 15.7 (1.2 ~ 1.6)

9.8 ~ 11.8 (1.0 ~ 1.2)
39.2 ~ 44.1 (4.0 ~ 4.5)
-
24.5 (2.5)
9.8 ~ 11.8 (1.0 ~ 1.2)
34.3 ~ 44.1 (3.5 ~ 4.5)
29.4 ~ 41.2 (3.0 ~ 4.2)
JB-8

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
resistance
12 V, 0.9 kW
11,5
MAX 35
4,350 rpm, MIN
13.5 V, 90A
1,000 ~ 18,000 rpm
14.55 0.2 V
MF 45AH
MF 55AH
12 V, 1.7 kW
11
MAX 90
2,600 rpm, MIN
12 V, 120A
1,000 ~ 18,000 rpm
14.55 0.2 V
MF 68AH
410 A
500 A
600 A
80 min
85 min
110 min
1.280 0.01
1.280 0.01
1.280 0.01
0.87 10 %
0.7 15 %
13.0 15 %
JB-9

Engine
Spark plugs
Unleaded (NGK)
Unleaded (CHAMPION)
Unleaded (Gap) mm(in.)
Leaded (NGK)
Leaded (CHAMPION)
Leaded (Gap) mm(in.)
GSL 1.4
GSL 1.6
BKR5ES-11
RC10YC4
1.0 ~ 1.1 (0.0394 ~ 0.0433)
BKR5ES
RC10YC
0.9 ~ 1.0 (0.0354 ~ 0.0394)
DSL U1.5
-
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Bosch
45 (39.60)
Returnless type
Return type
High pressure type
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Type
Driven by
MPa
(kgf/cm
)
kPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
High Pressure
Fuel Pump
Electrical
In-tank type
Electric motor
Mechanical
Drive Belt
160 (1,632)
343 (3.5)
JB-10
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic type
15~22 (1.5~2.2)
25~35 (2.5~3.5)
9~14 (0.9~1.4)
15~22 (1.5~2.2)
mm (in.)
mm (in.)
12~15 (1.2~1.5)
25~35 (2.5~3.5)
19~20 (1.9~2.0)
15~22 (1.5~2.2)
145 (5.70)
6~13 (0.24~0.51)
Manual Transaxle
Type
Gear ratio
1st
2nd
3rd
4th
5th
Rev.
FGR
M5CF1
3,615
2,053
1,370
1,031
0,837
3,583
4,056
M5CF2
3,615
1,962
1,257
0,905
0,702
3,583
3,471
JB-11

Engine
M/T oil quality
MT oil capacity
GSL 1.4
GSL 1.6
DSL U1.5

(lmp.qt)
1.90 (1.67)
2.0 (1.76)
1st
A4AF3
2,846
2nd
1,581
3rd
4th
Rev.
FGR
1,000
0,685
2,176
4.381/4.041
Diamond ATF SP III or SK ATF

SP III
6.1 (5.37)
UTJ-II22
BJ22
TJ22
BJ22
23
45
UTJ-II24
BJ24
TJ24
BJ24
23
46
Automatic Transaxle
Type
Gear ratio
ATF quality
(lmp.qt)
ATF capacity
Driveshaft
LH
Joint type
RH
Hub end play
Inner
Outer
Inner
Outer
Inner
Outer
mm(in.)
0.008 (0.0003) or less
JB-12

Wheel bearing
[NOTE]
BJ: Birfield Joint
TJ: Tripod Joint
UTJ-ll: U Type-ll Tri-pod Joint
Driveshaft lock nut
Knuckle to strut assembly bolt
Lower arm ball joint to knuckle bolt
Tie rod end to knuckle bolt
Brake caliper to knuckle bolt
Inner shaft bracket to engine block bolts
Wheel nut
Rear hub bearing flange nut
Rear brake to rear torsion beam axle mounting
Rear strut to torsion beam axle nut
Rear torsion beam axle to rear hub bearing
mounting nut
1.8 (0.18 )
200 ~ 260 (20 ~ 26)

100 ~ 120 (10 ~ 12)
100 ~ 120 (10 ~ 12)
16 ~ 34 (1.6 ~ 3.4)
24 ~ 34 (2.4 ~ 3.4)
69 ~ 75 (6.9 ~ 7.5)
40 ~ 50 (4 ~ 5)
90 ~ 110 (9 ~ 11)
200 ~ 260 (20 ~ 26)
65 ~ 75 (6.5 ~ 7.5)
110 ~ 120 (11 ~ 12)
50 ~ 60 (5 ~ 6)
JB-13

Suspension System
Front
MacPherson strut
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
Tire size
Gasoline
Tire pressure
Diesel
Camber
Power steering
Caster
Manual steering
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Front strut assembly to wheel housing panel
Front stabilizer bar bracket mounting
Rear shock absorber to wheel housing panel
Rear
Torsion beam
Gas pressurized
5J 14", 5.5J 14"
5.5J 14", 5.5J 15", 6.5J 16"
175/70 R14, 185/65 R14
195/55 R15, 205/45 R16
2.1kgf/cm2, (30psi)
2
2.2kgf/cm , (32psi)
030'
400'30'
035'30'
02 (00.079)
1330'
-130'
42 (0.1570.079)
-
90 ~ 110 (9.0 ~ 11.0)

20 ~ 30 (2.0 ~ 3.0)
100 ~ 120 (10.0 ~ 12.0)
50 ~ 70 (5.0 ~ 7.0)
FR: 120 ~ 140 (12.0 ~ 14.0), RR: 100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
35 ~ 45 (3.5 ~ 4.5)
45 ~ 55 (4.5 ~ 5.5)
40 ~ 60 (4.0 ~ 6.0)
JB-14
Rear shock absorber to torsion beam

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

22 ~ 32 (2.2 ~ 3.2)
100 ~ 120 (10.0 ~ 12.0)
Steering System
Type
Quality
Quantity
(lmp.qt)
Manual
Rack stroke
Power (175 tire) mm (in.)
Power (others)
kPa
Gasoline
Power steering pump
(kgf/cm
relief pressure
Diesel
)
Rack and Pinion

PSF-3
0.8 (0.70)
144 (5.67)
142 (5.59)
135 (5.43)
6669 ~ 7355 (68 ~ 75)
7551 ~ 8041 (77 ~ 82)
35 ~ 45 (3.5 ~ 4.5)
13 ~ 18 (1.3 ~ 1.8)
13 ~ 18 (1.3 ~ 1.8)
13 ~ 18 (1.3 ~ 1.8)
16 ~ 34 (1.6 ~ 3.4)
20 ~ 27 (2.0 ~ 2.7)
55 ~ 65 (5.5 ~ 6.5)
90 ~ 110 (9.0 ~ 11.0)
JB-15

Engine
GSL 1.4
GSL 1.6
DSL U1.5
Restraints
Type
Resistance
Driver Airbag (DAB)
Depowered
Gasoline
Diesel

Side Airbag (SAB)
Curtain Airbag (CAB)
Driver
Passenger
Driver
Passenger
Driver
Passenger
Seat Belt Pretensioner

(BPT)
Driver Airbag (DAB)
Bolt
Passenger Airbag
(PAB)
Nut
Side Airbag (SAB)
SRSCM Mounting Bolt
Front Impact Sensor (FIS) Mounting Bolt
Side Impact Sensor (SIS) Mounting Bolt
1.925 ~ 3.074
20.25 ~ 2.974
1.878 ~ 2.442
1.804 ~ 2.568
1.812 ~ 2.576
1.940 ~ 2.704
1.948 ~ 2.712
1.943 ~ 2.806
1.950 ~ 2.814
7.9 ~ 10.8 (0.8 ~ 1.1)
8.8 ~ 13.7 (0.9 ~ 1.4)
3.9 ~ 6.9 (0.4 ~ 0.7)
4.9 ~ 6.9 (0.5 ~ 0.7)
4.9 ~ 6.9 (0.5 ~ 0.7)
39.2 ~ 53.9 (4.0 ~ 5.5)
9.5 ~ 13.5 (1.0 ~ 1.4)
9.5 ~ 13.6 (1.0 ~ 1.4)
9.5 ~ 13.6 (1.0 ~ 1.4)
JB-16
Brake System
Brake fluid
Cut-in pressure (Split point)

Decompression ratio
Brake booster
Type
Effective diameter
Boosting ratio
Front brake (Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
As required
Quantity
Master cylinder
Type
I.D.
Piston stroke
DOT 3 or DOT 4
mm (in.)
mm (in.)
Tandem type
22.22 (0.875)
29 ~ 31(1.14 ~ 1.22)
Provided
MPa
(kgf/cm
)
2.94 (30)
mm (in.)
Vacuum
254 (10)
7:01
mm (in.)
mm (in.)
mm (in.)
mm (in.)
0.27 : 1

256 (10)
22 (0.87)
11 (0.43)
Single piston
54 (2.12)
JB-17

DSL U1.5
GSL 1.4
GSL 1.6
Engine
Rear brake (Disc)
Type
262 (10.3)
mm (in.)
Disc O.D.
10 (0.39)
mm (in.)
Disc thickness
10 (0.39)
mm (in.)
Pad thickness
Single piston
Cylinder type
31 (1.22)
mm (in.)
Cylinder I.D.
Rear brake (Drum)
Leading trailing
Type
203.2 (8)
mm (in.)
Drum I.D.
4.3 (0.17)
mm (in.)
Automatic
mm (in.)
Type
Lever
Actuation
168 (6.61)
mm (in.)
Drum I.D.
O.D=Outer Diameter
I.D=Inner Diameter
Anti-lock Brake System (ABS) / Electronic Stability Program (ESP)
Manufacturer and Name
4 channel 4 sensor (Solenoid)
HECU
System
0.4 ~ 1.5 (0.016 ~ 0.059)
mm(in.)
Air gap
Acitve wheel speed
48
sensor
teeth
Tone wheel
JB-18
Service standard
Brake pedal height
LHD
RHD
Brake pedal stroke

piston clearance
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
164.8 (6.49 )
168.2 (6.62)
125 (4.92)
3 ~ 8 (0.11 ~ 0.31)
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
0 (at 500 mmHg vacuum)

6 ~ 8 clicks
mm (in.)
11 (0.43)
Front disc thickness

Rear drum brake drum I.D
Bleeder screw
Caliper mounting bolt
Brake pedal member assembly bracket
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
22 (0.87)
4.3 (0.17)
203.2 (8)
10 (0.4)
10 (0.4)
7.9 ~ 111.8 (0.8 ~ 1.2)
12.74 ~ 15.68 (1.3 ~ 1.6)
5.88 ~ 9.8 (0.6 ~ 1.0)
12.74 ~ 16.64 (1.3 ~ 1.7)
21.56 ~ 32.36 (2.2 ~ 3.2)
83.36 ~ 93.16 (8.5 ~ 9.5)
7.9 ~ 11.8 (0.8 ~ 1.2)
JB-19

Engine
Brake pedal mounting nut
Rear drum backe bleeder screw
Wheel speed sensor mounting bolt
HECU mounting bracket bolt
HECU union screw
Yaw rate lateral G sensor mounting bolt
Master cylinder pressure sensor
GSL 1.4
DSL U1.5
GSL 1.6
24.51~ 34.32 (2.5 ~ 3.5)
7.9 ~ 9.8 (0.8 ~ 1.0)
5.88 ~ 8.82 (0.6 ~ 0.9)
8.04 ~ 9.51 (0.82 ~ 0.97)
7.9 ~ 9.8 (0.8 ~ 1.0)
11.76 ~ 15.68 (1.2 ~ 1.6)
9.8 ~ 12.74 (1 ~ 1.3)
34.3 ~ 44.1 (3.5 ~ 4.5)
7.9 ~ 10.79 (0.8 ~ 1.1)
22.56 ~ 26.48 (2.3 ~ 2.7)

Hood
Front door
Rear door
Trunk lid
Glass thickness
Type
Construction
Regulator system
Locking system
Construction
Regulator system
Locking system
Type
mm (in.)
Windshield
mm (in.)
Front door
mm (in.)
Rear window
Rear hinged, gas lifter type

Wire drum type
Pin-fork system
Wire drum type
Pin-fork system
Torsion bar type
5.0 (0.1969)
3.2 (0.1260)
3.2 (0.1260)
3.2 (0.1260)
JB-20
Front
Rear
Door hinge to body
Door hinge to door
Trunk lid lift to trunk lid
Trunk lid
Trunk lid latch to trunk
Hood hinge to body
Hood hinge to hood
Hood
Hood latch to body
Front seat mounting
Seat
Front seat mounting nut
Rear seat mounting
Seat belt height adjuster
Seat belt buckle
Front seat belt
Seat belt anchor
Seat belt lower anchor
Seat belt upper anchor
Seat belt anchor
Rear seat belt
Seat belt retractor
Seat belts
3 point type with Emergency Locking Retractor (E.L.R)

3 point type with Emergency Locking Retractor (E.L.R), 2point type
12.7~25.5 (1.3~2.6)
12.7~25.5 (1.3~2.6)
6.9~10.8 (0.7~1.1)
6.9~10.8 (0.7~1.1)
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.2~2.7)
9.8~14.7 (1.0~1.5)
34.3~53.9 (3.5~5.5)
23.5~35.3 (2.4~3.6)
43.1~64.7 (4.4~6.6)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
JB-21

Engine
GSL 1.4
GSL 1.6
DSL U1.5

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
FM
AM
Frequency range /
Channel space
MW
LW
Items
Life of battery
Button
AM/FM/Cassette
(M420)
AM/FM/CD
AM/FM/Cassette/ AM/FM/Cassette/
(M445)
MP3 (M455)
6CDC (M465)
DC 14.4V
Max 43W x 4
Max 55W x 4
4 x 4
10k x 4
80PF 75
87.5~108 MHz/ 100KHz (General), 50KHz(Europe)
531~1602 KHz/ 9KHz (General)
522~1620 KHz/ 9KHz (Europe)
Transmitter(TX)
10m or more
Door lock/unlock
433.92 MHz (Europe, Austrailia, Middle east)
315.00 MHZ (General)
JB-22
Lighting system
High
Low

Front position lamp
Front fog lamp
Rear tail/stop lamp
Back up lamp
License plate lamp
Side repeater
Room lamp
Overhead console lamp
W
W
W
W
W
W
W
W
W
W
W
W
W
60
55
21
5
27
12/5
16
21
21
5
5
10
10 x 2
High mounted stop lamp
16
Luggage lamp
Other system
Head lamp
Type
Manufacturer
Rear parking assist system
Immobilizer
SMARTRA system
Bosch
2 channel
JB-23

GSL 1.4
Engine
GSL 1.6
DSL U1.5

Air conditioner
Condeser
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
kcal/hr
APT(A/C pressure
transducer)
The method to
measure the pressure
Expansion valve
Type
Type
Capacity
Compressor
Refrigerant
oz.(g)
Blower unit
Type
Speed step
Blower
Speed control
Air filter
Type
6SBU16
ND-OIL8(PAG), 120 100cc
L5OS - TYPE
160cc/rev
9,500 5%
12,000 5%
voltage = 0.025 * pressure + 0.1
Voltage = 0.001758 * Pressure + 0.074162 [PSIA]
Block
R - 134a
17.6 0.88(500 25)
Actuator
Siroco fan
Auto + 8speed (Automatic) , 4speed (Manual)
Power mosfet (Automatic) , Blower resistor (Manual)
Particle filter
JB-24

Type
Heating capacity
Heater
PTC heater capacity
Temperature operating
Evaporator
A/C ON/OFF
()
Pin & Tube type

4,450 10% Kcal/hr
1,000W + 5% / -10%
Acuator
Acuator(Automatic) , (cable(Manyal)
Evaporator temperature sensor
OFF : 5.0 0.5 (41 32.9)
ON : 3.0 0.5 (37.4 32.9)
JB-25
Cerato
(LD)
LD-2
LD-9
LD-10
Fuel System..
LD-11
Clutch.
LD-11
Manual Transaxle.
LD-12
Automatic Transaxle
LD-12
Driveshaft..
LD-14
Suspension System.
Steering System LD-15
RestraintsLD-16
LD-17
Brake System
Body (Interior & Exterior). LD-21
LD-23
Heating, Ventilation & Air Conditioning..LD-25
LD-1
General Specifications - Cerato

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
kPa
(kg/cm)
Oil pressure
In-line, DOHC
In-line, DOHC
4
4
77 (3.0315)
82 (3.2283)
x 85.44 (3.3638)
x 93.5 (3.6811)
1.591
1.975
17.3 : 1
10.1 : 1
1-3-4-2
1-3-4-2
BTDC 5 10
660 100
660 100
660 100
660 100
3.7 (3.26)
3.0 (2.64)
3.3 (2.90)
Above SL / GF - 3
4.1
3.7
0.3
4.0
(3.60 )
(3.26 )
(0.26)
(3.52)
-
In-line, DOHC
4
77.2 (3.0315)
x 84.5 (3.3638)
1.582
17.3 : 1
1-3-4-2
830 100
830 100
830 100
830 100
5.3 (4.66 )
4.8 (4.22 )
0.5 (0.44)
3.3 (2.91)
Above API CH-4
245 (2.5) /1500 rpm
78.4 (0.8) / IDLE
10 (BTDC 40)
63 (ABDC 13)
11
59
175' 4
146' 4
Valve timing
Intake valve
Opens (ATDC)
Closes (ABDC)
LD-2
Exhaust valve
Opens (BBDC)
Closes (ATDC)
40
3
42
6
2325' 4
20 4
Cylinder head
mounting surface
Intake
mm (in.) Less than 0.05 (0.0020) Less than 0.03 (0.0012)

mm (in.)
Max. 0.15 (0.0059)
Exhaust
mm (in.)
0.03 (0.0012) for width

0.09 (0.0035) for length
0.025 (0.0010) for width
0.160 (0.0063) for
length for width
0.025 (0.0010)
0.160 (0.0063) for
length
Camshaft
LH : 35.452 ~ 35.652
(1.3957 ~ 1.4036)
RH : 35.537 ~ 35.737
(1.3991 ~ 1.4070)
LH : 35.700 ~ 35.900
(1.4055 ~ 1.4134)
RH : 35.452 ~ 35.652
(1.3957 ~ 1.4036)
20.944 ~ 20.960
(0.8246 ~ 0.8252)
Intake
mm (in.)
43.85 (1.7264)
44.618 (1.7566)
Exhaust
mm (in.)
42.85 (1.6870)
44.518 (1.7527)
Journal outer Diameter (Intake, Exhaust) mm (in.)
22.964 ~ 22.980
(0.9041 ~ 0.9047)
28 (1.1023)
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)
End play
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.)
mm (in.)
93.15 (3.6673)
92.8 (3.6457)
114.34 (4.5016)
116.8 (4.598)
93.0 (3.6614)
93.7 (3.6890)
Cam height
Valve
Valve length
Intake
Exhaust
LD-3

Engine
DSL U 1.6
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)
Exhaust
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
0.030 ~ 0.057
(0.0012 ~ 0.0022)
Face angle
mm (in.)
1.1 (0.0433)
mm (in.)
1.26 (0.0496)
Intake
mm (in.)
0.020 ~ 0.047
(0.0008 ~ 0.0019)
1.60.15(0.06300.005
9)
1.80.15(0.07090.005
9)
0.02 ~ 0.05
(0.0008 ~ 0.0019)
Exhaust
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)
Intake
mm (in.)
5.500 ~ 5.512
(0.2165 ~ 0.2170)
Exhaust
mm (in.)
5.500 ~ 5.512
(0.2165 ~ 0.2170)
Intake
mm (in.)
40.3 ~ 40.7
(1.5866 ~ 1.6024)
31.3 ~ 31.7
(1.2323 ~ 1.2480)
Exhaust
mm (in.)
40.3 ~ 40.7
(1.5866 ~ 1.6024)
31.3 ~ 31.7
(1.2323 ~ 1.2480)
Intake
mm (in.)
1.1 ~ 1.5 (0.043 ~

0.059)
0.8 ~
1.4(0.0315~0.0551)

(margine)
Exhaust
Valve guide
Inner diameter
GSL 2.0
Intake
Stem outer diameter
Valve stem to valve

guide clearance
GSL 1.6
Length
1.1 (0.0433)
1.2 (0.0472)
Valve seat
LD-4

Seat angle
Exhaust
mm (in.)
1.3 ~ 1.7 (0.051 ~

0.066)
-
1.2 ~
1.8(0.0472~0.0709)
45 ~ 4530'
LD-5
Valve spring
Free length
mm (in.)
44.0mm (1.7323)
Load
mm (in.)
Out of squareness
Valve clearance
Less than 1.5

20C (68F)
80C (176F)
20C (68F)
80C (176F)
48.86mm (1.9236)
44.9mm (1.7677)
18.8k0.9kg/39.0(1.535 17.50.9kg/32.0(1.2598
4)
)
41.01.5kg/30.5(1.2008 31.01.6kg/23.5(0.9252
)
)
1.5 or less
Less than 1.5
mm (in.)
mm (in.)
mm (in.)
mm (in.)
0.20 (0.0079)
0.29 (0.0114)
0.28 (0.0110)
0.34 (0.0134)
Cylinder bore
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)

Piston
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)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
1.83 ~ 1.85
(0.0720 ~ 0.0728)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
1.82 ~ 1.84
(0.0717 ~ 0.0724)
Oil ring groove
2.01 ~ 2.03
(0.0791 ~ 0.0799)
3.02 ~ 3.04
(0.1189 ~ 0.1197)
Intake
Exhaust
Cylinder block
Ring groove width
Piston OS
mm (in.)
0.25, 0.50 (0.010,

0 020)
LD-6

Engine
Piston ring
Side clearance
End gap
GSL 1.6
GSL 2.0
DSL U 1.6
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.04 ~ 0.08
(0.0015 ~ 0.0031)
0.09 ~ 0.13
(0.0035 ~ 0.0051)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.03 ~ 0.07
(0.0012 ~ 0.0027)
0.08 ~ 0.12
(0.0031 ~ 0.0047)
Oil ring groove
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)
0.14 ~ 0.28
(0.0055 ~ 0.0110)
0.20 ~ 0.35
(0.0079 ~ 0.0138)
0.20 ~ 0.35
(0.0079 ~ 0.0138)
0.30 ~ 0.45
(0.0118 ~ 0.0177)
0.20 ~ 0.70
(0.0079 ~ 0.0276)
0.37 ~ 0.52
(0.0146 ~ 0.0205)
0.20 ~ 0.60
(0.0078 ~ 0.0236)
0.35 ~ 0.50
(0.0138 ~ 0.0197)
0.20 ~ 0.40
(0.0079 ~ 0.0157)

Oil ring groove
mm (in.)
Piston pin
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)
Connecting rod small end inner diameter 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)
Connecting rod small end hole clearance mm (in.)
0.010 ~ 0.020
(0.0004 ~ 0.0008)
0.022 ~ 0.039
(0.0009 ~ 0.0015)
LD-7
Connecting rod
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)
End play
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)
End play
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)
Flywheel
Runout
Oil pump
mm (in.)
0.1 (0.0039)
0.1 (0.0039)
kPa
(kg/cm)
49049.0 (50.5)
Crankshaft
Cooling system
Cooling method
Forced circulation with

cooling fan
Coolant quantity
5.8 ~ 5.9 (5.10 ~ 5.19)

(lmp.qt)
Forced circulation with Forced circulation with

electrical fan
cooling fan
6.5~6.6 (5.72 ~ 5.81)
6.97 (6.13)
LD-8

Engine
C (F)
Opening
C (F)
Pull opening
Main valve
kPa
Radiator cap
Vacuum valve
kPa
(kg/cm)
opening press.
Type
Thermostat
Resistance
20C (68F)
80C (176F)
k
k
GSL 1.6
82 1.5 (179.6 2.7)
95 (203)
GSL 2.0
82 (177)
95 (203)
DSL U 1.6
85 1.5 (185.0 2.7)
100 (212)
93.16 ~ 122.58
(0.95 ~ 1.25)
93.16 ~ 122.58
(0.95 ~ 1.25)
93.16 ~ 122.58
(0.95 ~ 1.25)
MAX. 6.86 (0.07)
MAX. 6.86 (0.07)
0.98 ~ 4.90 (0.01 ~

0.05)
Thermister type
2.45 0.14
0,3222
Thermister type
2.45 0.14
0,3222
Thermister type
2.45 0.14
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)

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

Main moving system
Crankshaft
main bearing cap
Cylinder head
Camshaft bearing
cap nuts or bolts
Bolts
Long bolts
Short bolts
M6
M8
LD-9
Long bolts
17.7 ~ 21.6 (1.8 ~ 2.2)

+ 90 ~ 95 + 100
~105
Short bolts
Cylinder head bolt

Lubrication system
Oil filter
Oil pan bolts
Oil pan drain plug
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)

Rated voltage
Starter No-load
charasteristics
Generator
Battery
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
12.V, 0.9 kW
12.V, 0.9 kW
12 V, 1.7 kW
11,5
11
11
60 MAX
90 MAX
90 MAX
5.500 rpm, MIN
3,000 rpm, MIN
2,600 rpm, MIN
Battery voltage sensing Battery voltage sensing Battery voltage sensing
13.5 V, 90A
13.5 V, 90A
12 V, 120A
1,000 ~ 18,000 rpm
1,000 ~ 18,000 rpm
1,000 ~ 18,000 rpm
IC Regulator built-in
IC Regulator built-in
type
type
14.55 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
1.280 0.01
LD-10

Engine
Ignition coil
Spark plugs
Primary
Secondary
k
Unleaded (NGK)
Unleaded (Gap) mm (in.)
GSL 1.6
GSL 2.0
0.7 15 %
0.58 10 %
8.8 15 %
ZFR5F-11
BKR5ES-11
1.0 ~ 1.1 (0.0394 ~ 0.0433)
DSL U 1.6
-
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Type
Driven by
MPa
(kgf/cm
)
KPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
Bosch
Siemens
55 (48.39)
Returnless type
High pressure type
Bosch
Return type
High Pressure
Fuel Pump
Electrical
In-tank type
Electric motor
Mechanical
Drive Belt
160 (1,632)
338 ~ 348 (3.45 ~ 3.55)
LD-11
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic type
15~22 (1.5~2.2)
25~35 (2.5~3.5)
9~14 (0.9~1.4)
15~22 (1.5~2.2)
mm (in.)
mm (in.)
15~22 (1.5~2.2)
25~35 (2.5~3.5)
19~20 (1.9~2.0)
15~22 (1.5~2.2)
12~15 (1.2~1.5)
25~35 (2.5~3.5)
19~20 (1.9~2.0)
15~22 (1.5~2.2)
145 (5.70)
6~13 (0.24~0.51)
Manual Transaxle
Type
Gear ratio
M/T oil quality

MT oil capacity
1st
2nd
3rd
4th
5th
Rev.
M5CF1
3,615
2,053
1,370
1,031
0,837
3,583
FGR
4,056
(lmp.qt)
1.90 (1.67)
M5BF2
3,615
2,053
1,393
1,061
0,837
3,250
3.650 (EUR)
3.842 (GEN)
2.15 (1.95)
M5CF3
3,636
1,962
1,189
0,844
0,660
3,583
3,941
2.0 (1.76)
LD-12

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
Automatic Transaxle
Type
Gear ratio
A4CF1
2,846
1,581
1,000
0,685
2,176
4.381/4.041
1st
2nd
3rd
4th
Rev.
FGR
ATF quality
ATF capacity
(lmp.qt)
A4CF2
A4CF2
2,919
2,919
1,551
1,551
1,000
1,000
0,713
0,713
2,480
2,480
3,849
3,532
Diamond ATF SP III or SK ATF SP III
6.1 (5.37)
6.6 (5.81)
6.6 (5.81)
Driveshaft
M/T
Joint type
A/T
Hub end play
Wheel bearing
Inner
Outer
Inner
Outer
Inner
Outer
mm (in.)
UTJ-II
BJ
UTJ-II
BJ
UTJ-II
BJ
UTJ-II
BJ
23 or more
46 or more
0.008 (0.0003) or less
UTJ-II
BJ
UTJ-II
BJ
1.8 (0.18 )
LD-13
[NOTE]
BJ: Birfield Joint
TJ: Tripod Joint
Driveshaft lock nut
Wheel nut
Rear brake to rear axle carrier mounting bolt
Rear strut to carrier nut
Trailing arm to rear axle carrier mounting nut
Rear suspension arm to rear axle carrier
mounting nut
Brake disc to hub
200 ~ 250 (20 ~ 25)

130 ~ 150 (13 ~ 15)
60 ~ 72 (6 ~ 7.2)
16 ~ 34 (1.6 ~ 3.4)
69 ~ 85 (6.9 ~ 8.5)
90 ~ 110 (9 ~ 11)
200 ~ 260 (20 ~ 26)
65 ~ 75 (6.5 ~ 7.5)
110 ~ 130 (11 ~ 13)
100 ~ 120 (11 ~ 12)
130 ~150 (13 ~ 15)
5 ~ 6 (0.5 ~ 0.6)
LD-14

Suspension System
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
Tire size
Tire pressure
Camber
Caster
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Rear strut assembly to wheel housing panel
Rear strut assembly to carrier
Rear strut assembly self-locking nut
Front
Rear
MacPherson strut
Dual link
Gas pressurized
6.0J 15"
6.0J 15", 6.0J 16"
185/65 R15, 195/60 R16, 205/50 R16
2
2.1kgf/cm , (30psi)
030'
236'30'
02 (00.079)
1210'30'
-55'30'
42 (0.1570.079)
-
90 ~ 110 (9.0 ~ 11.0)

45 ~ 60 (4.5 ~ 6.0)
130 ~ 150 (13.0 ~ 15.0)
50 ~ 70 (5.0 ~ 7.0)
130 ~ 150 (13.0 ~ 15.0)
60 ~ 72 (6.0 ~ 7.2)
44 ~ 62 (4.4 ~ 62)
30 ~ 45 (3.0 ~ 4.5)
30 ~ 40 (3.0 ~ 4.0)
110 ~ 130 (11.0 ~ 13.0)
40 ~ 55 (4.0 ~ 5.5)
LD-15
Rear stabilizer link to stabilizer bar

Rear stabilizer bar bracket mounting bolts
Rear suspension arm tie rod nut
Rear suspension arm mounting bolt
Rear cross member mounting bolt
Trailing arm to bracket
Trailing arm bracket to body frame
Trailing arm to rear carrier
35 ~ 45 (3.5 ~ 4.5)
17 ~ 26 (1.7 ~ 2.6)
50 ~ 60 (5.0 ~ 6.0)
160 ~ 180 (16.0 ~ 18.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
40 ~ 50 (4.0 ~ 5.0)
100 ~ 120 (10.0 ~ 12.0)
Steering System
Type
Quality
Quantity
Rack stroke
Steering angle
Inner
Outer
(lmp.qt)
mm (in.)
kPa
(kgf/cm
)

Rack and Pinion

PSF-3
0.75 ~ 0.8 (0.66 ~ 0.70)
144 (5.67)
370.5
31.8
8,336 ~ 8,826 (85 ~ 90)
35 ~ 45 (3.5 ~ 4.5)
13 ~ 18 (1.3 ~ 1.8)
15 ~ 20 (1.5 ~ 2.0)
15 ~ 20 (1.5 ~ 2.0)
16 ~ 34 (1.6 ~ 3.4)
17 ~ 26 (1.7 ~ 2.6), GSL 2.0: 35 ~ 50 (3.0 ~ 5.0)
55 ~ 65 (5.5 ~ 6.5)
60 ~ 80 (6.0 ~ 8.0)
LD-16

GSL 1.6
Engine
GSL 2.0
DSL U 1.6
Restraints
Type
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
Buckled
Seat Belt Buckle Switch Unbuckled
(BS)
Buckled
Unbuckled
Driver Airbag (DAB)
Side Airbag (SAB)
SRSCM Mounting Bolt
Depowered
mA
k
1.7 ~ 5.0
1.7 ~ 5.0
1.7 ~ 5.0
1.7 ~ 5.0
1.7 ~ 5.0
8.7 ~ 16.5
3.0 ~ 8.2
0.9 ~ 0.1
360 ~ 440
8 ~ 10 (0.8 ~ 1.0)
19 ~ 27 (1.9 ~ 2.7)
5 ~ 7 (0.5 ~ 0.7)
6 ~ 8 (0.6 ~ 0.8)
40 ~ 55 (4.0 ~ 5.5)
8 ~ 10 (0.8 ~ 1.0)
LD-17
Brake System
Brake fluid
Quantity
Master cylinder
Type
CBS
ABS,TCS
I.D.
Cut-in pressure (Split

point)
Rear drum
Rear disc
Decompression ratio
Brake booster
Type
Effective diameter
Boosting ratio
mm (in.)
Tandem type
22.2 (0.874)
23.8 (0.937)
Provided
MPa
(kgf/cm
)
MPa
2.55 (26)
(kgf/cm
)
mm (in.)
CBS
ABS/TCS
Front brake (Disc)

Type
Disc O.D.
Disc thickness
Pad thickness
CBS
ABS
CBS
ABS
DOT 3 or DOT 4
As required
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
3.92 (40)
0.27 : 1
Vacuum
Tandem type with 7 + 8 in
7.5 :1
7.5 : 1/11.0 :1
257 (10.11)
275 (10.83)
24 (0.945)
26 (1.02)
11 (0.43)
275 (10.83)
275 (10.83)
26 (1.02)
26 (1.02)
LD-18

GSL 1.6
Engine
Cylinder type
Cylinder I.D.
CBS
ABS
Rear brake (Disc)

Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D
Rear brake (Drum)
Type
Drum I.D.
Parking brake
Type
Actuation
[NOTE
O.D: Outer Diameter
I.D: Inner Diameter
CBS: Conventional Brake System
TCS: Traction Control System
mm (in.)
mm (in.)
GSL 2.0
Double piston
54 (2.12)
57.2 (2.25)
mm (in.)

258 (10.16)
10 (0.39)
9 (0.35)
Single piston
33.96 (1.34)
mm (in.)
mm (in.)
mm (in.)
Leading trailing
203.2 (8)
4.5 (0.18)
Automatic
mm (in.)
mm (in.)
mm (in.)
DSL U 1.6
57.2 (2.25)
57.2 (2.25)

Lever
LD-19

HECU
System
Service standard
189 (7.24 )
mm (in.)
Brake pedal height
122 ~ 127 (4.8 ~ 5.0)
mm (in.)
Brake pedal stroke
3 ~ 8 (0.11 ~ 0.31)
mm (in.)
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
stopper clearance
mm (in.)
piston clearance
CBS
(minimum)
ABS
Front disc run out
Rear disc run out
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
8 ~ 9 clicks : Rear Disc type,

8 clicks : Rear Drum type
2.0 (0.079)
22 (0.866)
24 (0.945)
24 (0.945)
24 (0.945)
0.03 (0.0012)
0.005 (0.0002)
1.0 (0.039)
205.2 (8.08)
2.0 (0.079)
8 (0.315)
0.03 (0.0012)
0.005 (0.0002)
LD-20

Engine
Bleeder screw
Caliper assembly to knuckle
Front
(ABS & TCS)
Rear
HECU mounting bolt (ABS & TCS)
HECU mounting bracket bolt (ABS & TCS)
Brake tube nut (ABS & TCS)
Bleeder screw (ABS & TCS)
GSL 1.6
GSL 2.0
DSL U 1.6
8 ~ 12 (0.8 ~ 1.2)
13 ~ 16 (1.3 ~ 1.6)
7 ~ 9 (0.7 ~ 0.9)
13 ~ 17 (1.3 ~ 1.7)
22 ~ 32 (2.2 ~ 3.2)
8 ~ 12 (0.8 ~ 1.2)
25 ~ 35 (2.5 ~ 3.5)
8 ~ 10 (0.8 ~ 1.0)
69 ~ 85 (6.9 ~ 8.5)
25 ~ 30 (2.5 ~ 3.0)
200 ~ 260 (20 ~ 26)
5 ~ 11 (0.5 ~ 1.1)
50 ~ 60 (5 ~ 6)
35 ~ 55 (3.5 ~ 5.5)
8 ~ 9 (0.8 ~ 0.9)
8 ~ 9 (0.8 ~ 0.9)
11 ~ 14 (1.1 ~ 1.4)
17 ~ 26 (1.7 ~ 2.6)
13 ~ 17 (1.3 ~ 1.7)
7 ~ 13 (0.7 ~ 1.3)
LD-21

Hood
Type
Construction
Front door
Regulator system
Construction
Rear door
Regulator system
Trunk lid
Type
mm (in.)
Windshield
mm (in.)
Front door
Glass thickness
mm (in.)
Rear window
Front
Seat belts
Front passenger seat
Rear seat (Center)
Front fender
Mounting bolts

X-ARM type
X-ARM type
Torsion bar type
5.0 (0.1969)
3.2 (0.1260)
3.2 (0.1260)
3.5 (0.1378)
3 point type
3 point type
Fixed 2 point type
7~9 (0.7~0.9)
LD-22

GSL 1.6
Engine
Trunk lid
Sunroof
Hinge bolts (Body side)

Hinge bolts (Door side)
Checker bolts (Body
Checker bolts (Door
Door module bolts
Door module nuts
Door speaker bolts
Glass mounting bolts
Door glass grip bolts
Door channel bracket
Outside handle bolts
Outside handle screw
Inside handle screw
Latch screws
Striker screws
Hinge bolts (Trunk lid
side)
Latch bolts
Striker bolts
Mounting nuts
Mounting bolts
Glass height adjustment
screws
GSL 2.0
35~42 (3.5~4.2)
13~26 (1.3~2.6)
17~22 (1.7~2.2)
7~11 (0.7~1.1)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
4 ~ 8 (0.4~0.8)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~9 (0.7~0.9)
DSL U 1.6
7~9 (0.7~0.9)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
9~13 (0.9~1.3)
9~13 (0.9~1.3)
2~4 (0.2~0.4)
LD-23
Outside rearview mirror Mounting nuts

Hood
Hinge bolts (Hood side)
Front bumper
Bumper rail mounting
Rear bumper
Mounting bolts
Front seat mounting
Front seat
Rear seat mounting
Rear seat
Front seat mounting
Anchor bolt
Seat belt
Rear seat belt buckle
Retractor mounting bolt
7~11 (0.7~1.1)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
35~55 (3.5~5.5)
35~55 (3.5~5.5)
35~55 (3.5~5.5)
17~26 (1.7~2.6)
40~55 (4.0~5.5)
40~55 (4.0~5.5)
40~55 (4.0~5.5)

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
Frequency range /
Channel space
AM/FM/CD
FM
AM
FM
MW
LW
AM/FM/CD/MP3
AM/FM/6CDC/MP3
DC 14.4V
Max 43W x 4
4 x 4
80PF 75
87.5~108 MHz / 100KHz (General)
531 ~ 1602 KHz/9 KHz (General)
87.5 ~ 108.0 MHz/50 KHz (Europe)
522 ~ 1620 KHz/9 KHz (Europe)
LD-24

GSL 1.6
Engine
Items
Life of battery
Lighting system
High
Low

Front fog lamp
Back up lamp
License plate lamp
Side repeater
Room lamp
Glove box lamp
DSL U 1.6
Transmitter(TX)
30m or more
4 Door : 4 (Door lock, Door unlock, Trunk open, Panic)
5 Door : 3 (Door lock, Door unlock, Panic)
433.92 MHz
Button
Head lamp
GSL 2.0
W
W
W
W
W
W
W
W
W
W
W
W
W
60
55
21
27
21/5
16
21
21
5
5
10
10 x 2
5
LD-25
Other system
Immobilizer
Type
Manufacturer
SMARTRA system
Bosch

Air conditioner
Condeser
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
APT(A/C pressure
transducer)
The method to measure

the pressure
Expansion valve
Type
Type
Capacity [oz.(g)]
Compressor
Refrigerant
Blower unit
Type
Speed step
Blower
Speed control
Air filter
Type
6SBU16
ND-OIL8(PAG) 120 10cc
5PK - type
160 cc/rev
12,000 10% Kcal/hr
Voltage = 0.00878835 * pressure + 0.5
Block
R - 134a
17.64 0.88 (500 25)
Actuator
Siroco
Auto + 7speed (Autometic) , 4 speed (Manual)
Power mosfet (Autometic)
Particle filter
LD-26

Engine
Type
Heating capacity
Heater
method
Evaporator
C (F)
A/C ON/OFF
GSL 1.6
GSL 2.0
DSL U 1.6
Pin & Tube type

5,000 5% Kcal/hr
Actuator
Actuator
Evaporator temperture sensor
ON : 7.0 0.5 (44.6 32.9)
OFF : 5.0 0.5 (41.0 32.9)
LD-27
ED-1
General specifications - cee'd

Engine
Type
Number of cylinders
Petrol 1.4
Oil quantity
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
In-line, DOHC
In-line, SOHC
4
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Petrol 1.6
mm (in.)
cc
77 (3.0315) x 74.49 77 (3.0315) x 85.44

(2.952)
(3.3638)
1.396
82 (3.228) x 93.5
(3.681)
1.591
1.925
10.5 : 1
77.2 (3.0394) x 84.5

83 (3.27) x 92 (3.62)
(3.3268)
1.582
1.991
17.3 : 1
10.1 : 1
1-3-4-2
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
BTDC 5 10
660 100
830 100
850 100
4.1 (3.60)
5.7 (5.02)
7.4 (6.51)
4.0 (3.52)
5.3 (4.66)
6.7 (5.89)
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
3.7 (3.26)
5.5 (4.84)
0.4 (0.35)
3.3 (2.90)
Oil quality
Above SJ or SL
kPa
(kg/cm)
Oil pressure (Idle)
245 (2.5)
12/BTDC 38
10/BTDC 40
11
175' 4
7 (BTDC)
49/BBDC 1
63/ABDC 13
59
146' 4
35 (ABDC)
40
40
42
2325' 4
52 (BBDC)
20 4
6 (ATDC)
Valve timing
Intake valve
Exhaust valve
Opens (ATDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
ED-2
Cylinder head
0.03(0.0012) for
width
0.05(0.0020) for all
mm (in.)
Less than 0.05 (0.0020)
Max. 0.03 (0.0012)
0.03(0.0012) for
each cylinder
0.09(0.0035) for
length
0.012(0.00047)/51
51mm
mounting surface
Intake
mm (in.)
Max. 0.15 (0.0059)
Exhaust
mm (in.)
Intake
mm (in.)
42.85 (1.687)
43.85 (1.726)
44.618 (1.7566)
Exhaust
mm (in.)
42.85 (1.687)
42.85 (1.687)
44.518 (1.7527)
Journal outer Diameter (Intake, Exhaust)
mm (in.)
22.964 ~ 22.980 (0.9041 ~ 0.9047)
mm (in.)
0.020 ~ 0.057 (0.0008 ~ 0.0022)
End play
mm (in.)
0.10 ~ 0.20 (0.0039 ~ 0.0079)
Camshaft
Cam height
28 (1.1023)
0.025(0.0010) for
width
0.160(0.0063) for
length
LH:
35.452~35.652(1.39
57~1.4036)
LH:
35.700~35.737(1.39
91~1.4070)
20.944~20.960
(0.8246~0.8252)
0.03(0.0012) for
width
0.09(0.0035) for
length
34.697
(1.366)
34.570
(1.361)
28 (1.10)
0.05 ~ 0.15
(0.002 ~ 0.06)
ED-3

Engine
Valve
Valve length
Petrol 1.4
Petrol 1.6
Diesel D 2.0
mm (in.)
mm (in.)
93.15 (3.6673)
114.34 (4.5016)
93.0 (3.6614)
95.7 (3.77)
92.6 (3.6457)
116.8 (4.598)
93.7 (3.6890)
95.4 (3.76)
Intake
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)
5.953 (0.234)
Exhaust
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)
5.925 (0.233)
45.25 ~ 45.75
45.5 ~ 45.75
45.5
Face angle
Valve stem to valve

guide clearance
Diesel U 1.6
Intake
Exhaust
Stem outer diameter

(margin)
Petrol 2.0
Intake
mm (in.)
1.1 (0.0433)
1.6 0.15
(0.0630 0.0059)
1.1 (0.0433)
1.6 (0.063)
Exhaust
mm (in.)
1.26 (0.0496)
1.8 0.15
(0.0709 0.0059)
1.2 (0.0472)
1.3 (0.0512)
Intake
mm (in.)
0.020 ~ 0.047 (0.0008 ~ 0.0019)
0.020 ~ 0.050
(0.0008 ~ 0.9919)
0.030 ~ 0.057
(0.0012 ~ 0.0022)
0.022 ~ 0.067
(0.00086 ~ 0.00263)
Exhaust
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)
0.050 ~ 0.095
(0.0020 ~ 0.0037)
Intake
mm (in.)
Exhaust
mm (in.)
Intake
Exhaust
mm (in.)
mm (in.)
Intake
mm (in.)
Exhaust
mm (in.)
Valve guide
Inner. diameter
Length
Outter: 45.8 ~ 46.2

(1.8031 ~ 1.8189) Inner: 5.500 ~ 5.512
(0.2165~0.2170)
Outter: 52.8 ~ 53.2
(2.0787 ~ 2.0945)
40.3 ~ 40.7 (1.5866 ~ 1.6024)
40.3 ~ 40.7 (1.5866 ~ 1.6024)
31.3 ~ 31.7
(1.2323 ~ 1.2480)
1.1 ~ 1.5
(0.043 ~ 0.059)
0.8 ~ 1.4
(0.0315 ~ 0.0551)
1.3 ~ 1.7
(0.051 ~ 0.066)
1.2 ~ 1.8
(0.0472 ~ 0.0709)
45 ~ 4530'
36.5mm (1.437in.)
36.5mm (1.437in.)
36.5 (1.437)
Valve seat
Seat angle
1.21 ~ 1.61
(0.0477 ~ 0.6634)
44 ~ 44.5
ED-4
Valve spring
Free length
mm (in.)
Load
Out of squareness
MLA
MLA
outer
Cylinde
r head
MLA to
tappet
44.0 (1.7323)
48.86 (1.9236)
mm (in.)
Less than 1.5
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
44.9 (1.7677)
18.8k0.9kg/39.0
17.50.9kg/32.0
(41.42.0lb/1.5354) (38.62.0 lb/1.2598)
41.01.5kg/30.5
31.01.6kg/23.5
(90.43.3lb/1.2008) (68.33.5 lb/0.9252)
1.5 or less
Less than 1.5
38.8 (1.527)
21.25kg/32.0
(47.2lb/1.26)
-
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
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)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
Valve clearance
Intake
Exhaust
Cylinder block
mm (in.)
mm (in.)
0.20mm (0.0079in)
0.28mm (0.0110in)
Cylinder bore
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)
83 + 0.03
(3.27 + 0.0012)
0.042 (0.00165) for
width
0.096 (0.00378) for
length
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)
82.92 ~ 82.95
(3.26 ~ 3.27)
mm (in.)
0.020 ~ 0.040 (0.0008 ~ 0.0016)
0.060 ~ 0.080
(0.0024 ~ 0.0031)
0.07 ~ 0.09
(0.0027 ~ 0.0036)

Piston
ED-5

Engine
Ring groove width
Petrol 1.4
Petrol 1.6
Diesel D 2.0
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.83 ~ 1.85
(0.0720 ~ 0.0728)
1.915 ~ 1.945
(0.075 ~ 0.076)
No. 2 ring groove mm (in.)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.82 ~ 1.84
(0.0717 ~ 0.0724)
2.06 ~ 2.08
(0.08 ~ 0.082)
Oil ring groove
2.01 ~ 2.03 (0.0791 ~ 0.0799)
mm (in.)
3.02 ~ 3.04
(0.1189 ~ 0.1197)
0.04 ~ 0.08 (0.0015 ~ 0.0031)
0.09 ~ 0.13
(0.0035 ~ 0.0051)
0.064 ~ 0.114
(0.00252 ~ 0.00449)
0.03 ~ 0.07 (0.0012 ~ 0.0027)
0.08 ~ 0.12
(0.0031 ~ 0.0047)
0.065 ~ 0.11
(0.00256~0.00433)
Oil ring groove
mm (in.)

End gap
Diesel U 1.6
Piston OS
Piston ring
Side clearance
Petrol 2.0
0.20 ~ 0.35 (0.0079 ~ 0.0138)

Oil ring groove
mm (in.)
0.03 ~ 0.07
(0.00118 ~ 0.00275)
0.37 ~ 0.52 (0.0146 ~ 0.0205)

-
0.35 ~ 0.50
(0.0138 ~ 0.0197)
0.40 ~ 0.50
(0.016 ~ 0.024)
0.20 ~ 0.40
(0.0079 ~ 0.0157)
0.2 ~ 0.45
(0.0079 ~ 0.0177)
Piston pin
mm (in.)
20.001 ~ 20.006 (0.7874 ~ 0.7876)
27.995 ~ 28.000
(1.1022 ~ 1.1024)
mm (in.)
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)
0.004 ~ 0.015
(0.0002 ~ 0.0006)
mm (in.)
19.974 ~ 19.985 (0.7864 ~ 0.7868)
28.022 ~ 28.034
(1.1032 ~ 1.1037)
0.022 ~ 0.039
(0.0009 ~ 0.0015)

Connecting rod
ED-6
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)
0.024 ~ 0.042
(0.0009 ~ 0.0016)
End play
Crankshaft
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.)
0.021 ~ 0.042 (0.0008 ~ 0.0017)
End play
mm (in.)
0.05 ~ 0.25 (0.0020 ~ 0.0098)
0.06 ~ 0.260
(0.0023 ~ 0.010)
0.08 ~ 0.28
(0.0031 ~ 0.110)
0.09 ~ 0.32
(0.0035 ~ 0.0126)
49049.0
(50.5, 717.1psi)
57050.0
(82.677.25psi)
0.100 ~ 0.250mm
(0.0039 ~ 0.010in)
0.1 ~ 0.25 (0.0039 ~ 0.0098)
0.024 ~ 0.042
(0.0009 ~ 00017)
Oil pump
kPa
(kg/cm)
Cooling system
(lmp.qt)
Water-cooled,
pressurized. Forced
circulation with
5.5 ~ 5.8 (4.84~5.10)
6.2 ~ 6.3 (5.46 ~ 5.54)
6.3 (5.54)
7.3L (6.42)
85 1.5
(185.0 2.7)
83.5 ~ 86.5
(182 ~ 188)
Cooling method
Coolant quantity
Thermostat
Radiator cap
Opening
temperature
Pull opening
Full lift
C (F)
82 1.5 (179.6 2.7)
82 (177)
C (F)
mm (in.)
95 (203)
95 (201)
Main valve
opening press.
kPa
(kg/cm)
93.16 ~ 122.58(0.95 ~ 1.25)
93.16 ~ 122.58
(0.95 ~ 1.25)
107.914.7
(1.10.15,
15.642.13psi)
Vacuum valve
opening press.
kPa
(kg/cm)
MAX. 6.86 (0.07)
MAX. 6.86 (0.07)
-6.86 (-0.07)
100 (212)
10 (0.3937)
ED-7

Engine
Petrol 1.4
Type
20C (68F)
80C (176F)
Main moving system
Crankshaft main
Inner bolt (M11)
bearing cap
Cylinder head
Long bolts
Cylinder head bolt
Short bolts
Lubrication system
Resistance
k
k
Oil filter cap
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Thermister type
Heat-sensitive
thermistor type
Thermister type
2.450.14
2.31 ~ 2.59
2.450.14
0,3222
0,3222
17.7~21.6+902(1.8~2.2+902)
12.7 + (87~93)
19.6 + 90 (2.0 + 90)
24.5 + 90
(22.6~26.5) + (90~94) 27.5~31.4) + 120
9.80 ~ 11.76 (1.0 ~ 1.2)
32.4 ~ 36.3
39.2 (4.0) + 120 + 90
(47.1~51.0) +
(88~92)
+ (118~122)
49.0 + 120 + 90
19.6 ~ 26.5
(2.0 ~ 2.7)
22.6 ~ 24.5
(2.3 ~ 2.5)
18.62 ~ 23.52 (1.9 ~ 2.4)
11.8 ~ 15.7 (1.2 ~ 1.6)
Oil pan drain plug

Lower oil pan bolt
Diesel D 2.0
34.3 ~ 44.1 (3.5 ~ 4.5)
39.2 ~ 44.1 (4.0 ~ 4.5)
26.5 ~ 29.4
34.3 ~ 44.1 (3.5 ~ 4.5)
9.8 ~ 11.8 (1.0 ~ 1.2)
9.8 ~ 11.8 (1.0 ~ 1.2)
12 V, 1.2 kW
12 V, 1.7 kW

Rated voltage
Starter No-load
charasteristics
Generator
V
Voltage
A
Amperage
Speed
Type
Rated voltage
rpm
Speed in use
Regulator setting voltage
11
Max. 95
90A, MAX
2,500 rpm
2,600 rpm, MIN

Alternator voltage sensing
13.5V, 90A
1,000 ~ 18,000
12V, 120A
1,000 ~ 18,000
1,00 ~ 12,000
IC regulator built-in type
14.2 ~ 14.8V
14.1 0.3 V
ED-8
Battery
Ignition coil
Spark plugs
Type
Cold cranking amparage
at -18C (-0.4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
resistance
Unleaded (NGK)
CMF 80AH
54 - 26 GL
630 A
600 A
130 min
110 min
1.280 0.01
0.7 15%
0.58 10%
8.8 15%
ZFR5F-11
1.0 ~ 1.1 (0.0394 ~ 0.0433)
ED-9

Engine
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
Bosch
Bosch
Siemens
Bosch
Bosch
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Manufacturer
(lmp.qt)
Capacity
Type
Type
55 (12.1)
55 (12.1)
Returnless
Return type
High pressure type
High pressure type
Built in Fuel pump assy
Built in Engine room

-
Fuel Pump
Fuel Pressure
(Maximum)
Type
Driven by
Electrical
Mechanical
in-tank type
Plunger pumping type
Electric motor
Chain
MPa
(kgf/cm)
Regulated Fuel
kPa
(kgf/cm)
Pressure
338 ~ 348 (3.45 ~ 3.55)
Pressure
Camshaft
1,600 bar (160 Mpa / 23,206 psi)
Manual Transaxle
Before Dec. 15, 2008
Type
Gear ratio
M/T oil quality

M/T oil capacity
After Dec. 15, 2008
M5CF-1
1st
2nd
3rd
4th
5th
6th
Reverse
FGR (Final Gear Ratio)
(lmp qt)
M5CF2
M5CF3
M6GF2
3,786
3,615
3,308
3,636
3,615
2,053
1,950
1,962
1,962
1,794
1,37
1,257
1,189
1,542
1,031
0,976
0,844
1,176
0,837
0,778
0,660
0,921
0,732
3,583
3,583
3,416
3,583
4,412
4,294
4,188
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)
2.0 (1.76)
3,941
4.063 / 2.955
SAE 75W/85, API GL-4, TGO-7 (MS51714),
ZIC G-F TOP 75W/85,
HD GEAR OIL XLS 75W/85
2.0 (1.76)
1.9 (1.67)
ED-10
Type
M5CF1-1
1st
2nd
3rd
4th
5th
6th
Reverse
FGR (Final Gear Ratio)
Gear ratio
M/T oil quality
3,769
3,615
2,045
1,962
1,37
1,036
0,839
SAE 75W/85, API GL-4,

TGO-7 (MS517-14)
1.92 (1.67)
3,545
4,400
(lmp qt)
M/T oil capacity
4,267
Automatic Transaxle
Type
1st
2nd
3rd
4th
Rev.
FGR
Gear ratio
ATF quality
ATF capacity
(lmp.qt)
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
Genuine Diamond ATF SP-III, SK ATF SP-II

6.6 (5.81)
6.6 (5.81)
Driveshaft
Driveshaft
Joint
type
M/T
A/T
Max.
Permissible
Type
Center bearing
Dimension
Inner
Outer
Inner
Outer
Inner
Outer
AAR2000i
AAR2300i
AAR3300i
AC2000i
AC2300i
AC3300i
AAR2000i
AAR2300i
AC2000i
AC2300i
21
21
45
45
Radial ball bearing
Inner
Outer
30 mm (1.18 in.)
62 mm (2.44 in.)
ED-11

Engine
Front wheel
bearing
Petrol 1.4
Petrol 1.6
Type
Dimension
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
Double row angular contact ball bearing
Inner
Outer
45 mm (1.77 in.)
87 mm (3.43 in.)

28 (0.18 )
Front wheel bearing
[NOTE]
UFi : Under Cut Free improved (GKN)
AARi : Angular Adjusted Roller improved (GKN)
Outer : On tire side
196.1 ~ 274.6 (20.0 ~ 28.0)
Driveshaft lock nut
137.3~156.9(14.0~16.0)
Knuckle to strut assy nut
23.5 ~ 33.3 (2.4 ~ 3.4)
Tie rod end castle knuckle
78.5~98.1(8.0~10.0)
88.3 ~ 107.9 (9.0 ~ 11.0)
Wheel nut
58.8~68.6(6.0~7.0)
Carrier assembly to rear hub assembly bolts
34.3~53.9(3.5~5.5)
Trailing arm to carrier assembly bolts
137.3~156.9(14.0~16.0)
Rear shock absorber assembly to carrier assembly
34.3 ~ 53.9 (3.5 ~ 5.5)
49.0~58.8(5.0~6.0)
Rear caliper assembly to carrier assembly bolts
44.1~53.9(4.5~5.5)
Assist arm to carrier assembly bolts
196.1 ~ 274.6 (20.0 ~ 28.0)

23.5 ~ 33.3 (2.4 ~ 3.4)
88.3 ~ 107.9 (9.0 ~ 11.0)
34.3 ~ 53.9 (3.5 ~ 5.5)
Suspension System
Suspension type
Shock absorber type
Wheel size
Tire size
Tire pressure
Front
Rear
McPherson strut
Multi-link coil spring

Gas pressurized
5.5J 15, 6.0J 16, 7.0J 17
185/65 R15, 195/65 R15, 205/55 R16, 225/45 R17
kgf/
(psi)
2.4 (34), 2.6 (37)
ED-12
Camber
Caster
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Front strut assy to sheel housing panel
Front strut assy to knuckle
Front strut assy self-locking nut
Front stabilizer lik to strut assy
Front stabilizser bar bracket mounting bolts
Rear strut assy to wheel housing panel
Rear strub assy to carrier
Rear strut assy self-locking nut
Rear stabiliser link to stabiliser bar
Rear stabiliser bar bracket mounting bolts
-0.6 30'
-19' 30'
426' 30'
0 2 (0 0.079)
2.2 2 (0.087 0.079)
1339' 30'
90 ~ 110 (9.0 ~ 11.0)

45 ~ 60 (4.5 ~ 6.0)
140 ~ 160 (14.0 ~ 16.0)
50 ~ 70 (5.0 ~ 7.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
50 ~ 65 (5.0 ~ 6.5)
140 ~ 160 (14.0 ~ 16.0)
20 ~ 25 (2.0 ~ 2.5)
45 ~ 55 (4.5 ~ 5.5)
140 ~ 160 (14.0 ~ 16.0)
35 ~ 55 (3.5 ~ 5.5)
ED-13

Engine
Front stabilizer link to stabilizer bar
Rear shock absorber to carrier
Rear upper arm to carrier
Rear upper arm to cross member
Rear lower arm to carrier
Rear lower arm to cross member
Assist arm to carrier
Assist arm to cross member
Trailing arm to carrier
Trailing arm to body
Rear stabilizer link to carrier
Rear cross member mounting bolts
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
100 ~ 120 (10.0 ~ 12.0)

45 ~ 55 (4.5 ~ 5.5)
50 ~ 65 (5.0 ~ 6.5)
140 ~ 160 (14.0 ~ 16.0)
20 ~ 25 (2.0 ~ 2.5)
80 ~ 90 (8.0 ~ 9.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
140 ~ 160 (14.0 ~ 16.0)
35 ~ 45 (3.5 ~ 4.5)
35 ~ 45 (3.5 ~ 4.5)
45 ~ 55 (4.5 ~ 5.5)
140 ~ 160 (14.0 ~ 16.0)
Steering System
Type
Rack stroke
Steering angle
Electric Power Steering (Column assist type)

PSF-4
mm (in.)
Inner
Outer
140mm (5.51in.)
36.9130'
30.27
kPa
(kgf/cm)

9807 ~ 10199 (100 ~ 104)
40 ~ 50 (4.0 ~ 5.0)
13 ~ 18 (1.3 ~ 1.8)
15 ~ 20 (1.5 ~ 2.0)
30 ~ 35 (3.0 ~ 3.5)
ED-14

Power steering pump mounting bolts
24 ~ 34 (2.4 ~ 3.4)
60 ~ 80 (6.0 ~ 8.0)
55 ~ 65 (5.5 ~ 6.5)
35 ~ 55 (3.5 ~ 5.5)
ED-15

Engine
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
Piston stroke
Brake booster
Type
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
Rear brake(Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D
Parking brake
Type
Actuation
Drum I.D.
DOT 3 or DOT 4
As required
Tandem type
mm (in.)
mm (in.)
25.4 (1.0)
30 ~ 32 (1.18 ~ 1.26)
Provided
vacuum
9:1
mm (in.)
mm (in.)
mm (in.)
303 (11.93)
28 (1.10)
11 (0.43)
Single piston
mm (in.)
60 (2.36)
mm (in.)
mm (in.)
mm (in.)
284 (11.18)
10 (0.39)
10 (0.39)
Single piston
mm (in.)
34 (1.34)
Foot Type
mm (in.)
190 (7.48)
ED-16
O.D=Outer Diameter
I.D=Inner Diameter
Acitve wheel speed
teeth
Tone wheel
sensor
Service standard
mm (in.)
Brake pedal height
mm (in.)
Brake pedal full stroke
mm (in.)
Adjust Brake pedal full stroke
mm (in.)
mm (in.)
stopper clearance
47
193.5 (7.62 )
126.7 3 (4.99 0.12)
63.6 2 (2.50 0.08)
3 ~ 8 (0.11 ~ 0.31)
1.2 ~ 1.8 (0.05 ~ 0.07)
ED-17

Engine
mm (in.)
piston clearance
Parking brake pedal stroke when stroke
mm (in.)
assembly is pushed with 196N (20kgf,
44lb force)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Rear parking brake liner thickness
Bleeder screw
Brake pedal assembly bracket mounting nut
Active wheel speed sensor mounting bolt on the
brake plate
HECU mounting bolt
HECU port
Yaw rate lateral acceleration sensor bolt
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
0 (at 500 mmHg)
88 ~ 98 (3.46 ~ 3.86)
11 (0.43)
28 (1.10)
10 (0.39)
10 (0.39)
4.3 (0.17)
8 ~ 12 (0.8 ~ 1.2)
13 ~ 16 (1.3 ~ 1.6)
7 ~ 13 (0.7 ~ 1.3)
13 ~ 17 (1.3 ~ 1.7)
80 ~ 100 (8 ~ 10)
25 ~ 30 (2.5 ~ 3.0)
22 ~ 32 (2.2 ~ 3.2)
8 ~ 10 (0.8 ~ 1.0)
13 ~ 16 (1.3 ~ 1.6)
25 ~ 35 (2.5 ~ 3.5)
8 ~ 10 (0.8 ~ 1.0)
8 ~ 10 (0.8 ~ 1.0)
17 ~ 26 (1.7 ~ 2.6)
12.2 ~ 16.3 (1.22 ~ 1.63)
8 ~ 10 (0.8 ~ 1.0)
26 ~ 30 (2.6 ~ 3.0)
ED-18
Body(Interior & Exterior)

Hood
Front door
Rear door
Trunk lid
Glass thickness
Seat belts
Type
Construction
Regulator system
Locking system
Construction
Regulator system
Locking system
Type
mm (in.)
Windshield
mm (in.)
Front door
Rear door fixed mm (in.)
mm (in.)
Rear window
Front
Rear hinged, front opening type (gas lifter type)

X-ARM type
Pin-fork system
X-ARM type
Pin-fork system
5 (0.1969)
5 (0.1969)
5 (0.1969)
4 (0.1575)
3.5 (0.1378)
ED-19

Engine
Mounting bolts
Hinge bolts(Body side)
Hinge nuts(Body side)
Hinge bolts(Hood side)
Lifter bracket bolts
(Body side)
Front fender
Lifter stud ball(Hood side)
Safety hook & Release
lever bolts
Safety hook catch bolts
Hood latch bolts
Hinge bolts(Door side)
Checker bolts(Body side)
Checker nuts(Door side)
Door module bolts
Door module nuts
Glass bolts
Glass grip bolts
Outer handle bolts
Latch screws
Striker screws
Glass guide bolt
Latch bolts
Trunk lid
Striker bolts
Outer handle bolts
Hinge bolts(Trunk lid side)
Outside rearview mirror Mounting bolts
Crash pad
Mounting bolts
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0
7~9 (0.7~0.9)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
35~42 (3.5~4.2)
10~20 (1.0~2.0)
17~22 (1.7~2.2)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~22 (0.7~2.2)
7~11 (0.7~1.1)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
ED-20
Cowl cross bar

Front bumper
Rear bumper
Front seat
Rear seat
Sunroof
Seat belt
Mounting bolts-Side(M10)
Mounting boltsLower(M8)
Reinforcement nuts
Mounting bolts
Mounting nuts
Front seat mounting bolts
Cushion bolts
(Power seat)
Seatback bolts
Frame bolts(Power seat)
Frame nuts(Power seat)
Glass mounting screws
Mounting bolts and nut
Upper anchor bolt
Lower anchor bolt
33~55 (3.3~5.5)
17~26 (1.7~2.6)
9~14 (0.9~1.4)
35~55 (3.5~5.5)
45~55 (4.5~5.5)
45~55 (4.5~5.5)
17~26 (1.7~2.6)
17~26 (1.7~2.6)
17~26 (1.7~2.6)
17~26 (1.7~2.6)
2~4 (0.2~0.4)
7~9 (0.7~0.9)
40~55 (4.0~5.5)
40~55 (4.0~5.5)
ED-21

Engine
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
FM
AM
Frequency range /
FM
Channel space
MW
LW
Items
Life of battery
Button
Lighting system
High
Head lamp
Low
Front position lamp
Front fog lamp
Back up lamp
Rear fog lamp
H285
H295
DC 14.4V
Max 20W x 4
Max 35W x 6
4 x 4
2 x 6
80PF 75
87.5 ~ 108.0 MHz/50 KHz (Europe)
Transmitter(TX)
10m or more
3 (Door lock, Door unlock, Trunk lid open)

433.92 MHz
W
W
W
W
W
W
W
W
W
55
35
14.5 (LED) / 5 (BULB)
5
55
27/8
18
28
5
ED-22
License plate lamp

Side repeater
Room lamp
Glove box lamp
Trunk lamp
Other system
Type
Manufacturer
Type
Smart key
Manufacturer
Immobilizer
W
W
W
W
W
W
W
5
5
10
5
2.5 (LED)
5
5
SMARTRA system
Bosch
Touch sensor type (Front door)
SIEMENS
Front 4 channel/ Rear 4 channel
ED-23

Engine
Petrol 1.4
Petrol 1.6
Petrol 2.0
Diesel U 1.6
Diesel D 2.0

Air conditioner
Compressor
Condeser
APT
(A/C pressure
Expansion valve
Refrigerant
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
the pressure
Type
Type
oz.(g)
Capacity
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
Type
Evaporator
C (F)
A/C ON/OFF
VS16
FD46XG (PAG) , 150 10cc
6PK - TYPE
180 cc/rev
15,000 - 5% Kcal/hr
Block
R - 134a
22.9 0.88 (650 25)
Actuator
Siroco fan
Auto + 8 speed (Autometic)
Power mosfet
Particle filter
Pin & Tube type
4,058 5% Kcal/hr
Actuator
Actuator
Laminated type
Evaporator sensor
OFF : 0.5 0.5 (32.9 32.9)
ON : 3.0 0.5 (37.4 32.9)
ED-24
cee'd (ED)
ED-2
ED-8
ED-10
Fuel System..
ED-10
Clutch.
ED-10
Manual Transaxle.
ED-11
Automatic Transaxle
ED-11
Driveshaft..
ED-12
Suspension System.
Steering System ED-14
ED-16
Brake System
Body (Interior & Exterior). ED-19
ED-22
Heating, Ventilation & Air Conditioning..ED-24
Forte (TD)
TD-2
TD-9
TD-10
Fuel System..
TD-10
Clutch.
TD-11
Manual Transaxle.
TD-12
Automatic Transaxle
TD-14
Suspension System.
Steering System TD-15
RestraintsTD-16
TD-16
Brake System
Body (Interior & Exterior). TD-20
TD-23
Heating, Ventilation & Air Conditioning..TD-24
TD-1
General Specifications - TD
Engine
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
kPa
(kg/cm)
Oil pressure
GSL 1.6
GSL 2.0
In-line, DOHC
4
77 (3.0315)
x 85.44 (3.3638)
1.591
10.5:1
1-3-4-2
BTDC 0 10
660 100
660 100
660 100
690 100
In-line, DOHC
4
86 (3.385)
x 86 (3.385)
1.998
10.5 : 1
1-3-4-2
BTDC 10 5
650 100
DSL U 1.6
650 100
3.7 (3.26)
3.0 (2.64)
3.3 (2.90)
Above API SL or SM, SEA 5W-20(For Middle East area :
1.1(at 1,000rpm, 110C)
1.1(at 1,000rpm, 110C)
ATDC 10/BTDC 40
ABDC 63/ABDC 13
BBDC 40
ATDC 3
ATDC 7 ~ BTDC 38
ABDC 63 ~ 18
BBDC 38
ATDC 6
Less than 0.05 (0.0020)
Max. 0.05 (0.0019)
Valve timing
Intake valve
Exhaust valve
Opens (ATDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
Cylinder head
mounting surface
mm (in.)
Intake
mm (in.)
Exhaust
mm (in.)
TD-2
Camshaft
Intake
Exhaust
mm (in.)
mm (in.)
43.85 (1.726)
42.85 (1.687)
mm (in.)
22.964 ~ 22.980
(0.9041 ~ 0.9047)
mm (in.)
End play
mm (in.)
0.10 ~ 0.20
(0.0039 ~ 0.0079)
0.04 ~ 0.16
(0.0015 ~ 0.0062)
mm (in.)
mm (in.)
93.15 (3.6673)
92.6 (3.6457)
113.18 (4.4559)
105.84 (4.1669)
Cam height
43.8 (1.7244)
45.00 (1.7716)
Valve
Valve length
Intake
Exhaust
TD-3
Engine
Intake
mm (in.)
GSL 1.6
5.465 ~ 5.480
(0.2152 ~ 0.2157)
Exhaust
mm (in.)
5.458 ~ 5.470
(0.2149 ~ 0.2154)
Stem outer diameter

Face angle
(margine)
Exhaust
Valve stem to valve
guide clearance
GSL 2.0
5.465 ~ 5.480
(0.2151 ~ 0.2157)
5.458 ~ 5.470mm
(0.2149 ~ 0.2153in.)
45.25 ~ 45.75
1.02 (0.0401)
1.09 (0.0429)
0.020 ~ 0.047
(0.00078 ~ 0.00185)
Intake
mm (in.)
45.25 ~ 45.75
1.1 (0.0433)
1.26 (0.0496)
0.020 ~ 0.047
(0.0008 ~ 0.0019)
Exhaust
mm (in.)
0.030 ~ 0.054
(0.0012 ~ 0.0021)
0.030 ~ 0.054
(0.00118 ~ 0.00212)
Intake
mm (in.)
Exhaust
mm (in.)
Intake
mm (in.)
40.3 ~ 40.7
(1.5866 ~ 1.6024)
43.8 ~ 44.2
(1.7244 ~ 1.7401)
Exhaust
mm (in.)
40.3 ~ 40.7
(1.5866 ~ 1.6024)
43.8 ~ 44.2
(1.7244 ~ 1.7401)
Intake
Exhaust
mm (in.)
mm (in.)
47.44 (1.8677)
19.0 0.6kg/35.0mm
(41.88 1.32lb/1.3779in)
39.8 1.2kg/26.0mm
(87.74 2.64lb/1.0236in.)
mm (in.)
mm (in.)
DSL U 1.6
Valve guide
Inner diameter
Length
Valve seat
Seat angle
Valve spring
Free length
mm (in.)
44.0 (1.7323)
Load
mm (in.)
Out of squareness
Valve clearance
Intake
20C (68F)
80C (176F)
mm (in.)
mm (in.)
Less than 1.5
1.5 MAX.
0.17 ~ 0.23
(0.0067 ~ 0.0090)
TD-4
Exhaust
20C (68F)
80C (176F)
mm (in.)
mm (in.)
0.27 ~ 0.33
(0.0106 ~ 0.0129)
Cylinder block
Cylinder bore
mm (in.)
86.00 ~ 86.03
(3.3858 ~ 3.3870)

Piston
mm (in.)
mm (in.)
76.97 ~ 77.00
(3.0303 ~ 3.0315)
mm (in.)
0.020 ~ 0.040
(0.0008 ~ 0.0016)
No. 1 ring groove
mm (in.)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
1.235 ~ 1.250
(0.0486 ~ 0.0492)
No. 2 ring groove
mm (in.)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
1.230 ~ 1.250
(0.0484 ~ 0.0492)
Oil ring groove
mm (in.)
2.01 ~ 2.03
(0.0791 ~ 0.0799)
2.01 ~ 2.03
(0.0791 ~ 0.0799)
Ring groove width
Piston OS
85.975 ~ 86.0050
(3.3848 ~ 3.3860)
TD-5
Engine
Piston ring
GSL 1.6
GSL 2.0
No. 1 ring groove
mm (in.)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.05 ~ 0.08
(0.0019 ~ 0.0031)
No. 2 ring groove
mm (in.)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.04 ~ 0.08
(0.0015 ~ 0.003)
Oil ring groove
mm (in.)
0.06 ~ 0.15
(0.0024 ~ 0.0059)
0.06 ~ 0.15
(0.0023 ~ 0.0059)
No. 1 ring groove
mm (in.)
0.14 ~ 0.28
(0.0055 ~ 0.0110)
0.15 ~ 0.30
(0.0059 ~ 0.0118)
No. 2 ring groove
mm (in.)
0.30 ~ 0.45
(0.0118 ~ 0.0177)
0.37 ~ 0.52
(0.0145 ~ 0.0204)
Oil ring groove
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)
End play
mm (in.)
Side clearance
End gap
DSL U 1.6
Piston pin
Connecting rod
TD-6
Crankshaft
mm (in.)
51.942 ~ 51.960
(2.0449 ~ 2.0456)
mm (in.)
47.954 ~ 47.972
(1.8879 ~ 1.8886)
mm (in.)
End play
mm (in.)
0.021 ~ 0.042
(0.0008 ~ 0.0017)
0.05 ~ 0.25
(0.0020 ~ 0.0098)
Flywheel
Runout
Oil pump
mm (in.)
kPa
(kg/cm)
0.020 ~ 0.038
(0.0007 ~ 0.0014)
0.07 ~ 0.25
(0.0027 ~ 0.0098)
Cooling system
cooling fan
Cooling method
Coolant quantity
(lmp.qt)
Water-cooled, pressurized.
Forced circulation
ith
t
5.5 ~ 5.8L(5.81~6.13US qt.,
4.84~5.10lmp qt.)
TD-7
Engine
Opening
Pull opening
Main valve
opening press.
Radiator cap
Vacuum valve
opening press.
Type
Thermostat
Resistance
20C (68F)
80C (176F)
C (F)
C (F)
kPa
(kg/cm)
kPa
(kg/cm)
k
k
GSL 1.6
82 1.5 (179.6 2.7)
101 (214)
93.16 ~ 122.58
(0.95 ~ 1.25)
GSL 2.0
82 (177)
95 (201)
83 ~ 110
(0.83 ~ 1.1)
MAX. 6.86 (0.07)
-7kpa (-0.07) or less
Thermister type
2.45 0.14
0,3222
Thermister type
2.45 0.14
0,3222
DSL U 1.6

Main moving system
Crankshaft
main bearing cap
Cylinder head
Camshaft bearing
cap nuts or bolts
Bolts
Long bolts
Short bolts
M6
M8
19.6 (2.0) + 90
-
11.8 ~ 13.7(1.2 ~ 1.4)

18.6 ~ 22.6(1.9 ~ 2.3)
10.8 ~ 12.7(1.1 ~ 1.3)

27.4 ~ 31.4(2.8 ~ 3.2)
34.3 + 90 + 90
(3.5 + 90 +90)
Long bolts
17.7 ~ 21.6 (1.8 ~ 2.2)

+ 90 ~ 95 + 100 ~105
Short bolts
Cylinder head bolt

Lubrication system
Oil filter
17.7~21.6+902(1.8~2.2+
902)
11.8 ~ 15.7 (1.2 ~ 1.6)
Oil pan bolts
9.8 ~ 11.8(1.0 ~ 1.2)
Oil pan drain plug
34.3 ~ 44.1(3.5 ~ 4.5)
11.8 ~ 15.7 (1.2 ~ 1.6)

M6 x 10:9.8 ~ 11.8(1.0 ~
1.2)
M8 x 103:26.5 ~ 30.4
(2 7 ~ 3 1)
TD-8

Rated voltage
V
Voltage
Starter No-load
A
Amperage
charasteristics
Speed
Type
Rated voltage
Generator
Speed in use
Regulator setting voltage
Type
Cold cranking amperage
at -18C (-0.4F)
Battery
Reserve capacity
Specific gravity [at 20C(68F)]
12.V, 0.9 kW
12 V, 1.2 kW
11,5
11,5
60 MAX
90A, MAX
5500 rpm, MIN
2,600 rpm, MIN
13.5 V, 90A
1,000 ~ 18,000 rpm
IC Regulator built-in type
14.55 0.2 V (At 20C full chareged batt)
36 - 21GL
48-23 GL
410 A
550 A
80 min
92 min
1.280 0.01
TD-9
Engine
Ignition coil
Spark plugs
Primary
Secondary
Unleaded (NGK)
Unleaded
GSL 1.6
0.7 15 %
-
GSL 2.0
0.62 10 %
7.0 15 %
mm (in.)
1.0 ~ 1.1(0.0394~0.0433)
1.0 ~ 1.1(0.0394~0.0433)
DSL U 1.6
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Manufacturer
(lmp.qt)
Capacity
Type
Type
50 ( 44.0)
Returnless
Paper type
Type
Fuel Pump
Electrical
In-tank type
Electric motor
Driven by
Fuel Pressure
(Maximum)
Fuel Pressure
Regulator
Pressure
MPa(kgf/cm)
Regulated Fuel
KPa(kgf/cm)
Pressure
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic type
mm (in.)
mm (in.)
15~22 (1.5~2.2)
15~22 (1.5~2.2)
15~22 (1.5~2.2)
15~22 (1.5~2.2)
Gasoline : 140 3 (5.5 0.12)

6 ~ 13 (0.24 ~ 0.51)
TD-10
Manual Transaxle
Type
Gear ratio
M/T oil quality

MT oil capacity
1st
2nd
3rd
4th
5th
Rev.
3,615
1,95
1,286
0,971
0,774
3,545
3,308
1,962
1,189
0,905
0,702
3,583
FGR
4,267
4,188
(lmp.qt)
TD-11
Engine
GSL 1.6
GSL 2.0
2,919
1,551
1
0,713
2,48
4,375
2,919
1,551
1
0,713
2,48
3,681
DSL U 1.6
Automatic Transaxle
Type
Gear ratio
1st
2nd
3rd
4th
Rev.
FGR
ATF quality
ATF capacity
(lmp.qt)
Driveshaft
M/T
Joint type
A/T
Hub end play
Wheel bearing
[NOTE]
BJ: Birfield Joint
TJ: Tripod Joint
Driveshaft lock nut
Wheel nut
Inner
Outer
Inner
Outer
Inner
Outer
mm (in.)
23
46
196 ~ 274 (20.2 ~28.0)
80 ~ 100 (8.0 ~ 10.0)
TD-12

Rear brake to rear axle carrier mounting bolt
Rear strut to carrier nut
Rear suspension arm to rear axle carrier mounting
nut
Brake disc to hub
TD-13
Suspension System
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
Tire size
Tire pressure
Camber
Caster
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Front
Rear
MacPherson strut
Torsion Beam Axle
Gas pressurized
5.5J x 15
5.0J x 15, 6.0J x 16, 7.0J x 17
185/70 R15, 195/65 R15, 205/60 R16, 215/50 R17
2.2kg/cm (32psi)
-0.640.5
-1.50.5
4.380.5
02.0
4.42.2
13.610.5
90 ~ 110 (9.0 ~ 11.0)
100 ~ 120 (10 ~ 12)
TD-14
Steering System
Type
Quality
Quantity
Rack stroke
Steering angle
Rack and Pinion

PSF-3
(lmp.qt)
mm (in.)
Inner
Outer
40.962, 38.382 (215Tire)

32.33, 30.90 (215Tire)
kPa(kgf/cm)

85 ~ 90
13 ~ 18 (1.3 ~ 1.8)
30 ~ 35 (3.0 ~ 3.5)
TD-15
Engine
GSL 1.6
GSL 2.0
DSL U 1.6
Restraints
Type
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
Buckled
Seat Belt Buckle Switch Unbuckled
(BS)
Buckled
Unbuckled
Driver Airbag (DAB)
Side Airbag (SAB)
SRSCM Mounting Bolt
1.6 ~ 5.8
mA
k
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
Brake fluid
Quantity
Master cylinder
Type
Tandem type
CBS
ABS,TCS
I.D.
Cut-in pressure (Split

point)
Decompression ratio
mm (in.)
Provided
Rear drum
MPa(kgf/cm)
Rear disc
MPa(kgf/cm)
TD-16
Brake booster
Type
Effective diameter
Boosting ratio
Vacuum
mm (in.)
CBS
ABS/TCS
7.5 :1
Front brake (Disc)

Type
Disc O.D.
Disc thickness
Pad thickness
CBS
ABS
CBS
ABS
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)

280 (11.02)
172 (6.77)
26 (1.02)
11 (0.43)
TD-17
Engine
Cylinder type
Cylinder I.D.
GSL 1.6
CBS
ABS
mm (in.)
mm (in.)
Rear brake (Disc)

Type
mm (in.)
Disc O.D.
mm (in.)
Disc thickness
mm (in.)
Pad thickness
Cylinder type
mm (in.)
Cylinder I.D
Rear brake (Drum)
Type
mm (in.)
Drum I.D.
mm (in.)
mm (in.)
Parking brake
Type
Actuation
[NOTE
]
O.D: Outer Diameter
I.D: Inner Diameter
CBS: Conventional Brake System
TCS: Traction Control System
HECU
System
Service standard
mm (in.)
Brake pedal height
mm (in.)
Brake pedal stroke
mm (in.)
GSL 2.0
Single piston
57.15 (2.25)
DSL U 1.6

262 (10.31)
10 (0.39)
10 (0.39)
Single piston
31 (1.22)
Leading trailing
203 (7.99)
4.3 (0.17)
Automatic
Lever
DIH (Drum in hat)
4 Channel 4 Sensor (Solenoid)

LHD : 190.7 (7.51), RHD : 167.5 (6.59)
135 (5.31)
3 ~ 8 (0.08 ~ 0.20)
TD-18

stopper clearance
piston clearance
mm (in.)
LHD : 1.0 ~ 2.0 (0.04 ~ 0.08), RHD : 0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
0.6 ~ 1.4 (at 500 mmHg vacuum)
Parking brake lever stroke when lever assembly is

pulled with 196N (20kgf, 44lb force)
CBS
(minimum)
ABS
Front disc run out
Rear disc run out
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
6 ~ 8 clicks
11 (0.43)
26 (1.02)
3 (0.12)
10 (0.35)
10 (0.39)
TD-19
Engine
Bleeder screw
Front
(ABS & TCS)
Rear
HECU mounting bolt (ABS & TCS)
HECU mounting bracket bolt (ABS & TCS)
Brake tube nut (ABS & TCS)
Bleeder screw (ABS & TCS)
GSL 1.6
GSL 2.0
DSL U 1.6
9.8 ~ 15.7 (1.0 ~ 1.6)

12.7 ~ 15.7 (1.3 ~ 1.6)
6.9 ~ 12.7 (0.7 ~ 1.3)
21.6 ~ 31.4 (2.2 ~ 3.2)
F:78.5 ~ 98.1 (8.0 ~ 10.0), R:63.7 ~ 73.6 (6.5 ~ 7.5)

24.5 ~ 29.4 (2.5 ~ 3.0)

Hood
Front door
Rear door
Trunk lid
Type
Construction
Regulator system
Construction
Regulator system
Type
Rear hinged, Front opening type, stay type

X-arm type
X-arm type
Inner hinged, torsion bar
TD-20
mm (in.)
Windshield
mm (in.)
Front door
Glass thickness
mm (in.)
Rear door
mm (in.)
Rear window
Front
Seat belts
Front passenger seat
Rear
seat
Front fender
Mounting bolts
- LH : 3 point type P.T (pretensioner) with Emergency Locking Retractor (E.L.R)

LH / RH / CTR : 3 point type with E.L.R & A.L.R
TD-21
Engine
Hinge bolts (Door side)
Checker bolts (Body side)
Checker bolts (Door side)
Door module bolts
Door module nuts
Door speaker bolts
Glass mounting bolts
Door glass grip bolts
Door channel bracket
Outside handle bolts
Outside handle screw
Inside handle screw
Latch screws
Striker screws
Hinge bolts (Trunk lid
side)
Trunk lid
Latch bolts
Striker bolts
Mounting nuts
Mounting bolts
Sunroof
Glass height adjustment
screws
Outside rearview mirror Mounting nuts
Hood
Hinge bolts (Hood side)
Front bumper
Bumper rail mounting bolts
Rear bumper
Mounting bolts
GSL 1.6
GSL 2.0
34.3~41.2 (3.5~4.2)
21.6~26.5 (2.2~2.7)
16.7~21.6 (1.7~2.2)
16.7~21.6 (0.7~1.1)
DSL U 1.6
6.9~10.8 (0.7~1.1)
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.7~2.7)
TD-22
Front seat
Rear seat
Seat belt

Rear seat mounting bolts
Anchor bolt
Rear seat belt buckle
6.9~10.8 (3.5~5.5)
34.3~53.9 (3.5~5.5)

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
Frequency range /
Channel space
RADIO/CD(A100)
Rated output
FM
AM
FM
MW
LW
RADIO/CD/MP3(A200)
RADIO/CDC/MP3(A300)
DC 14.5V
Rated output : Min. 12W
4.0 0.6(Front, Rear), 3.4 0.5(Tweeter)
80PF 75
PLL SYNTHESIZED TUNING
87.5 ~ 108.0 MHz/50 KHz (Europe)
TD-23
Engine
Items
Life of battery
GSL 1.6
DSL U 1.6

30m or more
4 Door : 4 (Door lock, Door unlock, Trunk open, Panic)
Button
Lighting system
Head lamp
GSL 2.0
433.92 MHz
High
Low

Front fog lamp
Back up lamp
License plate lamp
Side repeater
Room lamp
Glove box lamp
Other system
Type
Immobilizer
Manufacturer
W
W
W
W
W
W
W
W
W
W
W
W
W
55
55
40046
27
39954
16
21
21
5
5
8
8

Air conditioner
Compressor
Type
Oil type & Capacity
Pulley type
Displacement
6SBU16D
FD46XG(PAG) 120 10cc
6PK-TYPE
180cc/rev
TD-24
Condeser
APT(A/C pressure
transducer)
Expansion valve
Refrigerant
Heat rejection
The
method
to
Type
Type
Capacity [oz.(g)]
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
method
Evaporator
C (F)
A/C ON/OFF
13,400 - 5% kcal/hr
Voltage = 0.00878835 * Pressure + 0.5
Block
R-134a
17.63 0.88 (500 25)
Actuator
Sirocco
Auto + 8 speed (Automatic) 0~4 (Manual)
Power mosfet
Particle filter
Pin & Tube type
Min 4,600 kcal/hr
Actuator
Actuator
ON : 3.0 0.5 (37.4 32.9)
OFF: 1.0 0.5 (33.8 32.9)
TD-25
Magentis /
Optima(MG)
MG-2
MG-11
MG-12
Fuel System..
MG-13
Clutch.
MG-14
Manual Transaxle.
MG-14
Automatic Transaxle
MG-15
Driveshaft..
MG-16
Suspension System.
Steering System MG-18
RestraintsMG-19
MG-20
Brake System
Body (Interior & Exterior). MG-23
MG-25
Heating, Ventilation & Air Conditioning..MG-27
MG-1
General specifications - Magentis/Optima

Engine
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
V-type, DOHC
6
In-line, SOHC
4
Engine
Type
Number of cylinders
In-line, DOHC
4
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
Neutral,N,PD-range
Neutral,N,PD-range
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
10.5 : 1
1-3-4-2
BTDC 8 5
650 100
650 100
650 100
650 100
2.656
10.4 : 1
1-2-3-4-5-6
BTDC 7 10
650 100
650 100
650 100
650 100
1.991
17.3 : 1
1-3-4-2
850 100
850 100
850 100
850 100
5.1 (4.49)
4.0 (3.52)
4.3 (3.78)
4.5 (3.96)
4.2 (3.70)
0.3 (0.26)
-
5W-20(SJ or SL above/GF-3)
5W-20(SJ or SL
above/GF-3)
ACEA : C3
130 (1.32) [at

1000rpm,110C(2
30F)]
rpm
rpm
rpm
rpm
Total
(lmp.qt)
Oil pan
(lmp.qt)
Oil filter
(lmp.qt)
Excluding oil filte (lmp.qt)
Including oil filter (lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
MG-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
-11 ~ 34
22 ~ 67
34
10
-4 ~ 56
60 ~ 0
46
10
7
43
52
6
mm (in.)
Less than 0.05 (0.0020)
0.03(0.0012) or
less
0.03 (0.0012) for

width
0.09 (0.0035) for
length
Intake
mm (in.)
Less than 0.10 (0.0039)
0.15(0.0059) or
less
Exhaust
mm (in.)
Less than 0.10 (0.0039)
0.15(0.0059) or
less
Intake
Exhaust
mm (in.)
mm (in.)
43.80 (1.7244)
45.00 (1.7716)
44.5(1.7520)
34.697 (1.366)
34.570 (1.361)
Intake
mm (in.)
No.1 : 30 (1.1811)
No.2,3,4,5 : 24 (0.9449)
28 (1.10)
mm (in.)
No.1 : 40 (1.5748)
No.2,3,4,5 : 24 (0.9449)
27.964 ~ 27.980
(1.1009 ~ 1.1016)
Cylinder head
mounting surface
Camshaft
Cam height

Exhaust
MG-3

Engine
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
Intake
mm (in.)
No.1 : 0.020 ~ 0.057

(0.00078 ~ 0.00224)
No.2,3,4,5 : 0.045 ~ 0.082
(0.00177 ~ 0.00323)
Exhaust
mm (in.)
No.1,2,3,4,5 : 0.045 ~ 0.082

(0.00177 ~ 0.00323)
mm (in.)
0.1 ~ 0.22 (0.0039 ~ 0.0086)
0.1 ~ 0.2
(0.0039 ~ 0.0079)
0.05 ~ 0.15
(0.002 ~ 0.006)
Intake
Exhaust
mm (in.)
mm (in.)
113.18 (4.4559)
105.89 (4.1689)
110.1 (4.3346)
111.1 (4.3740)
95.7 (3.77)
95.4 (3.76)
Intake
mm (in.)
5.465 ~ 5.480 (0.2151 ~ 0.2157)
5.965 ~ 5.980
(0.2348 ~ 0.2354)
5.953 (0.234)
Exhaust
mm (in.)
5.458 ~ 5.470 (0.2149 ~ 0.2153)
5.950 ~ 5.965
(0.2343 ~ 0.2348)
5.925 (0.233)
mm (in.)
mm (in.)
45.25 ~ 45.75
1.02 (0.0401)
1.09 (0.0429)
45 ~ 45.5
1.0 (0.0394)
1.3 (0.0512)
44.5
1.6 (0.063)
1.3 (0.0512)
End play
0.020 ~ 0.057
0.040 ~ 0.074
(0.0008 ~ 0.0022) (0.0020 ~ 0.0029)
Valve
Valve length
Stem outer diameter

Face angle
(margin)
Exhaust
Valve stem to valve
guide clearance
Intake
0.020 ~ 0.050
mm (in.) 0.020 ~ 0.047 (0.00078 ~ 0.00185)
(0.0008 ~ 0.0020)
Exhaust
mm (in.) 0.030 ~ 0.054 (0.00118 ~ 0.00212)
0.022 ~ 0.067
(0.00086 ~
0.00263)
0.035 ~ 0.065
0.050 ~ 0.095
(0.0014 ~ 0.0026) (0.0020 ~ 0.0037)
MG-4
Valve guide
Inner diameter
Intake
mm (in.)
5.500~5.512 (0.2165 ~ 0.2170)
Exhaust
mm (in.)
Intake
mm (in.)
Length
43.8 ~ 44.2 (1.7244 ~ 1.7401)
6.000 ~ 6.015
(2.2362 ~ 2.2368)
45.8 ~ 46.2
(1.8031 ~ 1.8189)
46.8 ~ 47.2
(1.8425 ~ 1.8583)
36.5 (1.437)
Exhaust
mm (in.)
Intake
mm (in.)
1.16 ~ 1.46 (0.0457 ~ 0.0575)
1.21 (0.0477)
Exhaust
mm (in.)
1.35 ~ 1.65 (0.0531 ~ 0.0649)
1.61 (0.0634)
44.75 ~ 45.10
44 ~ 44.5
47.44 (1.8677)
46.8 (1.8425)
38.8 (1.527)
19.0 0.6kg / 35.0 (1.3779),

39.81.2kg / 26.0 (1.0236 )
18.4 ~ 20.3Kg
/ 35 (1.3779),
34.9 ~ 38.6Kg
/ 26.5 (1.0433)
21.25kg / 32
(1.26)
Less than 1.5
1.5 or less
Valve seat
Seat angle
Valve spring
Free length
Load
Out of squareness
mm (in.)
mm (in.)
MG-5

Engine
MLA
GSL 2.7
DSL D 2.0 VGT
mm (in.) 31.964 ~31.980 (1.2584 ~ 1.2591)
29.964 ~ 29.980
(1.1797 ~ 1.1803)
Cylinder head tappet bore inner diameter mm (in.) 32.000 ~ 32.025 (1.2598 ~ 1.2608)
30.000 ~ 30.025
(1.1811 ~ 1.1821)
MLA to tappet bore clearance
MLA outer diameter
GSL 2.0
GSL 2.4
mm (in.)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
0.020 ~ 0.061
(0.0008 ~ 0.0024)
Intake
mm (in.)
0.17 ~ 0.23
(0.0067 ~ 0.0090)
0.17 ~ 0.23
(0.0067 ~ 0.0090)
Exhaust
mm (in.)
0.27 ~ 0.33
(0.0106 ~ 0.0129)
0.27 ~ 0.33
(0.0106 ~ 0.0129)
Valve clearance
Cylinder block
Cylinder bore
mm (in.)
mm (in.)
Piston
86.00 ~ 86.03
88.00 ~ 88.03
86.70 ~ 86.73
(3.3858 ~ 3.3870) (3.4645 ~ 3.4657) (3.4134 ~ 3.4146)
Less than 0.05 (0.0020)
Less than
0.05 (0.0019)
83 + 0.03
(3.27 + 0.0012)
0.096 (0.00378)
for length
85.975 ~ 86.005 87.975 ~ 88.005

86.67 ~ 86.70
82.92 ~ 82.95
mm (in.) (3.3848 ~ 3.3860 (3.4636 ~ 3.4648
(3.4122 ~ 3.4134)
(3.26 ~ 3.27)
)
)
0.02 ~ 0.04
0.07 ~ 0.09
mm (in.) 0.015 ~ 0.035 (0.0028 ~ 0.0014)
(0.0008 ~ 0.0016) (0.0027 ~ 0.0036)
MG-6
Ring groove width
1.22 ~ 1.24 (0.0006 ~ 0.0488)
1.23 ~ 1.25
(0.0484 ~ 0.0492)
1.915 ~ 1.945
(0.075 ~ 0.076)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
2.06 ~ 2.08
(0.08 ~ 0.082)
Oil ring groove
mm (in.)
2.01 ~ 2.03 (0.0791 ~ 0.0799)
2.01 ~ 2.03
3.02 ~ 3.04
(0.0791 ~ 0.0799) (0.119 ~ 0.1196)
0.03 ~ 0.07 (0.0012~0.0028 )
0.03 ~ 0.07 (0.0012~0.0028 )
Oil ring groove
mm (in.)
0.06 ~ 0.15 (0.0024 ~ 0.0059)
0.15 ~ 0.30 (0.0059 ~ 0.0118)
0.30 ~ 0.45 (0.0118 ~ 0.0177)
Oil ring groove
0.20 ~ 0.70 (0.0078 ~ 0.0275)
Piston ring
Side clearance
End gap
mm (in.)
0.04 ~ 0.08
(0.0016 ~ 0.0031)
0.03 ~ 0.07
(0.0012 ~ 0.0027)
0.06 ~ 0.15
(0.0024 ~ 0.0059)
0.15 ~ 0.30
(0.0059 ~ 0.0118)
0.064 ~ 0.114
(0.0025~0.0045)
0.065 ~ 0.11
(0.0026~0.0043)
0.03 ~ 0.07
(0.0012~0.0028)
0.2 ~ 0.3
(0.0079~0.0118)
0.30 ~ 0.45
0.3 ~ 0.45
(0.0118 ~ 0.0177) (0.0118~0.0177)
0.20 ~ 0.70
0.2 ~ 0.45
(0.0078 ~ 0.0275) (0.0079~0.0177)
Piston pin
mm (in.) 21.001 ~ 21.006 (0.8268 ~ 0.8270 )
21.001 ~ 21.007
(0.8268 ~ 0.8270)
mm (in.)
21.016 ~ 21.021 (0.8274~0.8276 )
21.014 ~ 21.023
(0.8273 ~ 0.8277)
mm (in.)
0.010 ~ 0.020 (0.0004 ~ 0.0008 )
0.011 ~ 0.018
(0.0004 ~ 0.0007)
20.974 ~ 20.985
(0.8257 ~ 0.8262)
Connecting rod small end inner diameter mm (in.) 20.974 ~ 20.985 (0.8257 ~ 0.8262 )
MG-7

Engine
GSL 2.0
GSL 2.4
-
GSL 2.7
DSL D 2.0 VGT
0.016 ~ 0.033
(0.0006 ~ 0.0013)
51.000 ~ 51.018
(2.0079 ~ 2.0086)
Connecting rod
mm (in.) 51.000 ~ 51.018 (2.0079 ~ 2.0086)
mm (in.)
0.028 ~ 0.046 (0.0011 ~ 0.0018)
End play
mm (in.)
0.10 ~ 0.25 (0.0039 ~ 0.0098)
0.018 ~ 0.036
0.024 ~ 0.042
(0.0007 ~ 0.0014) (0.0009 ~ 0.0016)
0.1 ~ 0.25
(0.0039 ~ 0.0098)
Crankshaft
mm (in.) 51.942 ~ 51.960 (2.0449 ~ 2.0456)
61.982 ~ 62.000 60.002 ~ 60.020

(2.4402 ~ 2.4409) (2.362 ~ 2.363)
mm (in.) 47.954 ~ 47.972 (1.8879 ~ 1.8886)
47.982 ~ 48.000 50.008 ~ 50.026

(1.8891 ~ 1.8898) (1.9688 ~ 1.9695)
mm (in.)
0.026 ~ 0.049 (0.0010 ~0.0019)
0.004 ~ 0.022
0.024 ~ 0.042
(0.0002 ~ 0.0009) (0.0009 ~ 0.0016)
End play
mm (in.)
0.007 ~ 0.25 (0.0027 ~ 0.0098)
0.07 ~ 0.25
0.09 ~ 0.32
(0.0028 ~ 0.0098) (0.0035 ~ 0.0126)
kPa
(kg/cm)
Oil pump
490.33 ~ 588.40
(5.0 ~ 6.0)
570 50
(5.8 0.5)
MG-8
Cooling system
Cooling method
Coolant quantity
Thermostat
Opening
Full opening
temperature
Full lift
(lmp.qt)
C (F)

8.2~8.3
(7.22~7.30)
822
(179 635 6)
6.4~6.9 (5.631~6.07)
821.5 (179.6 34.7)
5 (4.4)
85 (185)
C (F)
95 (201)
95 (203)
100 (212)
mm (in.)
10 (0.3937)
or more
93.16 ~ 122.58(0.95 ~ 1.25)
93.16 ~ 122.58
(0.95 ~ 1.25 )
107.9 14.7
(1.10.15)
6.86 (0.07) or less
0.98 ~ 4.90
(0.01 ~ 0.05 )
-6.86
(-0.07)
Main valve
kPa
Radiator cap
Vacuum valve
kPa
Type
20C (68F)
k
Resistance
80C (176F)
k
Main moving system
Bolts
Crankshaft
Bolts (M10)
main bearing cap
Bolts (M8)
Thermister type
2.31 ~ 2.59
0,3222
19.6 (2.0) + 90
26.46 (2.7) + 45
-
19.6 (2.0) + 90
29.4 (3.0) + 90
15.7 (1.6) + 90
25 (2.5) + 90
-
Bolts (15mm)
28 ~ 35 (2.8 ~
3.5) + 120
Bolts (12mm)
33.7 ~ 37.7
(3.37 ~ 3.77)
Crankshaft bedplate
MG-9

Engine
Cylinder head
Camshaft bearing cap nuts

or bolts
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
Bolts
26.5 ~ 29.5
(2.65 ~ 2.95)
Bolts (M6)
10.78 ~ 12.74 (1.1 ~ 1.3)
10.8 ~ 12.7
(1.1 ~ 1.3)
Bolts (M8)
27.44 ~ 31.36 (2.8 ~ 3.2)
Cylinder head bolt
34.3 (3.5) + 90 +90
Lubrication system
Oil filter
20.6 ~ 25.5
(2.1 ~ 2.6)
24.5 (2.5)
+ 60 + 45
50 (5.0)
+ 120 + 120
11.76 ~ 15.68 (1.2 ~ 1.6)
Bolts
Bolts (M6)
Bolts (M8)
9.8 ~ 11.76 (1.0 ~ 1.2)

26.46 ~ 30.38 (2.7 ~ 3.1)
10 ~ 12 (1.0 ~
1.2)
-
Oil pan drain plug
34.3 ~ 44.1
(3.5 ~ 4.5)
35 ~ 45
(3.5 ~ 4.5)
Lower oil pan bolt
9.8 ~ 11.8
(1.0 ~ 1.2)
Oil pan nuts or bolts
MG-10

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
Spark plugs
Voltage
Amperage
Speed
Type
Rated voltage
V
A
Speed in use
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
resistance
Unleaded (NGK)
Unleaded (CHAMPION)
Unleaded
mm(in.)
(Gap)
12 V, 1.2 kW
12 V, 1.2 kW
11,5
11,5
90, MAX
90, MAX
2,600 rpm, MIN
2,600 rpm, MIN
13.5 V, 110A
13.5 V, 110A
1,000 ~18,000
1,000 ~18,000 rpm
rpm
14.2 ~ 14.8V
14.2 ~ 14.8V
MF 60AH
MF 68AH
MF 68AH
12V, 2.0KW
11
120, MAX
4,000rpm, MIN
12V, 120A
5,900 ~12,000
rpm
14.4 0.3V
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
0.62 10 %
0.715 0.015
7.0 15 %
BKR5ES-11
RC 10YC4
ILFR5B11
-
1.0 ~ 1.1 (0.0394 ~ 0.0433)
1.0 ~ 1.1
(0.0394 ~ 0.0433)
MG-11

Engine
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
Capacity
Type
Type
Type
Driven by
Fuel Pressure
(Maximum)
Fuel Pressure
Regulator
(lmp.qt
)
Pressure
MPa
(kgf/cm
)
kPa
Regulated Fuel
(kgf/cm
Pressure
)
Siemens
Delphi
62 (54.55)
Returnless type
High pressure type
Bosch
Return type
Built in
engine room
High Pressure
Fuel Pump
Electrical
Mechanical
In-tank type
Plunger Pumping
Type
Electric motor
Drive Belt
160 (1,632)
338~348 (3.45~3.55)
375 ~ 385
(3.82 ~ 3.92)
MG-12
Clutch
Clutch operation
Hydraulic type
Hydraulic type
Clutch disc
Single dry with

diaphragm
Single dry with

diaphragm

Service standard
Clutch pedal stroke
mm (in.)
mm (in.)
Diaphragm spring
strap
Self Adjusting
Clutch
Self Adjusting
Clutch
25~36 (2.5~3.6)
17~26 (1.7~2.6)
13~16 (1.3~1.6)
15~22 (1.5~2.2)
12~15 (1.2~1.5)
17~26 (1.7~2.6)
13~16 (1.3~1.6)
-
25~36 (2.5~3.6)
17~26 (1.7~2.6)
13~16 (1.3~1.6)
-
145 (5.70)
6~13 (0.24~0.51)
145 (5.70)
6~13 (0.24~0.51)
MG-13

Engine
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
M5GF1
3,636
2,056
1,333
0,971
0,775
3,455
4,333
M5GF2
3,267
1,794
1,552
1,176
0,974
3,416
4.333/3.250
M6GF2
3,615
1,794
1,542
1,176
0,974
0,829
3,416
4.063/2.955
SAE 75W/85,
API GL-4
Manual Transaxle
Type
Gear ratio
1st
2nd
3rd
4th
5th
6th
Rev.
FGR
M/T oil quality

(lmp.qt)
MT oil capacity
2.1 (1.85)
1.9 (1.67)
1.9 (1.67)
F4A42-2
2,842
1,529
1,000
0,712
2,480
4,042
A5GF1
3,789
2,064
1,421
1,034
0,728
3,808
3,311
A5GF1
3,789
2,064
1,421
1,034
0,728
3,808
3,311
F4A51-3
2,842
1,495
1,000
0,731
2,720
4,520
Automatic Transaxle
Type
Gear ratio
ATF quality
ATF capacity
1st
2nd
3rd
4th
5th
Rev.
FGR

(lmp.qt)
7.8 (6.86)
9.5 (8.36)
9.5 (8.36)
8.5 (7.48)
MG-14
Driveshaft
M/T
Joint type
A/T
Inner
Outer
Inner
Outer
Inner
Outer
Lubricants
Joint type
Recommended grease
Quantity
g
Front wheel bearing
Rear hub bearing assembly
[NOTE]
Hub nut
Driveshaft nut (Castle nut)
Lower arm ball joint assembly to knuckle bolts
Inner shaft bearing bracket
Wheel speed sensor bolt
Front caliper assembly to knuckle bolts
Tie rod end castle nut
UTJ-II#24
BJ#24
UTJ-II#24
BJ#24
UTJ-II#25
BJ#25
23
46.5
BJ#24
BJ#25
RBA
130
160
UTJ-II#24
UTJ#25
CW-13TJ
160
200
1.8 (0.18)
1.5 (0.15)
90 ~ 110 (9.0 ~ 11.0)

200 ~ 280 (20.0 ~ 28.0)
100 ~ 120 (10.0 ~ 12.0)
50 ~ 65 (5.0 ~ 6.5)
7 ~ 10 (0.4 ~ 1.0)
140 ~ 160 (14.0 ~ 16.0)
24 ~ 34 (2.4 ~ 3.4)
MG-15

Engine
Front strut assembly to knuckle bolts
Rear lower arm to carrier assembly bolts
Rear upper arm to carrier assembly bolts
Rear strut assembly to carrier assembly bolts
GSL 2.0
GSL 2.4
GSL 2.7
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
50 ~ 60 (5.0 ~ 6.0)
140 ~ 160 (14.0 ~ 16.0)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
70 ~ 90 (7.0 ~ 9.0)
DSL D 2.0 VGT
Suspension System
Front
MacPherson strut
Suspension type
Shock absorber type
Wheel size
Wheel alignment
Gas pressurized
6.0J 15", 6.5J 16"
6.5J 16", 6.5J 17"
205/65 HR15 [2.1 (30)]
205/60 HR16 [2.3 (33)]
215/50 VR17 [2.3 (33)]
Steel
Aluminum
kgf/cm 2
(psi)
Tire size [Tire pressure]

Camber
Caster
Toe-in
King-pin
mm (in.)
Rear
Multi link
-0.530'
4.7430'
02 (00.079)
13.130'
-130'
22(0.0790.079)
-
MG-16

Hub nuts
Rear shock absorber bracket to body
Rear upper arm to rear cross member
Rear lower arm to rear cross member
Rear assist arm to carrier
Rear assist arm to rear cross member
Rear stabilizer link to trailing arm
90 ~ 110 (9.0 ~ 11.0)

45 ~ 60 (4.5 ~ 6.0)
140 ~ 160 (14.0 ~ 16.0)
50 ~ 70 (5.0 ~ 7.0)
FR: 140 ~ 160 (14.0 ~ 16.0), RR: 100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
140 ~ 160 (14.0 ~ 16.0)
45 ~ 55 (4.5 ~ 5.5)
80 ~ 100 (8.0 ~ 10.0)
140 ~ 160 (14.0 ~ 16.0)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
MG-17

Engine
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
Steering System
Type
Quality
Quantity
Rack stroke
Steering angle
Inner
Outer
(lmp.qt)
mm (in.)
kPa
(kgf/cm
)

Rack and Pinion

PSF-4
1.0 (0.88)
140 (5.51)
39.52130'
32.17
8336 ~ 9022 (85 ~ 92)
40 ~ 50 (4.0 ~ 5.0)
13 ~ 18 (1.3 ~ 1.8)
18 ~ 28 (1.8 ~ 2.8)
30 ~ 35 (3.0 ~ 3.5)
24 ~ 34 (2.4 ~ 3.4)
17 ~ 26 (1.7 ~ 2.6), GSL -2.7I: 35 ~ 50 (3.5 ~ 5.0)
55 ~ 65 (5.5 ~ 6.5)
60 ~ 80 (6.0 ~ 8.0)
MG-18
Restraints
Type
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
Driver Airbag (DAB)
Bolt
Passenger Airbag
(PAB)
Nut
Side Airbag (SAB)
SRSCM Mounting Bolt
Depowered
1.5 ~ 6.0
1.5 ~ 4.5
1.5 ~ 4.5
1.5 ~ 4.5
1.5 ~ 4.5
7.9 ~ 10.8 (0.8 ~ 1.1)
18.6 ~ 26.5 (1.9 ~ 2.7)
8.8 ~ 13.7 (0.9 ~ 1.4)
10.9 ~ 14.7 (1.1 ~ 1.5)
4.9 ~ 6.9 (0.5 ~ 0.7)
39.2 ~ 53.9 (4.0 ~ 5.5)
10.2 ~ 13.8 (1.0 ~ 1.4)
10.2 ~ 13.8 (1.0 ~ 1.4)
10.2 ~ 13.8 (1.0 ~ 1.4)
MG-19

GSL 2.0
Engine
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
Piston stroke
Proportioning valve(CBS)
Cut-in pressure(Split point)
Decompression ratio
Brake booster
Type
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
Disc I.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
DOT 3
As required
mm (in.)
mm (in.)
Tandem type
23.81(0.937)
30 ~ 31 (1.18 ~ 1.22)
Provided
kPa
(kgf/cm
)
3.43 (35)
0.32 : 1
vacuum
9:1
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)

280 (11.02)
172 (6.77)
26 (1.02)
11 (0.43)
Single piston
57.2 (2.25)
MG-20
Rear brake(Disc)
Type
262 (10.31)
mm (in.)
Disc O.D.
185 (7.28)
mm (in.)
Disc I.D.
10 (0.39)
mm (in.)
Disc thickness
15 (0.59)
mm (in.)
Pad thickness
Single piston
Cylinder type
34 (1.34)
mm (in.)
Cylinder I.D
Parking brake
DIH(Drum in hat)
Type
Lever
Actuation
186 (6.61)
mm (in.)
Drum I.D.
[NOTE]
O.D=Outer Diameter
I.D=Inner Diameter
CBS : Conventional Brake System
HECU
System
0.4 ~ 1.5 (0.016 ~ 0.059)
mm(in.)
Air gap
Acitve wheel speed
48
sensor
teeth
Tone wheel
Service standard
171 (6.73)
mm (in.)
LHD
Brake pedal height
189.2 (7.45)
mm (in.)
RHD
128 (5.04)
mm (in.)
Brake pedal stroke
76.2 2 (3.0 0.08)
mm (in.)
Adjust Brake pedal stroke
MG-21

Engine
mm (in.)
stopper clearance
mm (in.)
mm (in.)
piston
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Rear brake lining thickness
Bleeder screw
Brake pedal member assembly bracket mounting
nut (cowl side upper mounting)
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
0.5 ~ 1.0 (0.02 ~ 0.04)

3 ~ 8 (0.11 ~ 0.31)
8 clicke
11 (0.43)
26 (1.02)
15 (0.59)
10 (0.39)
4.3 (0.17)
34.3 ~ 53.9 (3.5 ~ 5.5)
7.9 ~ 11.8 (0.8 ~ 1.2)
12.7 ~ 15.7 (1.3 ~ 1.6)
6.9 ~ 12.7 (0.7 ~ 1.3)
13.7 ~ 16.6 (1.4 ~ 1.7)
21.6 ~ 31.4 (2.2 ~ 3.2)
78.5 ~ 98.1 (8.0 ~ 10.0)
24.5 ~ 29.4 (2.5 ~ 3.0)
16.7 ~ 25.5 (1.7 ~ 2.6)
24.5 ~ 34.3 (2.5 ~ 3.5)
MG-22

wheel speed sensor mounting bolt
HECU union screw
HECU bracket mounting nut
Yaw rate Lateral G sensor mouning bolt
7.9 ~ 9.8 (0.8 ~ 1.0)

6.9 ~ 10.8 (0.7 ~ 1.1)
16.7 ~ 25.5 (1.7 ~ 2.6)
11.8 ~ 15.7 (1.2 ~ 1.6)
5.9 ~ 9.8 (0.6 ~ 1.0)
4.9 ~ 7.8 (0.5 ~ 0.8)

Hood
Front door
Rear door
Trunk lid
Glass thickness
Seat belts
Type
Construction
Regulator system
Locking system
Construction
Regulator system
Locking system
Type
mm (in.)
Windshield
mm (in.)
Front door
mm (in.)
Rear window
Front
Rear

X-ARM type
Pin-fork system
X-ARM type
Pin-fork system
5 (0.1969)
4 (0.1575)
4 (0.1575)
3.5 (0.1378)
3 point type with Emergency Locking Retractor (E.L.R), 2pont type
MG-23

Engine
Door hinge to body
Door hinge to door
Striker
Checker to body
Checker to door
Trunk lid
Trunk lid latch
Hood hinge to body
Hood
Hood hinge to hood
Hood latch to body
Front seat mounting
Seat
Rear seat mounting
Front seat belt height
Front seat belt buckle
Front seat belt anchor
Seat belt
Front seat belt lower
Front seat belt upper
Rear seat belt anchor
Rear seat belt retractor
GSL 2.0
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.2~2.7)
16.7~21.6 (1.7~2.2)
16.7~21.6 (1.7~2.2)
6.9~10.8 (0.7~1.1)
6.9~8.8 (0.7~0.9)
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.2~2.7)
6.9~10.8 (0.7~1.1)
34.3~53.9 (4.0~5.5)
23.5~35.3 (2.4~3.6)
16.7~25.5 (1.7~2.6)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
MG-24

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
The others
FM
AM
Frequency range /
FM
Channel space
MW
LW
Items
Life of battery
Button
AM/FM/Cassette AM/FM/Cassette
AM/FM/Cassette/6CDC (M465)
(M420/M440)
/MP3 (M455)
DC 14.4V
Max 50W x 4
Max 43W x 4
10 x 4
4 x 4
80PF 75
-
External amp,
woofer speaker

87.5 ~ 108.0 MHz/50 KHz (Europe)
Transmitter(TX)
10m or more
433.92 MHz
MG-25

GSL 2.0
Engine
Lighting system
Head lamp
High
Low

Front position lamp
Side repeater lights
Front fog lamp
Rear tail/stop lamp (Outside)
Rear tail lamp (Inner) - General
Back up lamp
License plate lamp
Side repeater
Room lamp
Luggage lamp
Door courtesy lamp
Other system
Type
Immobilizer
Manufacturer
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
GSL 2.4
GSL 2.7
DSL D 2.0 VGT
55
55
21
5
5
51
21/5
8
16
21
21
5
5
10
10 x 2
16
5
5
SMARTRA system
Bosch
3 channel
MG-26

Air conditioner
Compressor
Condeser
APT
(A/C pressure
Expansion valve
Refrigerant
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
the pressure
Type
Type
Capacity
oz.(g)
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
method
Evaporator
A/C ON/OFF ()
VS
FD46XG (PAG) , 150 10cc
6PK - TYPE
180 cc/rev
14800 - 5% Kcal/hr
Block
R - 134a
17.6 0.88(500 25)
Actuator
Siroco
Auto + 8speed (Autometic) , 1~8 speed (Manual)
Particle filter
Pin & Tube type
4,300 5% Kcal/hr
Actuator
Actuator
OFF : 3.0 0.5 (37.4 32.9)
ON : 5.0 0.5 (41 32.9)
MG-27
Opirus(GH)
F/L
GH-2
GH-9
GH-10
Fuel System..
GH-11
Automatic Transaxle
GH-11
Driveshaft..
GH-13
Suspension System.
Steering System GH-15
GH-16
Brake System
Body (Interior & Exterior). GH-19
GH-22
Heating, Ventilation & Air Conditioning..GH-24
GH-1
General specifications - Opirus F/L

Engine
GSL 3.8
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
V-type, DOHC
6
96 (3.7795) x 87.0 (3.425)
3,778
10.4 : 1
1-2-3-4-5-6
BTDC 10 5
650 100
650 100
650 100
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, 110C(230F)]
GH-2
Valve timing
Intake valve
Exhaust valve
Opens (ATDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
Cylinder head
Intake
mounting surface
Exhaust
Camshaft
Intake
Cam height
Exhaust
10
62
42
6
mm (in.)
mm (in.)
mm (in.)
Less than 0.05 (0.0019)

Less than 0.1 (0.0039)
Less than 0.1 (0.0039)
mm (in.)
mm (in.)
46.8 (1.8425)
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)
mm (in.)
No.1 : 0.020 ~ 0.057 (0.0008 ~ 0.0022)

No.2,3,4 : 0.030 ~ 0.067 (0.0012 ~ 0.0026)
End play
mm (in.)
0.02 ~ 0.18 (0.0008 ~ 0.0071)
GH-3

Engine
Valve
Valve length
Stem outer diameter
Face angle
(margin)
Valve stem to valve
guide clearance
Valve guide
Inner. diameter
Length
GSL 3.8
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
105.27 (4.1445)
105.50 (4.1535)
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)
1.73 ~ 2.03 (0.06811 ~ 0.07992)
0.020~0.047 (0.00078 ~0.00185)
0.030 ~ 0.054 (0.00118 ~0.00212)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
5.500 ~ 5.512 (0.2165 ~ 0.2170)

5.500 ~ 5.512 (0.2165 ~ 0.2170)
41.8 ~ 42.2 (1.6457 ~ 1.6614)
41.8 ~ 42.2 (1.6457 ~ 1.6614)
Intake
Exhaust
mm (in.)
mm (in.)
1.15 ~ 1.45 (0.05118~0.05709)

1.35 ~ 1.65 (0.05315~0.06496)
44.75 ~ 45.20
Valve seat
Seat angle
GH-4
Valve spring
Free length
mm (in.)
43.86 (1.7267)
Load
mm (in.)
19.30.8kg / 34.0(1.3386)
42.31.3kg / 24.2 (0.9527)
Out of squareness
MLA
MLA outer diameter
Less than 1.5
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Cylinder head tappet

bore inner diameter
MLA to tappet bore
clearance
Valve clearance
Intake
Exhaust
Cylinder block
Cylinder bore
Piston
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
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)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
mm (in.)
mm (in.)
0.17 ~ 0.23 (0.0067 ~ 0.0090)

0.27 ~ 0.33 (0.0106 ~ 0.0129)
mm (in.)
mm (in.)
96.00 ~ 96.03 (3.7795 ~ 3.7807)

Less than 0.05 (0.0019) [Less than 0.02 (0.0008) / 150x150]
mm (in.)
mm (in.)
95.96 ~ 95.99 (3.7779 ~ 3.7791)

0.03 ~ 0.05 (0.0012 ~ 0.0020)
GH-5

Engine
Ring groove width

Oil ring groove mm (in.)
GSL 3.8
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
2.01 ~ 2.03 (0.0791 ~ 0.0799)
-

0.03 ~ 0.07 (0.0012 ~ 0.0027)

0.03 ~ 0.07 (0.0012 ~ 0.0027)
0.06 ~ 0.15 (0.0024 ~ 0.0059)
0.17 ~ 0.32 (0.0067 ~ 0.0126)
0.32 ~ 0.47 (0.0126 ~ 0.0185)
0.20 ~ 0.70 (0.0078 ~ 0.0275)
Piston OS
Piston ring
Side clearance
End gap
Piston pin
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
23.001 ~ 23.006 (0.9055 ~ 0.9057)

23.016 ~ 23.021 (0.9061 ~ 0.9063)
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
Connecting rod
End play
Crankshaft
End play
Oil pump
mm (in.)
mm (in.)
mm (in.)
58.000 ~ 58.018 (2.2834 ~2.2842)

0.038 ~ 0.056 (0.0015 ~ 0.0022)
0.1 ~ 0.25 (0.0039 ~ 0.0098)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
68.942 ~ 68.960 (2.7142 ~ 2.7149)

54.954 ~ 54.972 (2.1635 ~ 2.1642)
0.022 ~ 0.040 (0.0008 ~ 0.0016)
0.10 ~ 0.28 (0.0039 ~ 0.0110)
kPa
(kg/cm)
450 ~ 550 (4.59 ~ 5.61)
Cooling system
Cooling method
Coolant quantity
Thermostat
Radiator cap
(lmp.qt)
C (F)
C (F)
mm (in.)
Opening
Pull opening
Full lift
Main valve
kPa
Vacuum valve
kPa
8.7 (7.66)
82 2 (179.6 35.6)
95 (203)
10 (0.3937)
93.16 ~ 122.58 (0.95 ~ 1.25)
0.98 ~ 4.90 (0.01 ~ 0.05)
GH-7

Engine
Type
20C (68F)
Resistance
80C (176F)
Main moving system
Inner bolt (M11)
Crankshaft main
Out bolt (M8)
bearing cap
Side bolt (M8)
Cylinder head
Long bolts
Cylinder head bolt
Short bolts
Lubrication system
Oil filter cap
Oil pan drain plug
Lower oil pan bolt
GSL 3.8
k
k
Thermister type
2.31 ~ 2.59
0,3222
19.60 (2.0) + 90
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)
39.2 (4.0) + 120 + 90
18.62 ~ 23.52 (1.9 ~ 2.4)
24.50 (2.5)
34.30 ~ 44.10 (3.5 ~ 4.5)
9.80 ~ 11.76 (1.0 ~ 1.2)
GH-8

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
Spark plugs
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
amparage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
resistance
Unleaded (NGK)
12 V, 1.2 kW
11,5
Max. 85
2,600 rpm, MIN
13.5V, 130A
1,000 ~ 18,000 rpm
14.2 ~ 14.8V
CMF 80AH
630 A
130 min
1.280 0.01
0.62 10 %
7.0 15 %
IFR5G-11
1.0 ~ 1.1 (0.0394 ~ 0.0433)
GH-9

Engine
GSL 3.8
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Type
Driven by
MPa
(kgf/cm
)
kPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
Delphi
70 (61.59)
Returnless type
High pressure type
Electrical
In-tank type
Electric motor
375 ~ 385 (3.82 ~ 3.92)
GH-10
Automatic Transaxle
Type
A5HF1
3,840
2,092
1,440
1,048
0,728
3,859
3,333
1st
2nd
3rd
4th
5th
Rev.
FGR
Gear ratio
ATF quality
ATF capacity

(lmp.qt)
10.9 (9.59)
Driveshaft
Driveshaft
Center bearing
Front wheel
bearing
Joint type
Max.
Permissible
angle
Type
Dimension
Inner
Outer
Inner
Outer
Inner
Outer
Type
Dimension
Inner
Outer
AARi
UFi
26
50
Radial ball bearing
30 mm (1.18 in.)
62 mm (2.44 in.)
Double row angular contact ball bearing
45 mm (1.77 in.)
87 mm (3.43 in.)
GH-11

GSL 3.8
Engine
28 (0.18 )
Front wheel bearing
[NOTE]
UFi : Under Cut Free improved (GKN)
AARi : Angular Adjusted Roller improved (GKN)
90 ~ 110 (9 ~ 11)
Wheel nut
200 ~ 280 (20 ~ 28)
Driveshaft castle nut
35 ~ 45 (3.5 ~ 4.5)
Front upper arm to self locking nut
140 ~ 160 (14 ~ 16)
Front subframe mounting bolt
60 ~ 80 (6 ~ 8)
Front shock absorber lower mounting to bolt
140 ~ 160 (14 ~ 16)
Front lower arm connector nut (to fork)
100 ~ 120 (10 ~ 12)
Lower arm and ball joint
75 ~ 90 (7.5 ~ 9.0)
Lower arm ball joint self locking nut
24 ~ 34 (2.4 ~ 3.4)
Tie rod end self locking nut
100 ~ 120 (10 ~ 12)
Stabilizer link self locking nut
45 ~ 55 (4.5 ~ 5.5)
Stabilizer link mouning nut
60 ~ 70 (6 ~7)
Hub assembly
7 ~11 (0.7 ~ 1.1)
Wheel speed sensor
80 ~ 100 (8 ~ 10)
5 ~ 6 (0.5 ~ 0.6)
Rear brake disc
140 ~ 160 (14 ~ 16)
Rear lower arm to knuckle
50 ~ 60 (5 ~ 6)
Rear Brake caliper to knuckle bolt
80 ~ 90 (8 ~ 9)
Rear upper arm to carrier self locking nut
GH-12
Rear axle mounting bolt

Inner shaft heat cover mounting bolt
Inner shaft bearing bracket mounting bolt
60 ~ 70 (6 ~ 7)
9 ~ 14 (0.9 ~ 1.4)
50 ~ 65 (5 ~ 6.5)
Suspension System
Front
Double wishbone
Suspension type
Shock absorber type
Wheel size
Gas pressurized
6.5J 17"
235/55 R17
Steel
Aluminum
Tire size
Tire pressure
Camber
Caster
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Mounting fork to lower arm
Front strut assembly to mounting fork
Front upper arm to body
Front upper arm to knuckle
Rear
Multi link
2
2.1kgf/cm , (30psi)
-30'30'
432'45'
02 (00.079)
943'
-130'
22 (0.0790.079)
90 ~ 110 (9.0 ~ 11.0)
45 ~ 60 (4.5 ~ 6.0)
140 ~ 160 (14.0 ~ 16.0)
60 ~ 80 (6.0 ~ 8.0)
100 ~ 120 (10.0 ~ 12.0)
20 ~ 25 (2.0 ~ 2.5)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
55 ~ 65 (5.5 ~ 6.5)
35 ~ 45 (3.5 ~ 4.5)
GH-13

Engine
Rear upper arm to cross member
Assist arm to carrier
Assist arm to cross member
Rear stabilizer link to carrier
Rear cross member mounting bolts
GSL 3.8
100 ~ 120 (10.0 ~ 12.0)
45 ~ 55 (4.5 ~ 5.5)
50 ~ 65 (5.0 ~ 6.5)
140 ~ 160 (14.0 ~ 16.0)
20 ~ 25 (2.0 ~ 2.5)
80 ~ 90 (8.0 ~ 9.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
140 ~ 160 (14.0 ~ 16.0)
140 ~ 160 (14.0 ~ 16.0)
35 ~ 45 (3.5 ~ 4.5)
35 ~ 45 (3.5 ~ 4.5)
45 ~ 55 (4.5 ~ 5.5)
140 ~ 160 (14.0 ~ 16.0)
GH-14
Steering System
Type
Rack stroke
Steering angle
mm (in.)
Inner
Outer
kPa
(kgf/cm
)

Power steering pump mounting bolts
Rack and Pinion

PSF-4
144 (5.67)
36.9130'
30.27
9807 ~ 10199 (100 ~ 104)
40 ~ 50 (4.0 ~ 5.0)
13 ~ 18 (1.3 ~ 1.8)
15 ~ 20 (1.5 ~ 2.0)
30 ~ 35 (3.0 ~ 3.5)
24 ~ 34 (2.4 ~ 3.4)
60 ~ 80 (6.0 ~ 8.0)
55 ~ 65 (5.5 ~ 6.5)
35 ~ 55 (3.5 ~ 5.5)
GH-15

GSL 3.8
Engine
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
Piston stroke
Brake booster
Type
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
mm (in.)
mm (in.)
DOT 3 or DOT 4
As required
Tandem type
25.4 (1.0)
30 ~ 32 (1.18 ~ 1.26)
Provided
vacuum
9:1
mm (in.)
mm (in.)
mm (in.)
mm (in.)

303 (11.93)
28 (1.10)
11 (0.43)
Single piston
60 (2.36)
GH-16
Rear brake(Disc)
Type
284 (11.18)
mm (in.)
Disc O.D.
10 (0.39)
mm (in.)
Disc thickness
10 (0.39)
mm (in.)
Pad thickness
Single piston
Cylinder type
34 (1.34)
mm (in.)
Cylinder I.D
Parking brake
Type
Foot Type
Actuation
190 (7.48)
mm (in.)
Drum I.D.
O.D=Outer Diameter
I.D=Inner Diameter
Acitve wheel speed
47
teeth
Tone wheel
sensor
Service standard
193.5 (7.62 )
mm (in.)
Brake pedal height
126.7 3 (4.99 0.12)
mm (in.)
63.6 2 (2.50 0.08)
mm (in.)
3 ~ 8 (0.11 ~ 0.31)
mm (in.)
1.2 ~ 1.8 (0.05 ~ 0.07)
mm (in.)
stopper clearance
GH-17

Engine
mm (in.)
piston clearance
Parking brake pedal stroke when stroke
mm (in.)
assembly is pushed with 196N (20kgf,
44lb force)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Bleeder screw
brake plate
HECU mounting bolt
GSL 3.8
0 (at 500 mmHg)
88 ~ 98 (3.46 ~ 3.86)
11 (0.43)
28 (1.10)
10 (0.39)
10 (0.39)
4.3 (0.17)
8 ~ 12 (0.8 ~ 1.2)
13 ~ 16 (1.3 ~ 1.6)
7 ~ 13 (0.7 ~ 1.3)
13 ~ 17 (1.3 ~ 1.7)
80 ~ 100 (8 ~ 10)
25 ~ 30 (2.5 ~ 3.0)
22 ~ 32 (2.2 ~ 3.2)
8 ~ 10 (0.8 ~ 1.0)
13 ~ 16 (1.3 ~ 1.6)
25 ~ 35 (2.5 ~ 3.5)
8 ~ 10 (0.8 ~ 1.0)
8 ~ 10 (0.8 ~ 1.0)
GH-18

HECU port
17 ~ 26 (1.7 ~ 2.6)
12.2 ~ 16.3 (1.22 ~ 1.63)
8 ~ 10 (0.8 ~ 1.0)
26 ~ 30 (2.6 ~ 3.0)

Hood
Front door
Rear door
Trunk lid
Glass thickness
Seat belts
Type
Construction
Regulator system
Locking system
Construction
Regulator system
Locking system
Type
mm (in.)
Windshield
mm (in.)
Front door
Rear door fixed mm (in.)
mm (in.)
Rear window
Front

X-ARM type
Pin-fork system
X-ARM type
Pin-fork system
5 (0.1969)
5 (0.1969)
5 (0.1969)
4 (0.1575)
3.5 (0.1378)
GH-19

Engine
Mounting bolts
Hinge nuts(Body side)
Hinge bolts(Hood side)
Lifter bracket bolts
(Body side)
Front fender
Lifter stud ball(Hood side
Safety hook & Release
lever bolts
Safety hook catch bolts
Hood latch bolts
Hinge bolts(Door side)
Checker bolts(Body
Checker nuts(Door side)
Door module bolts
Door module nuts
Glass bolts
Glass grip bolts
Outer handle bolts
Latch screws
Striker screws
Glass guide bolt
GSL 3.8
7~9 (0.7~0.9)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
35~42 (3.5~4.2)
10~20 (1.0~2.0)
17~22 (1.7~2.2)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~22 (0.7~2.2)
7~11 (0.7~1.1)
GH-20

Latch bolts
Trunk lid
Striker bolts
Outer handle bolts
Hinge bolts(Trunk lid side
Crash pad
Mounting bolts
Mounting boltsCowl cross bar
Mounting boltsLower(M8)
Front bumper
Reinforcement nuts
Rear bumper
Mounting bolts
Mounting nuts
Front seat
Front seat mounting
Cushion bolts
(Power seat)
Rear seat
Seatback bolts
Frame bolts(Power
Frame nuts(Power seat)
Sunroof
Glass mounting screws
Mounting bolts and nut
Upper anchor bolt
Seat belt
Lower anchor bolt
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
7~11 (0.7~1.1)
33~55 (3.3~5.5)
17~26 (1.7~2.6)
9~14 (0.9~1.4)
35~55 (3.5~5.5)
45~55 (4.5~5.5)
45~55 (4.5~5.5)
17~26 (1.7~2.6)
17~26 (1.7~2.6)
17~26 (1.7~2.6)
17~26 (1.7~2.6)
2~4 (0.2~0.4)
7~9 (0.7~0.9)
40~55 (4.0~5.5)
40~55 (4.0~5.5)
GH-21

GSL 3.8
Engine

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
FM
AM
Frequency range /
FM
Channel space
MW
LW
Items
Life of battery
Button
Lighting system
High
Head lamp
Low
H285
H295
DC 14.4V
Max 20W x 4
4 x 4
Max 35W x 6
2 x 6
80PF 75
87.5 ~ 108.0 MHz/50 KHz (Europe)
Transmitter(TX)
10m or more
433.92 MHz
W
W
W
55
35
14.5 (LED) / 5 (BULB)
GH-22
Front position lamp

Front fog lamp
Back up lamp
Rear fog lamp
License plate lamp
Side repeater
Room lamp
Glove box lamp
Trunk lamp
Other system
Type
Immobilizer
Manufacturer
Type
Smart key
Manufacturer
W
W
W
W
W
W
W
W
W
W
W
W
W
5
55
27/8
18
28
5
5
5
10
5
2.5 (LED)
5
5
SMARTRA system
Bosch
Touch sensor type (Front door)
SIEMENS
Front 4 channel/ Rear 4 channel
GH-23

GSL 3.8
Engine

Air conditioner
Compressor
Condeser
APT
(A/C pressure
Expansion valve
Refrigerant
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
the pressure
Type
Type
oz.(g)
Capacity
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
VS16
FD46XG (PAG) , 150 10cc
6PK - TYPE
180 cc/rev
15,000 - 5% Kcal/hr
Block
R - 134a
22.9 0.88 (650 25)
Actuator
Siroco fan
Auto + 8 speed (Autometic)
Power mosfet
Particle filter
GH-24

Type
Heating capacity
Heater
Type
Evaporator
C (F)
A/C ON/OFF
Pin & Tube type

4,058 5% Kcal/hr
Actuator
Actuator
Laminated type
Evaporator sensor
OFF : 0.5 0.5 (32.9 32.9)
ON : 3.0 0.5 (37.4 32.9)
GH-25
Soul (AM)
AM-2
AM-9
AM-10
Fuel System..
AM-10
Clutch.
AM-11
Manual Transaxle.
AM-11
Automatic Transaxle
AM-12
Driveshaft..
AM-13
Suspension System.
Steering System AM-15
RestraintsAM-16
AM-17
Brake System
Body (Interior & Exterior). AM-21
AM-22
Heating, Ventilation & Air Conditioning..AM-26
AM-1
General specifications - SOUL

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
In-line, DOHC
4
77 (3.0315)
x 85.44 (3.3638)
1.591
10.5:1
1-3-4-2
BTDC 6 10
660 100
660 100
660 100
690 100
In-line, DOHC
4
82mm (3.228in)
x 93.5mm (3.681in)
1975cc (120.52cu.in)
10.1 : 1
1-3-4-2
BTDC 5 10
660 100 rpm
660 100 rpm
660 100 rpm
660 100 rpm
In-line, DOHC
4
77.2 (3.0394)
x 84.5 (3.3268)
1.582
17.3 : 1
1-3-4-2
850 100(830 100 MT)
850 100
850 100(830 100 MT)
850 100
3.7 (3.26)
3.0 (2.64)
3.3 (2.90)
4.1 (3.60 )
3.7 (3.26 )
4.0 (3.52)
5.7 (5.02)
4.8 (4.22 )
5.3 (4.66)
Engine
Type
Number of cylinders
Bore x Stroke
mm (in.)
Total displacement
Compression ratio
Firing order
Ignition Timing
Idle Speed
cc
A/C
OFF
Neutral,N,P-range
D-range
Neutral,N,P-range
A/C ON D-range
rpm
rpm
rpm
rpm
Engine oil
Oil quantity
(lmp.qt)
Total
(lmp.qt)
Oil pan
Drain and refill (lmp.qt)
API SL, SM or above

API SL, SM or above
ILSAC GF3, GF4 or above ILSAC GF3, GF4 or above
Oil quality
kPa
(kg/cm)
Oil pressure
107kPa
(1.1kg/cm, 15.6psi)
or above
100kPa (1.0kg/cm, 14.5psi)/at

800rpm
ATDC 10/BTDC 40
ATDC 11 ~ BTDC 29
ABDC 63/ABDC 13
ABDC 59 ~ ABDC 19
With CPF: ACEA C3

Without CPF: ACEA B4
78.45kPa
(0.8kg/cm, 11.38psi)
or above
Valve timing
Intake valve
Exhaust valve
Opens (ATDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
BBDC 40
Opens (BBDC)
ATDC 3
Closes (ATDC)
175' 4
146' 4
2325' 4
20 4
AM-2
Cylinder head
Flatness of manifold mounting

surface
mm (in.)
Less than 0.05 (0.0020)
Intake
mm (in.)
Exhaust
mm (in.)
Max:0.03mm
0.05 (0.0020in) for all
(0.0012in)Limit:0.06mm(0.0 0.03 (0.0012in) for each
024in)
cylinder
0.025 (0.0010) for width
Max:0.15mm
0.160 (0.0063) for length
(0.0059in)Limit:0.03mm(0.0
0.025 (0.0010) for width
012in)
0.160 (0.0063) for length
Camshaft
LH : 35.452 ~ 35.652
(1.3957 ~ 1.4036)
RH : 35.537 ~ 35.737
(1.3991 ~ 1.4070)
LH : 35.700 ~ 35.900
(1.4055 ~ 1.4134)
RH : 35.452 ~ 35.652
(1.3957 ~ 1.4036)
20.944 ~ 20.960
(0.8246 ~ 0.8252)
Intake
mm (in.)
43.85 (1.7264)
44.618mm (1.7566in)
Limit:44.518mm(1.7527in)
Exhaust
mm (in.)
42.85 (1.6870)
44.518mm (1.7527in)
Limit:44.418mm (1.7487in)
mm (in.)
22.964 ~ 22.980
(0.9041 ~ 0.9047)
28 (1.1023)
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)
End play
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)
Cam height
AM-3

Engine
Valve
Valve length
GSL 1.6
GSL 2.0
DSL U 1.6
Intake
Exhaust
mm (in.)
mm (in.)
93.15 (3.6673)
92.6 (3.6457)
114.34 (4.5016)
116.8 (4.598)
93.0 (3.6614)
93.7 (3.6890)
Intake
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)
Exhaust
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 ~ 4530'
45.5 ~ 45.75
Stem outer diameter

Face angle
Intake
mm (in.)
1.1 (0.0433)
1.60.15(0.06300.0059)
1.1 (0.0433)
Exhaust
mm (in.)
1.26 (0.0496)
1.80.15(0.07090.0059)
1.2 (0.0472)
Intake
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)
Exhaust
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)
Intake
mm (in.)
5.500 ~ 5.512
(0.2165 ~ 0.2170)
Exhaust
mm (in.)
5.500 ~ 5.512
(0.2165 ~ 0.2170)
Intake
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)
Exhaust
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)
Thickness of valve head (margine)
Valve stem to valve guide clearance

Valve guide
Inner diameter
Length
AM-4
Valve seat
Intake
mm (in.)
Exhaust
mm (in.)
1.1 ~ 1.5 (0.043 ~ 0.059)
0.8 ~ 1.4(0.0315~0.0551)
1.3 ~ 1.7 (0.051 ~ 0.066)
1.2 ~ 1.8(0.0472~0.0709)
45 ~ 4530'
44.0mm (1.7323)
48.86mm (1.9236)
44.9mm (1.7677)
18.80.9kg/39.0(41.42.0lb/1.5
354in)
41.01.5kg/30.5(90.43.3lb/1.2
008in)
17.50.9kg/32.0(1.2598)
31.01.6kg/23.5(0.9252)
Less than 1.5
1.5 or less
Less than 1.5
mm (in.)
mm (in.)
mm (in.)
mm (in.)
0.20 (0.0079)
0.29 (0.0114)
0.28 (0.0110)
0.34 (0.0134)
Cylinder bore
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)

Piston
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)
No. 1 ring groov mm (in.)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
1.23 ~ 1.25mm
1.83 ~ 1.85
(0.0720 ~ 0.0728)
1.22 ~ 1.24
(0.0480 ~ 0.0488)
1.22 ~ 1.24mm
1.82 ~ 1.84
(0.0717 ~ 0.0724)
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)

Seat angle
Valve spring
Free length
mm (in.)
Load
mm (in.)
Out of squareness
Valve clearance
Intake
Exhaust
20C[68F]
80C[176F]
20C[68F]
80C[176F]
Cylinder block
Ring groove width
Piston OS
AM-5

Engine
Piston ring
GSL 1.6
GSL 2.0
DSL U 1.6
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.04 ~ 0.08
(0.0015 ~ 0.0031)
0.09 ~ 0.13
(0.0035 ~ 0.0051)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.03 ~ 0.07
(0.0012 ~ 0.0027)
0.08 ~ 0.12
(0.0031 ~ 0.0047)
0.06 ~ 0.15
(0.0024 ~ 0.0059)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.14 ~ 0.28
(0.0055 ~ 0.0110)
0.20 ~ 0.35
(0.0079 ~ 0.0138)
0.20 ~ 0.35
(0.0079 ~ 0.0138)
0.30 ~ 0.45
(0.0118 ~ 0.0177)
0.37 ~ 0.52
(0.0146 ~ 0.0205)
0.35 ~ 0.50
(0.0138 ~ 0.0197)
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)
Side clearance
End gap
Piston pin
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)
Side clearance
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)
End play
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)
Flywheel
Runout
Oil pump
mm (in.)
0.1 (0.0039)
0.1 (0.0039)
kPa
(kg/cm)
49049.0 (50.5)
Connecting rod
Crankshaft
AM-7

Engine
Cooling system
Cooling method
Coolant quantity
Thermostat
Radiator cap
Opening
Pull opening
(lmp.qt)
C (F)
C (F)
GSL 1.6
GSL 2.0
DSL U 1.6

water pump

electrical fan

water pump
6.5(5.71)
82 1.5 (179.6 2.7)
95 (203)
7.2liter (7.6U.S qts,

6.3lmp.qts)
82C (177F)
95C (201F)
93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm, 13.51 ~
17.78psi)
7.2 (6.33)
85 1.5 (185.0 2.7)
100 (212)
Main valve
kPa
93.16 ~ 122.58
(0.95 ~ 1.25)
Vacuum valve
kPa
MAX. 6.86 (0.07)
MAX. 6.86 (0.07)
MAX. 6.86 (0.07)
Thermister type
Heat-sensitive thermistor
type
Thermister type
2.45 0.14
0,3222
2.31 ~ 2.59k
0.3222k
2.45 0.14
0,3222
17.7~21.6+ 902
(1.8~2.2+902)
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)

18.6 ~ 22.6(1.9 ~ 2.3)
13.7 ~ 14.7 (1.4 ~ 1.5)
mark 9/10 : 12.7 ~ 14.7

(1.3 ~ 1.5)
93.16 ~ 122.58
(0.95 ~ 1.25)

Type
Resistance
20C (68F)
80C (176F)
k
k

Main moving system
Crankshaft
main bearing cap
Cylinder head
Camshaft bearing
cap nuts or bolts
Bolts
Long bolts
Short bolts
M6
M8
AM-8
Long bolts
17.7 ~ 21.6 (1.8 ~ 2.2)
+ 90 ~ 95 + 100 ~105
Cylinder head bolt

Short bolts
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
(47.1~51.0) +
(88~92) + (118~122)
Lubrication system
Oil filter
11.8 ~ 15.7 (1.2 ~ 1.6)
11.8 ~ 15.7 (1.2 ~ 1.6)
Oil filter upper cap :

25(2.5)
Oil pan bolts

Oil pan drain plug
9.8 ~ 11.8 (1.0 ~ 1.2)

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

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

34.3 ~ 44.1 (3.5 ~ 4.5)
12.V, 0.9 kW
11,5
60 MAX
5.500 rpm, MIN
13.5 V, 90A
1,000 ~ 18,000 rpm
14.55 0.2 V
36-20GL
12 V, 1.2 Kw
11
90 MAX
2,800 rpm, MIN
13.5 V, 90A
1,000 ~ 18,000 rpm
14.55 0.2 V
48-23GL
12 V, 1.7 kW
11
90 MAX
2,600 rpm, MIN
12 V, 120A
1,000 ~ 18,000 rpm
14.55 0.2 V
56-26 FL
410 A
550 A
600 A
80 min
92 min
1.280 0.01(at 20(68))
1.280 0.01(at
20C(68F))
113 min
1.280 0.01(at
20(68))
0.58 10 %
8.8 15 %
BKR5ES-11, RC10YC4
1.0 ~ 1.1 mm (0.0394 ~

0.0433 in.)

Rated voltage
Starter
No-load charasteristics
Generator
Battery
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity
Ignition coil
Spark plugs
0.7 15 %
Primary
k
Secondary
RER8MC
Unleaded (NGK)
Unleaded
mm(in.) 1.0 ~ 1.1(0.0394 ~ 0.0433)
(Gap)
AM-9

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
Bosch
48(42)
Returnless type
Paper type
Built in Fuel Pump
assembly
Siemens
Bosch
48(42)
Return type
High pressure type
Fuel System
Engine Management System
Fuel Tank
Fuel Return System
Fuel Filter
Manufacturer
Capacity
Type
Type
(lmp.qt)

Mechanical,Plunger
Pumping
Type
HI
Fuel Pump
Type
LOW
Driven
by
Timing chain
Type
Electrical,in tank
Driven
by
Electrical motor
Mechanical,Gear
pumping
Involved in High Pressure
Fuel Pump
MPa
(kgf/cm)
Fuel Pressure (Maximum)
Pressure
Regulated Fuel KPa

(kgf/cm)
Pressure
1600 bar
333 ~ 345 (3.4 ~ 3.5)
Clutch
Clutch operation
Clutch disc
Hydraulic type
AM-10

Clutch pedal bracket
Clutch pedal support member to master cylinder
Service standard
Clutch pedal stroke
15~22 (1.5~2.2)
17~26 (1.7~2.6)
17 ~26(1.7~2.6)
15~22 (1.5~2.2)
15~22 (1.5~2.2)
25~35 (2.5~3.5)
17 ~26(1.7~2.6)
15~22 (1.5~2.2)
12~15 (1.2~1.5)
17~26 (1.7~2.6)
17 ~26(1.7~2.6)
15~22 (1.5~2.2)
168.7 (6.64)
6~13 (0.24~0.51)
mm (in.)
mm (in.)
Manual Transaxle
Type
Gear ratio
1st
2nd
3rd
4th
5th
Rev.
M5CF1-1
3,615
1,962
1,286
0,971
0,839
3,545
M5CF2
3,308
1,962
1,257
0,976
0,778
3,583
M5CF3
3,636
1,962
1,189
0,844
0,660
3,583
FGR
4,267
4,188
3,941
M/T oil quality

MT oil capacity
(lmp.qt)
SAE 75W/85, API GL-4,TGO-7(MS517-14)

1.90 (1.67)
2.0 (1.76)
2.0(1.76lmp qt)
Automatic Transaxle
Type
Gear ratio
ATF quality
ATF capacity
A4CF1
2,919
1,551
1,000
0,713
2,480
4,619
1st
2nd
3rd
4th
Rev.
FGR
(lmp.qt)
6.8(5.98)
A4CF2
2,919
1,551
1
0,713
2,48
4,375
6.6 (5.81)
A4CF2
2,919
1,551
1,000
0,713
2,480
3,849
6.6 (5.81)
AM-11

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
TJ
BJ
TJ
BJ
TJ
BJ
TJ
BJ
21
43
TJ
BJ
TJ
BJ
Nm
Kgf.m
lb-ft
90 ~ 110
240.2 ~ 269.6
100 ~ 120
60 ~ 72
16 ~ 34
65 ~ 75
65 ~ 75
70 ~ 90
9.0 ~ 11.0
24.5 ~27.5
10.0 ~12.0
6.0 ~ 7.2
1.6 ~ 3.4
6.5 ~ 7.5
6.5 ~ 7.5
7.0 ~ 9.0
65 ~ 80
177.2 ~ 198.9
72 ~ 87
43 ~ 52
12 ~ 25
47 ~ 54
47 ~ 54
51 ~ 65
Driveshaft
M/T
Joint type
A/T
Inner
Outer
Inner
Outer
Inner
Outer
[NOTE]
BJ : Birfield Joint
TJ : Tripod Joint
UTJ-ll : U Type-ll Tri-pod Joint
Item
Hub nuts
Driveshaft lock nut
Strut assembly to knuckle
Lower arm to knuckle
Front caliper to knuckle
Rear caliper to carrier
Rear carrier to torsion axle
AM-12
Suspension System
Front Suspension
Suspension type
MacPherson Strut
Shock absorber
Type
Coil spring
Free Height [I.D. color]
Gas
313.5mm (Yellow Yellow)
290.3mm (Yellow White)
Rear Suspension
Suspension type
Shock absorber
Torsion Beam Axle
Type
Gas
301.3mm (Blue - 1)
Coil spring
Free Height [I.D. color]
303.5mm (Yellow - 1)
268.0mm (Red 1)
Wheel & Tire

Wheel
Aluminum
Steel
6.5J x 16
7.0J x 18
6.0J x 15
195/65 R15
Tire
205/55 R16
225/45 R18
Tire pressure
2.3kg/cm (33psi)

AM-13
Engine
GSL 1.6
GSL 2.0
DSL U 1.6
195/65 R15
205/55 R16
225/45 R18
-2.0 2.0mm
-2.0 2.0mm
-2.0 2.0mm
Camber angle
-030' 30'
-030' 30'
-030' 30'
Caster angle
324' 30'
324' 30'
324' 30'
King-pin angle
1432' 30'
1432' 30'
1432' 30'
Toe-in
4.0 2.0mm
4.0 2.0mm
4.0 2.0mm
Camber angle
-130' 30'
-130' 30'
-130' 30'
Nm
90 ~ 110
160 ~ 180 /100 ~ 120
24 ~ 34
60 ~ 80
100 ~ 120
45 ~ 55
100 ~ 120
140 ~ 160
90 ~ 110
100 ~ 120
100 ~ 120
100 ~ 120
Kgf.m
9 ~ 11
16 ~ 18 /10 ~ 12
2.4 ~ 3.4
6~8
10 ~ 12
4.5 ~ 5.5
10 ~ 12
14 ~ 16
9.0 ~ 11.0
10.0 ~12.0
10.0 ~12.0
10.0 ~ 12.0
lb-ft
65 ~ 80
115 ~ 130 /72 ~ 87
72 ~ 87
43 ~ 58
72 ~ 87
32 ~ 40
72 ~ 87
101 ~ 115
65 ~ 80
72 ~ 87
72 ~ 87
72 ~ 87
Wheel Alignment
Item
Toe-in
Front
Rear
Tightening Torques
Item
Front Suspension
Rear Suspension
Hub nuts
Lower arm to sub frame
Steering gear box to
Stabilizer bar to
Stabilizer bar to sub
Stabilizer bar to front
Front strut assembly to
Hub nuts
Shock absorber to body
Shock absorber to
Torsion beam axle to
AM-14
Steering System
Type
Manual Steering System
Type
Steering gear
Rack stroke
Inner
Steering angle(Max.)
Outer
Rack & Pinion
Non 215 Tire
140mm
215 Tire
134mm
Non 215 Tire
40.962
215 Tire
38.382
Non 215 Tire
32.33
215 Tire
30.90
Tightening Torques
Tightening torque
Item
N.m
Kgf.m
lb-ft
Hub nuts
90 ~ 110
9.0 ~ 11.0
65 ~ 80
Steering column mounting bolts and nuts
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
Steering gear box mounting bolts
60 ~ 80
6.0 ~ 8.0
43 ~ 58
AM-15

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
Restraints
Item
Resistance ()
Driver Airbag (DAB)
1.6 ~ 6.0
1.6 ~ 6.0
Side Airbag (SAB)
1.6 ~ 6.0
1.6 ~ 6.0
Seat Belt Retractor Pretensioner (BPT)
1.6 ~ 6.0
Anchor Pretensioner
1.6 ~ 6.0
Tightening Torques
Item
Nm
kgf.m
lb-ft
Driver Airbag (DAB)
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
SRSCM
7.8 ~ 9.8
0.8 ~ 1.0
5.7 ~ 7.3
Front Impact Sensor (FIS) Mounting nut
7.8 ~ 9.8
0.8 ~ 1.0
5.7 ~ 7.3
7.8 ~ 9.8
0.8 ~ 1.0
5.7 ~ 7.3

Side Airbag (SAB)
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
Master cylinder
Type
Piston stroke
Brake booster
Type
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
Disc I.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
Tandem type
45 mm (1.77 in)
Provided
Vacuum
9:01

280 mm (11.02 in)
172 mm (6.77 in)
26 mm (1.02 in)
11 mm (0.43 in)
Single piston
57.0 mm (2.24 in)
AM-17

Engine
Rear brake(Disc)
Type
Disc O.D.
Disc I.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
Rear brake(Drum)
Type
Drum I.D.
Parking brake (Disc type)
Actuation
Type
Drum I.D.
GSL 1.6
GSL 2.0
DSL U 1.6

262 mm (10.31 in)
185 mm (7.28 in)
10 mm (0.39 in)
10 mm (0.39 in)
Single piston
30.0 mm (1.22 in) - Australia only
34.0 mm (1.34 in) - Except Australia
Leading trailing
203.2 mm (8.00 in)
5.14 mm (0.20 in)
Automatic
DIH (Drum in hat)

Lever
168 mm(6.61 in)
[NOTE]
O.D : Outer Diameter
I.D : Inner Diameter
AM-18
Specification(ABS)
System
Type
Operating Voltage
Operating Temperature
Motor power

Motor, valve relay intergrated type
10 ~ 16 V
-40 ~ 120 C (-40 ~ 248F)
210 W
Specification (Total control-ABS, EBD, TCS, ESP)

System
Type
HECU
Operating Voltage
Operating Temperature
Motor power

Motor, valve relay intergrated type
10 ~ 16V
-40 ~ 120C(-40 ~ 248F)
270W
HECU
Service Standard
Brake pedal height
Brake pedal stroke
Stop lamp switch outer case to pedal stopper clearance
Booster push rod to master cylinder piston clearance
Parking brake lever stroke when lever assembly is pulled with
196N (20Kg, 44lb force)
Rear brake lining thickness
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)
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.)
26 mm (1.02 in)
10 mm (0.35 in)
10 mm (0.39 in)
Disc Brake : 2.6 mm (0.10 in)
Drum Brake : 5.14 mm (0.20 in)
AM-19

Engine
Tightening Torques
Bleeder screw
Brake tube to HECU-ABS
Brake tube to HECU-ESP
Caliper mounting bolt (Front)
Caliper mounting bolt (Rear)
Brake hose to caliper
Brake pedal member assembly bracket mounting nut
Yaw rate & Lateral G sensor mounting bolt
GSL 1.6
GSL 2.0
DSL U 1.6
N.m
12.7 ~ 16.7
16.7 ~ 25.5
6.9 ~ 12.7
12.7 ~ 16.7
18.6 ~ 22.6
21.6 ~ 31.4
78.5 ~ 98.1
63.7 ~ 73.6
24.5 ~ 29.4
16.7 ~ 25.5
11.8 ~ 14.7
6.9 ~ 10.8
16.7 ~ 25.5
10.8 ~ 13.7
7.8 ~ 10.8
kgf.m
1.3 ~ 1.7
1.7 ~ 2.6
0.7 ~ 1.3
1.3 ~ 1.7
1.9 ~ 2.3
2.2 ~ 3.2
8.0 ~ 10.0
6.5 ~ 7.5
2.5 ~ 3.0
1.7 ~ 2.6
1.2 ~ 1.5
0.7 ~ 1.1
1.7 ~ 2.6
1.1 ~ 1.4
0.8 ~ 1.1
lb-ft
9.4 ~ 12.3
12.3 ~ 18.8
5.1 ~ 9.4
9.4 ~ 12.3
13.7 ~ 16.6
15.9 ~ 23.1
57.9 ~ 72.3
47.0 ~ 54.3
18.1 ~ 21.7
12.3 ~ 18.8
8.7 ~ 10.8
5.1 ~ 8.0
12.3 ~ 18.8
8.0 ~ 10.1
5.8 ~ 8.0
AM-20

Specifications
Hood
Front Door
Rear Door
Tailgate
Seat Belts
Type
Construction
Regulator system
X-arm type
Locking system
Pin-fork system
Construction
Regulator system
X-arm type
Locking system
Pin-fork system
Type
Inner hinged, gas lifter
Front
Rear
Tightening Torques
Items
Hood
Tailgate

Seat
N.m
Kgf.m
Lb-ft
Hood latch to body
6.9~10.8
0.7~1.1
5.1~8.0
Tailgate striker
15.7~23.5
1.6~2.4
11.6~17.4
Tailgate latch
21.6~26.5
2.2~2.7
15.9~19.5
Checker to body
16.7~21.6
1.7~2.2
12.3~15.9
Checker to door
Front seat mounting
bolts
6.9~10.8
0.7~1.1
5.1~8.0
37.2~58.8
4.0~6.0
28.9~43.4
AM-21

Engine
GSL 1.6
GSL 2.0
DSL U 1.6
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
Tightening Torques
adjuster
mounting bolt
mounting bolt
anchor
anchor
attaching bolt
mounting bolt
Seat belt

Audio
Model
Radio/CD/MP3(Internal Amp)
Radio/CD/MP3(External Amp)
Power supply
Rated output
Antenna
DC 14.4V
Min 14W
80PF 75
Tuning type
PLL SYNTHESIZED TUNING
Frequency range / Channel space
FM
87.5 ~ 108.0 MHz/100 KHz (for General)
AM
531 ~ 1602 KHz/9 KHz (for General)
FM
87.5 ~ 108.0 MHz/50 KHz (for Europe)
AM-22
MW
522 ~ 1620 KHz/9 KHz (for Europe)
LW
153 ~ 279 KHz/1 KHz (for Europe)
Front
20 (Max. 40)
Rear
20 (Max. 40)
Tweeter
20 (Max. 40)
Center
20 (Max. 40)
Woofer
20 (Max. 40)
Front
4.0 0.6, 2.0 0.3 (External Amp)
Rear
4.0 0.6, 2.0 0.3 (External Amp)
Tweeter
4.0 0.6
Center
2.0 0.3
Woofer
2.0 0.3
Speaker
Input Power(W)
Speaker Impedance()
Speaker Number
External Amplifier
Power Supply
Output Power (W)
LOAD Impedance ()
DC 14.4V
315W (457CH)
2
AM-23

Engine
Rated voltage
Service voltage range
Temperature range
Modulation method
Keyless entry transmitterPower source
Life of battery
Button
Lighting system
Head lamp (High/Low)
Front fog lamp
Position lamp
Rear stop/tail lamp
Back up lamp
License plate lamp
Side repeater
Room lamp
Luggage room lamp
GSL 1.6
GSL 2.0
DSL U 1.6
DC 3V
DC 2.5V ~ 3.2V
-4F ~ 140F (-20C ~ +60C)
FSK
CR2032 (Lithium 3V battery, 1EA)
30m or more
4 (Door lock, Door unlock, Tailgate and Panic)
433.92 MHz
W
W
W
W
W
W
W
W
W
W
W
W
W
W
60 / 55
21
27
5
21 / 5
16
21
21
5
5
10
10
5
5
AM-24
Rear parking assist system control

unit
Ultrasonic sensor
Piezo buzzer
Voltage rating
Operation voltage
Operation temperature
Operation current
Operation frequency
Detective method
Voltage rating
Detecting range
Operation voltage
Operation current
Beam width
Number of sensors
Voltage rating
Operation voltage
Operation current
Sound, tone
Immobili
zer
Immobilizer
Type
Manufacturer
DC 12V
DC 9 ~ 16 V
-30C ~ + 80C
MAX 600 mA
40 5 KHz
Direct and indirect detection
DC 8 V
40 cm ~ 120 cm
DC 9 ~ 16 V
MAX 20 mA
-30C ~ + 80C
Horizontal : 1005(70cm), Vertical : 505(50cm)
4 (Right, center, Left)
DC 12 V
DC 9 ~ 16 V
-30C ~ + 80C
MAX 60 mA
Oscillation frequency : 2.20.5 KHz
Sound level : MIN 70 dB (DC 13V /m)
SMARTRA system
Bosch
AM-25

Engine
GSL 1.6
GSL 2.0
DSL U 1.6

Air conditioner
Item
Compressor
Condenser
APT(A/C pressure transducer)
Expansion valve
Refrigerant
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
the pressure
Type
Type
Capacity [oz.(g)]
Specification
VS12
FD46XG(PAG) 100 10cc
5PK-TYPE
126cc/rev
12,300min
Voltage = 0.00878835 * Pressure + 0.37081095
Block
R-134a
19.4 0.88 (550 25)
Blower unit
Item
Fresh and recirculation
Blower
Air filter
Operating method
Type
Speed step
Speed control
Type
Specification
Actuator
Sirocco
0~4 (Manual)
Blower resistor(Manual)
Particle filter
Type
Heating capacity
Temperature control
A/C ON/OFF [C(F)]
Specification
Pin & Tube type
4,500 - 5%
Actuator
Actuator
ON : 3.0 0.5 (37.4 32.9), OFF: 1.0 0.5 (33.8 32.9)

Item
Heater
Evaporator
AM-26
Carens(UN
)
UN-2
UN-8
UN-9
Fuel System..
UN-10
Clutch.
UN-11
Manual Transaxle.
UN-11
Automatic Transaxle
UN-12
Driveshaft..
UN-14
Suspension System.
Steering System UN-15
RestraintsUN-16
UN-17
Brake System
Body (Interior & Exterior). UN-20
UN-22
Heating, Ventilation & Air Conditioning..UN-23
UN-1
General specifications - Carens

Engine
DSL D2.0 VGT
GSL 2.0
rpm
rpm
In-line, SOHC
4
83 (3.27) x 92 (3.62)
1991
17.3 : 1
1-3-4-2
790 100
790 100
In-line, DOHC
4
86 (3.3858) x 86 (3.3858)
1.998
10.5 : 1
1-3-4-2
BTDC 8 15
650 100
650 100
rpm
790 100
650 100
rpm
790 100
650 100
ACEA : C3
5.2 (4.58)
4.0 (3.52)
4.3 (3.78)
5W-20(SJ or SL above/GF-3)
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
mm (in.)
cc
Neutral,N,PD-range
Neutral,N,Prange
D-range
Engine oil
Oil quantity
Total
(lmp.qt)
Oil pan
(lmp.qt)
Oil filter
(lmp.qt)
Excluding oil filte (lmp.qt)
Including oil filter (lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
UN-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
7
43
52
6
-11 ~ 34
22 ~ 67
34
10
mm (in.)
0.03 (0.0012) for width

0.09 (0.0035) for length
Less than 0.05 (0.0020)
Intake
Exhaust
mm (in.)
mm (in.)
Less than 0.10 (0.0039)

Less than 0.10 (0.0039)
Intake
Exhaust
mm (in.)
mm (in.)
34.697 (1.366)
34.570 (1.361)
43.80 (1.7244)
45.00 (1.7716)
Intake
mm (in.)
Cylinder head
mounting surface
Camshaft
Cam height
28 (1.10)
mm (in.)
No.1 : 40 (1.5748)
No.2,3,4,5 : 24 (0.9449)
Intake
mm (in.)
No.1 : 0.020 ~ 0.057

(0.00078 ~ 0.00224)
No.2,3,4,5 : 0.045 ~ 0.082
(0.00177 ~ 0.00323)
Exhaust
mm (in.)
Exhaust
End play
Valve
Valve length
No.1 : 30 (1.1811)
No.2,3,4,5 : 24 (0.9449)
Intake
Exhaust
0.040 ~ 0.074
(0.0020 ~ 0.0029)
No.1,2,3,4,5 : 0.045 ~ 0.082

(0.00177 ~ 0.00323)
mm (in.)
0.05 ~ 0.15 (0.002 ~ 0.006)
0.1 ~ 0.22 (0.0039 ~ 0.0086)
mm (in.)
mm (in.)
95.7 (3.77)
95.4 (3.76)
113.18 (4.4559)
105.89 (4.1689)
UN-3

Engine
DSL D2.0 VGT

5.953 (0.234)
5.925 (0.233)
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)
GSL 2.0
5.465 ~ 5.480 (0.2151 ~ 0.2157)
5.458 ~ 5.470 (0.2149 ~ 0.2153)
45.25 ~ 45.75
1.02 (0.0401)
1.09 (0.0429)
0.020 ~ 0.047 (0.00078 ~ 0.00185)
0.030 ~ 0.054 (0.00118 ~ 0.00212)
5.500 ~ 5.512 (0.2165 ~ 0.2170)
36.5 (1.437)
43.8 ~ 44.2 (1.7244 ~ 1.7401)
Stem outer diameter
Intake
Exhaust
mm (in.)
mm (in.)
Face angle
(margin)
Valve stem to valve
guide clearance
Valve guide
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Intake
Exhaust
mm (in.)
mm (in.)
Seat angle
Valve spring
Free length
1.21 (0.0477)
1.61 (0.0634)
44 ~ 44.5
1.16 ~ 1.46 (0.0457 ~ 0.0575)

1.35 ~ 1.65 (0.0531 ~ 0.0649)
44.75 ~ 45.10
mm (in.)
38.8 (1.527)
47.44 (1.8677)
Load
mm (in.)
21.25kg / 32 (1.26)
19.0 0.6kg / 35.0 (1.3779),

39.81.2kg / 26.0 (1.0236 )
Less than 1.5
31.964 ~31.980 (1.2584 ~ 1.2591)

32.000 ~ 32.025 (1.2598 ~ 1.2608)
Inner diameter
Length
Valve seat
Out of squareness
MLA
mm (in.)
MLA outer diameter
Cylinder head tappet bore inner diameter mm (in.)
UN-4
mm (in.)
MLA to tappet bore clearance
Valve clearance
mm (in.)
Intake
mm (in.)
Exhaust
Cylinder block
mm (in.)
Cylinder bore
mm (in.)
Piston
mm (in.)
mm (in.)
Ring groove width
Piston ring
Side clearance
End gap
Piston pin
mm (in.)
mm (in.)
mm (in.)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
0.17 ~ 0.23 (0.0067 ~ 0.0090)

0.27 ~ 0.33 (0.0106 ~ 0.0129)
83 + 0.03 (3.27 + 0.0012)

0.096 (0.00378) for length
86.00 ~ 86.03 (3.3858 ~ 3.3870)

Less than 0.05 (0.0020)
82.92 ~ 82.95 (3.26 ~ 3.27)

0.07 ~ 0.09 (0.0027 ~ 0.0036)
1.915 ~ 1.945 (0.075 ~ 0.076)
2.06 ~ 2.08 (0.08 ~ 0.082)
3.02 ~ 3.04 (0.119 ~ 0.1196)
85.975 ~ 86.005 (3.3848 ~ 3.3860 )

0.015 ~ 0.035 (0.0028 ~ 0.0014)
1.22 ~ 1.24 (0.0006 ~ 0.0488)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
2.01 ~ 2.03 (0.0791 ~ 0.0799)
0.064 ~ 0.114 (0.00252~0.00449)

0.065 ~ 0.11 (0.00256~0.00433)
0.03 ~ 0.07 (0.00118~0.00275)
0.2 ~ 0.3 (0.0079~0.0118)
0.3 ~ 0.45 (0.0118~0.0177)
0.2 ~ 0.45 (0.0079~0.0177)
0.03 ~ 0.07 (0.0012~0.0028 )

0.03 ~ 0.07 (0.0012~0.0028 )
0.06 ~ 0.15 (0.0024 ~ 0.0059)
0.15 ~ 0.30 (0.0059 ~ 0.0118)
0.30 ~ 0.45 (0.0118 ~ 0.0177)
0.20 ~ 0.70 (0.0078 ~ 0.0275)
21.001 ~ 21.006 (0.8268 ~ 0.8270 )

21.016 ~ 21.021 (0.8274~0.8276 )
0.010 ~ 0.020 (0.0004 ~ 0.0008 )
20.974 ~ 20.985 (0.8257 ~ 0.8262 )
UN-5

Engine
Connecting rod
End play
Crankshaft
End play
Oil pump
mm (in.)
mm (in.)
mm (in.)
Thermostat
Opening
temperature
Full opening
temperature
Full lift
GSL 2.0
0.024 ~ 0.042 (0.0009 ~ 0.0016)

-
51.000 ~ 51.018 (2.0079 ~ 2.0086 )

0.028 ~ 0.046 (0.0011 ~ 0.0018 )
0.10 ~ 0.25 (0.0039 ~ 0.0098 )
mm (in.) 60.002 ~ 60.020 (2.362 ~ 2.363)

mm (in.) 50.008 ~ 50.026 (1.9688 ~ 1.9695)
mm (in.) 0.024 ~ 0.042 (0.0009 ~ 0.0016)
0.09 ~ 0.32 (0.0035 ~ 0.0126)
mm (in.)
kPa
(kg/cm)
51.942 ~ 51.960 (2.0449 ~ 2.0456)

47.954 ~ 47.972 (1.8879 ~ 1.8886)
0.020 ~ 0.038 (0.0008 ~0.0015)
00.07 ~ 0.25 (0.0027 ~ 0.0098)
570 50 (5.8 0.5)
(lmp.qt)
5 (4.4)
6.7 (5.90)
C (F)
85 (185)
821.5 (179.6 34.7)
C (F)
100 (212)
95 (201)
mm (in.)
Cooling system
Cooling method
Coolant quantity
DSL D2.0 VGT
UN-6
Main valve
kPa
Radiator cap
Vacuum valve
kPa
(kg/cm)
opening press.
Type
k
20C (68F)
Resistance
k
80C (176F)
Main moving system
Crankshaft
Bolts
main bearing cap
Bolts (15mm)
Crankshaft bedplate
Bolts (12mm)
Cylinder head
Bolts
Camshaft bearing cap nuts or bol Bolts (M6)
Bolts (M8)
Cylinder head bolt
Lubrication system
Oil filter
Bolts
Bolts (M6)
Bolts (M8)
Oil pan drain plug
107.9 14.7 (1.10.15)
93.16 ~ 122.58 (0.95 ~ 1.25)
6.86 (0.07)
6.86 (0.07) or less

Thermister type
2.31 ~ 2.59
0,3222
25 (2.5) + 90
19.6 (2.0) + 90
26.46 (2.7) + 45
27.5 ~ 31.4 (2.8 ~ 3.2) + 90

36.3 ~ 37.0 (3.7 ~ 3.8)
26.5 ~ 29.4 (2.7 ~ 3.0)

63.7 (6.5) + 120 + 120
10.78 ~ 12.74 (1.1 ~ 1.3)

27.44 ~ 31.36 (2.8 ~ 3.2)
34.3 (3.5) + 90 +90
7.8 ~ 9.8 (0.8 ~ 1.0)

34.3 ~ 44.1 (3.5 ~ 4.5)
11.76 ~ 15.68 (1.2 ~ 1.6)

9.8 ~ 11.76 (1.0 ~ 1.2)
26.46 ~ 30.38 (2.7 ~ 3.1)
UN-7

Engine
DSL D2.0 VGT
GSL 2.0

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
Spark plugs
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
Secondary
k
resistance
Unleaded (NGK)
Unleaded (CHAMPION)
12V, 2.0KW
12 V, 1.2 kW
11,5
11,5
120, MAX
90, MAX
4,000rpm, MIN
2,600 rpm, MIN
12V, 120A
13.5 V, 110A
1,000 ~ 12,000 rpm
1,000 ~ 18,000 rpm
14.55 0.2V
14.4 0.3V
CMF 90 AH
MF 60AH
MF 68AH
720A
550 A
600 A
160min
92 min
110 min
1.280 0.01
1.280 0.01
1.280 0.01
0.62 10 %
7.0 15 %
BKR5ES-11
RC 10YC4
1.0 ~ 1.1 (0.0394 ~ 0.0433)
UN-8
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Type
Driven by
MPa
(kgf/cm
)
KPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
Siemens
55 (48.39)
Returnless type
Bosch
55 (48.39)
Return type
High pressure type

High Pressure Fuel Pump
Mechanical
Electrical
In-tank type
Camshaft
Electric motor
160 (1,632)
-
338 ~ 348 (3.45 ~ 3.55)
UN-9

Engine
DSL D2.0 VGT
GSL 2.0
Clutch
Manual transaxle type
Clutch operation
Faling diameter(Outer inner)
Clutch release cylinder inner diameter
Clutch disc
Manual transaxle type
Clutch operation
Faling diameter(Outer inner)
Clutch release cylinder inner diameter
Clutch disc
Clutch tube to clutch hose
Service standard
Clutch pedal stroke
M6GF2(DSL 2.0L VGT)

M5GF1
Hydraulic type
240 155 mm(9.446.10in)
235 155 mm(9.256.10in)
C.S.C 32.2 44 mm(1.261.73in)
20.64 mm(0.812 in)
M5GF1(DSL 2.0L WGT)
Hydraulic type
235 155 mm(9.256.10in)
20.64 mm(0.812 in)
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)
25~35 (2.5~3.5)
mm (in.)
mm (in.)
145 (5.70)
6~13 (0.24~0.51)
UN-10
Manual Transaxle
Type
Gear ratio
1st
2nd
3rd
4th
5th
6th
Rev.
FGR
M/T oil quality

MT oil capacity
Type
Gear ratio
M/T oil quality

MT oil capacity
(lmp.qt)
1st
2nd
3rd
4th
5th
6th
Rev.
FGR
(lmp.qt)
M6GF2(DSL 2.0L VGT)

3,615
1,794
1,542
1,176
0,974
0,829
3,416
4.063 / 2.955
1.9 (1.67)
M5GF1(DSL 2.0L WGT)
3,636
2,056
1,296
0,971
0,775
3,455
4,553
2.1 (0.46)
M5GF1
3,636
2,056
1,296
0,971
0,775
3,455
4,553
2.1 (0.46)
-
UN-11

Automatic Transaxle
Engine
Type
Gear ratio
1st
2nd
3rd
4th
Rev.
FGR
ATF quality
ATF capacity
(lmp.qt)
DSL D2.0 VGT

GSL 2.0
F4A42
F4A51-3
2,842
2,842
1,495
1,529
1,000
1,000
0,731
0,712
2,720
2,480
3,274
4,042
8.5 (7.5)
7.8 (6.9)
Driveshaft
M/T
Joint type
A/T
M/T
A/T
Lubricants
Joint type
Recommended grease
Quantity
Inner
Outer
Inner
Outer
Inner
Outer
Inner
Outer
UTJ-II#24
BJ#24
UTJ-II#24
BJ#24
UTJ-II#25
BJ#25
UTJ-II#25
BJ#25
23
46.5
23
46.5
BJ #24/#25
RBA
130
UTJ-II #24/#25
CW-13TJ
160
UN-12

Front wheel bearing
[NOTE]
BJ : Birfield Joint
UTJ-ll : U Type Tri-pod Joint
Wheel nut
Driveshaft nut (castle nut)
Front lower arm ball joint assembly to knuckle
Wheel speed sensor bolt
Rear lower arm to carrier assembly bolts
Rear lower arm to cross member bolts
Rear upper arm to carrier assembly bolts
Rear strut assembly to carrier assembly bolts
1.8 (0.18 )
1.5 (0.15)
88.3 ~ 107.9 (9.0 ~ 11.0)

196.1 ~ 274.6 (20 ~ 28)
98.1 ~ 117.7 (10.0 ~ 12.0)
6.9 ~ 9.8 (0.7 ~ 1.0)
78.5 ~ 98.1 (8.0 ~ 10.0)
23.5 ~ 33.3 (2.4 ~ 3.4)
137.3 ~ 156.9 (14.0 ~ 16.0)
137.3 ~ 156.9 (14.0 ~ 16.0)
137.3 ~ 156.9 (14.0 ~ 16.0)
107.9 ~ 127.5 (11.0 ~ 13.0)
49 ~ 58.8 (5.0 ~ 6.0)
137.3 ~ 156.9 (14.0 ~ 16.0)
44.1 ~ 53.9 (4.5 ~ 5.5)
44.1 ~ 53.9 (4.5 ~ 5.6)
58.8 ~ 68.6 (6.0 ~ 7.0)
UN-13

Suspension System
Front
MacPherson strut
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
kgf/cm 2
(psi)
Camber
Caster
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Rear shock absorber bracket to body
Rear
Multi link
Gas pressurized
6.0J 15"
6.0J 15", 6.5J 16", 6.5J 17"
205/65 R15 [2.3 (33)]
205/65 R15 [2.2 (32)]
205/60 R16 [2.4 (35)]
205/60 R16 [2.4 (35)]
225/50 R17 [2.3 (33)]
225/50 R17 [2.2 (32)]
-0.530'
-130'
4.7430'
22(0.0790.079)
02 (00.079)
13.130'
90 ~ 110 (9.0 ~ 11.0)
45 ~ 60 (4.5 ~ 6.0)
140 ~ 160 (14.0 ~ 16.0)
70 ~ 95 (7.0 ~ 9.5)
FR: 140 ~ 160 (14.0 ~ 16.0), RR: 100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
140 ~ 160 (14.0 ~ 16.0)
110 ~ 130 (11.0 ~ 13.0)
UN-14

110 ~ 130 (11.0 ~ 13.0)

140 ~ 160 (14.0 ~ 16.0)
140 ~ 160 (14.0 ~ 16.0)
45 ~ 55 (4.5 ~ 5.5)
80 ~ 100 (8.0 ~ 10.0)
140 ~ 160 (14.0 ~ 16.0)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
45 ~ 55 (4.5 ~ 5.5)
Steering System
Type
Rack stroke
Quality
Quantity
17" tire
15", 16" tire
17" tire
Steering angle
15", 16" tire
(lmp.qt)
mm (in.)
Inner
Outer
Inner
Outer
kPa
(kgf/cm
)

Rack and Pinion

PSF-4
1.0 (0.88)
136 (5.35)
140 (5.51)
37.851.5
31.23
39.521.5
32.17
8336 ~ 9022 (85 ~ 92)
40 ~ 50 (4.0 ~ 5.0)
13 ~ 18 (1.3 ~ 1.8)
18 ~ 27 (1.8 ~ 2.7)
UN-15

Engine
GSL 2.0
DSL D2.0 VGT

30 ~ 35 (3.0 ~ 3.5)
24 ~ 34 (2.4 ~ 3.4)
17 ~ 26 (1.7 ~ 2.6)
55 ~ 65 (5.5 ~ 6.5)
60 ~ 80 (6.0 ~ 8.0)
Restraints
Type
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
Driver Airbag (DAB)
Bolt
Passenger Airbag
(PAB)
Nut
Side Airbag (SAB)
SRSCM Mounting Bolt
Depowered
1.6 ~ 5.8
1.6 ~ 5.8
1.6 ~ 5.8
1.6 ~ 5.8
1.6 ~ 5.8
7.9 ~ 9.8 (0.8 ~ 1.0)
17.2 ~ 26.5 (1.8 ~ 2.7)
2.45 ~ 3.73 (0.25 ~ 0.38)
7.0 ~ 9.0 (0.7 ~ 0.9)
7.0 ~ 9.0 (0.7 ~ 0.9)
39.2 ~ 53.9 (4.0 ~ 5.5)
7.0 ~ 9.0 (0.7 ~ 0.9)
6.8 ~ 9.2 (0.7 ~ 0.9)
6.8 ~ 9.2 (0.7 ~ 0.9)
UN-16
Brake System
Brake fluid
Quantity
DOT 3
As required
Master cylinder
Type
I.D.
Piston stroke
Proportioning valve(CBS)
mm (in.)
mm (in.)
Tandem type
25.4 (1.00)
31 (1.22)
Provided
MPa
(kg/cm)
1.96 (20)
Decompression ratio
Brake booster
Type
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
Disc I.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
Rear brake(Disc)
Type
Disc O.D.
Disc I.D.
0.27 : 1
vacuum
9:1
mm (in.)

280 (11.02)
166 (6.54)
26 (1.02)
10 (0.39)
Single piston
60.6 (2.39)
mm (in.)
mm (in.)

275 (10.83)
185 (7.28)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
UN-17

Engine
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D
Parking brake
Type
Actuation
Drum I.D.
GSL 2.0
DSL D2.0 VGT
mm (in.)
10 (0.39)
10 (0.39)
Single piston
38.18 (1.50)
mm (in.)
DIH(Drum in hat)
Lever
168 (6.61)
mm (in.)
mm (in.)
O.D=Outer Diameter
I.D=Inner Diameter
HECU
System
Acitve wheel speed
0.4 ~ 1.5 (0.015 ~ 0.059)
mm(in.)
Air gap
48
sensor
teeth
Tone wheel
Service standard
148.7 (5.85 )
mm (in.)
LHD
Brake pedal height
173 (6.81 )
mm (in.)
RHD
128 (5.04)
mm (in.)
Brake pedal stroke
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
stopper clearance
3 ~ 8 (0.11 ~ 0.31)
mm (in.)
UN-18

piston clearance
Parking brake pedal stroke when pedal is
pushed with 196N (20kgf, 44lb force)
Rear brake liner thickness
mm (in.)
0 (at 500 mmHg)
mm (in.)
88 ~ 98 (3.46 ~ 3.86)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
10 (0.39)
26 (1.02)
10 (0.39)
10 (0.39)
mm (in.)
3.3 (0.13)

Bleeder screw
Front
Rear
(cowl side upper mounting)
HECU union screw
34.3 ~ 53.9 (3.5 ~ 5.5)

7.9 ~ 11.8 (0.8 ~ 1.2)
12.7 ~ 15.7 (1.3 ~ 1.6)
6.9 ~ 12.7 (0.7 ~ 1.3)
13.7 ~ 16.7 (1.4 ~ 1.7)
21.6 ~ 31.4 (2.2 ~ 3.2)
78.5 ~ 98.1 (8.0 ~ 10)
49.0 ~ 58.8 (5.0 ~ 6.0)
24.5 ~ 29.4 (2.5 ~ 3.0)
16.7 ~ 25.5 (1.7 ~ 2.6)
12.7 ~ 15.7 (1.3 ~ 1.6)
7.9 ~ 9.8 (0.8 ~ 1.0)
6.9 ~ 10.8 (0.7 ~ 1.1)
16.7 ~ 25.5 (1.7 ~ 2.6)
12.0 ~ 16.0 (1.22 ~ 1.63)
UN-19

Engine
Yaw rate Lateral G sensor mounting bolt
GSL 2.0
DSL D2.0 VGT

10.8 ~ 13.7 (1.1 ~ 1.4)
4.9 ~ 7.8 (0.5 ~ 0.8)

Hood
Type
Construction
Front door
Regulator system
Locking system
Construction
Regulator system
Rear door
Locking system
Tailgate
Type
mm (in.)
Windshield
mm (in.)
Front door
Glass thickness
Rear window
mm (in.)
glass
Front
Seat belts
Rear
Door hinge to body
Door hinge to door
Striker
Tailgate hinge to body
Tailgate
Tailgate hinge to

Wire drum type
Pin-fork system
Wire drum type
Pin-fork system
5 (0.1969)
4 (0.1575)
4 (0.1575)
3.5 (0.1378)
12.7~25.5 (1.3~2.6)
9.8~19.6 (1.0~2.0)
6.9~10.8 (0.7~1.1)
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.2~2.7)
UN-20
Hood
Seat
Seat belt
Hood hinge to body

Hood hinge to hood
Hood latch to body
Front seat mounting
Rear seat mounting
Rear seat frame
mounting bolts
adjuster
mounting bolt
mounting bolt
anchor
anchor
attaching bolt
mounting bolt
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)
34.3~53.9 (3.5~5.5)
16.7~25.5 (1.7~2.6)
16.7~25.5 (1.7~2.6)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
UN-21

Engine
GSL 2.0
DSL D2.0 VGT

Audio
Radio / Tape
(M420)
Radio / Tape / CD Radio / CDC /

/ MP3(M455)
MP3 (M466)
DC 14.4V
Max 43W x 4
Max 43W x 4
Max 43W x 4
3.2Vrms
4 x 4
10k x 4
80PF 75
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
FM
AM
Frequency range /
Channel space
MW
LW
Items
Life of battery
Button
Radio / CD(M445)
Transmitter(TX)
30m or more
3 (Door lock, Door unlock, Tail gate unlock)
433.92 MHz(EUR, AUS)
315 MHz (GEN)
Lighting system
Head lamp
High
Low
W
W
55
55
UN-22

Front fog lamp
Rear tail/stop lamp
Back up lamp
License plate lamp
Side repeater
Room lamp
Center
Rear

Rear map lamp
Other system
Immobilizer
W
W
W
W
W
W
W
W
W
W
W
W
W
Type
Manufacturer
28
27
28/8
18
27
5
5
5
10
5
10
LED
10
SMARTRA system
Bosch

Air conditioner
Compressor
Condeser
APT(A/C pressure
transducer)
Expansion valve
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
the pressure
Type
VS18
PAG , 120 10cc
6PK - TYPE
180 cc/rev
15,000 - 5% Kcal/hr
Voltage = 5 * (0.025 * pressure + 0.1) [Kgf/]
Voltage = 5 * (0.001758 * pressure + 0.074612) [PSIA]
Block
UN-23

Engine
Refrigerant
GSL 2.0
DSL D2.0 VGT
Type
Capacity
oz.(g)
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
method
Evaporator
A/C ON/OFF
()
R - 134a
15.8 0.88 (450 25)
Actuator
Siroco
Particle filter
Pin & Tube type
4,500 5% Kcal/hr
Actuator
Actuator
ON : 2.5 0.5 (41 32.9)
OFF : 0.5 0.5 (37.4 32.9)
UN-24
Sportage(KM
)
KM-2
KM-9
KM-10
Fuel System..
KM-11
Clutch.
KM-11
Manual Transaxle.
KM-12
Automatic Transaxle
KM-12
Driveshaft..
KM-15
Suspension System.
Steering System KM-16
RestraintsKM-17
KM-18
Brake System
Body (Interior & Exterior). KM-22
KM-23
Heating, Ventilation & Air Conditioning..KM-25
KM-1
General specifications - Sportage

Engine
DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7
In-line, SOHC
4
In-line, SOHC
4
In-line, DOHC
4
V-type, DOHC
6
82 (3.2283)
x 93.5 (3.6811)
86.7 (3.4133)
x 75 (2.9528)
2.656
10.1:1
1-2-3-4-5-6
BTDC 12 5
700 100
700 100
750 100
750 100
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
83 (3.27) x 92 (3.62)
1.991
17.7:1
1.991
17.3:1
720 40
720 40
720 40
720 40
790 100
790 100
790 100
790 100
1.975
10.1 : 1
1-3-4-2
BTDC 8 5
700 100
700 100
850 100
850 100
4.0 (3.52)
3.7 (3.26)
0.3 (0.26)
Above SL, SJ
7.0 (6.1)
-
156.9 (1.6)
(ATDC) 11
59
6
46
1-3-4-2
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
kPa
(kg/cm)
Oil pressure (Idle)

Valve timing
Intake valve
Opens (ATDC)
Closes (ABDC)
7
43
KM-2
Exhaust valve
Opens (BBDC)
Closes (ATDC)
52
6
42
6
38
14
Cylinder head
mounting surface
Camshaft
Intake
Exhaust
Intake
mm (in.)
0.03 (0.0012) for width

0.09 (0.0035) for length
0.03(0.0012) or less
mm (in.)
mm (in.)
0.15(0.0059) or less
0.15(0.0059) or less
mm (in.)
34.697 (1.366)
Cam height
Exhaust
mm (in.)
34.570 (1.361)
28 (1.10)
mm (in.)
0.040 ~ 0.074 (0.0020 ~ 0.0029)
End play
mm (in.)
0.05 ~ 0.15 (0.002 ~ 0.006)
CVVT:
44.518 ~ 44.718
(1.7527 ~ 1.7605)
Without CVVT:
44.720 ~ 44.920
(1.7606 ~ 1.7685)
CVVT:
44.418 ~ 44.618
(1.7487 ~ 1.7566)
Without CVVT:
44.620 ~ 44.820
(1.7567 ~ 1.7646)
43.95 ~ 44.15
(1.7303 ~ 1.7382)
27.964 ~ 27.980 25.964 ~ 25.980

(1.1009 ~ 1.1016) (1.0222 ~ 1.0228)
0.02 ~ 0.061 (0.0008 ~ 0.0024)
0.10 ~ 0.20
0.1 ~ 0.15
(0.0039 ~ 0.0079) (0.0039 ~ 0.0059)
KM-3

Engine
Valve
Valve length
Stem outer diameter
DSL D2.0 WGT
Intake
Exhaust
Intake
Exhaust
Face angle
(margin)
Exhaust
Intake
Valve stem to valve
guide clearance
DSL D2.0 VGT
95.7 (3.77)
95.4 (3.76)
5.953 (0.234)
5.925 (0.233)
44.5
1.6 (0.063)
mm (in.)
1.3 (0.0512)
mm (in.)
mm (in.) 0.022 ~ 0.067 (0.00086 ~ 0.00263)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Exhaust
mm (in.)
0.050 ~ 0.095 (0.0020~ 0.0037)
Intake
mm (in.)
36.5 (1.437)
Exhaust
mm (in.)
36.5 (1.437)
Intake
mm (in.)
1.21 (0.0477)
Exhaust
mm (in.)
1.61 (0.0634)
GSL 2.0
GSL 2.7
114.34 (4.5016)
96.1 (3.783)
116.8 (4.5984)
97.15 (3.825)
5.965 ~ 5.98 (0.235 ~ 0.2354)
5.95 ~ 5.965 (0.234 ~ 0.235)
45 ~ 45 30'
45 ~ 45.5
1.15 (0.0453)
1.0 (0.0394)
1.35 (0.0531)
1.3 (0.0512)
0.02 ~ 0.05 (0.0008 ~ 0.0020)
0.035 ~ 0.065
0.030 ~ 0.065
(0.0014 ~ 0.0026) (0.0012 ~ 0.0026)
Valve guide
Length
45.8 ~ 46.2
(1.8031 ~ 1.8189)
54.3 ~ 54.6
(2.1378 ~ 2.1496)
Valve seat
Seat angle
Valve spring
Free length
mm (in.)
44 ~ 44.5
1.1 ~ 1.5
(0.0433 ~
1.3 ~ 1.7
(0.0512 ~ 0.0669)
45 ~ 45 30'
38.8 (1.527)
48.86 (1.9236)
42.5 (1.6732)
KM-4
Load
mm (in.)
Out of squareness
Valve clearance
Intake
Exhaust
Cylinder block
21.25kg / 32 (1.26)
-
mm (in.)
mm (in.)
Cylinder bore
mm (in.)
83 + 0.03 (3.27 + 0.0012)
mm (in.)
0.042 (0.00165) for width

0.096 (0.00378) for length
0.012 (0.00047) / 5050mm
mm (in.)
82.92 ~ 82.95 (3.26 ~ 3.27)
mm (in.)
0.07 ~ 0.09 (0.0027 ~ 0.0036)

1.915 ~ 1.945 (0.075 ~ 0.076)

2.06 ~ 2.08 (0.08 ~ 0.082)
3.02 ~ 3.04 (0.119 ~ 0.1196)
18.80.9kg/
39 (1.5354)
Max. 1.5
0.20 (0.0079)
0.28 (0.0110)
82.00 ~ 82.03
(3.2283 ~ 3.2295)
Total : Less than
0.05 (0.0020)
Bore to bore :
Less than 0.03
(0.0012)
21kg / 35(1.3780)
Max. 1.5
86.7 (3.4134)
Max.
0.03(0.0012)
Piston
Ring groove width

Piston OS
0.25 (0.010), 0.5 (0.020)
81.970 ~ 82.000
86.68 ~ 86.71
(3.2272 ~ 3.2283) (3.413 ~ 3.414)
0.020 ~ 0.040
0.01 ~ 0.03
(0.0008 ~ 0.0016) (0.0004 ~ 0.0012)
1.23 ~ 1.25 (0.0484 ~ 0.0492)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
2.51 ~ 2.53 (0.0988 ~ 0.0996)
0.25 (0.010),
0.50 (0.020)
Piston ring
Side clearance
No. 1 ring groovemm (in.) 0.064 ~ 0.114 (0.00252 ~ 0.00449)

No. 2 ring groovemm (in.) 0.065 ~ 0.11 (0.00256 ~ 0.00433)
Oil ring groove
mm (in.)
0.03 ~ 0.07 (0.00118 ~ 0.00275)
0.04 ~ 0.08 (0.0016 ~ 0.0031)

0.03 ~ 0.07 (0.0012 ~ 0.0028)
0.06 ~ 0.15
(0.0024 ~ 0.0059)
KM-5

Engine
DSL D2.0 WGT
DSL D2.0 VGT
0.25 ~ 0.3 (0.0079 ~ 0.0118)
0.3 ~ 0.45 (0.0118 ~ 0.0177)
Oil ring groove
mm (in.)
0.2 ~ 0.45 (0.0079 ~ 0.0177)
mm (in.)
mm (in.)
mm (in.)
End gap
GSL 2.0
GSL 2.7
0.23 ~ 0.38
0.20 ~ 0.35
(0.0091 ~ 0.0150) (0.0079 ~ 0.0138)
0.33 ~ 0.48
0.37 ~ 0.52
(0.0130 ~ 0.0189) (0.0146 ~ 0.0205)
0.20 ~ 0.60
0.2 ~ 0.7
(0.0079 ~
(0.0079 ~ 0.0276)
Piston pin
20.001 ~ 20.006
(0.7874 ~ 0.7876)
20.016 ~ 20.021
(0.7880 ~ 0.7882)
0.010 ~ 0.020
(0.0004 ~ 0.0008)
19.974 ~ 19.985
(0.7864 ~ 0.7868)
-0.032 ~ -0.016
(-0.0013 ~0.0006)
Connecting rod
mm (in.)
28.022 ~ 28.034 (1.103 ~ 1.104)
mm (in.)
0.024 ~ 0.042 (0.0009 ~ 0.0016)
End play
Crankshaft
mm (in.)
mm (in.)
60.002 ~ 60.020 (2.362 ~ 2.363)
48.000 ~ 48.018
(1.8898 ~ 1.8905)
0.024 ~ 0.044
0.018 ~ 0.036
(0.0009 ~ 0.0017) (0.0007 ~ 0.0014)
0.10 ~ 0.25 (0.0039 ~ 0.0098)
56.942 ~ 56.962 61.982 ~ 62.000
(2.2418 ~ 2.2426) (2.4402 ~ 2.4409)
KM-6
44.946 ~ 44.966 47.982 ~ 48.000

(1.7695 ~ 1.7703) (1.8891 ~ 1.8898)
mm (in.) 50.008 ~ 50.026 (1.9688 ~ 1.9695)
mm (in.)
0.024 ~ 0.042 (0.0009 ~ 0.0016)
0.028 ~ 0.048
0.004 ~ 0.022
(0.0011 ~ 0.0019) (0.0002 ~ 0.0009)
End play
mm (in.)
0.09 ~ 0.32 (0.0035 ~ 0.0126)
0.06 ~ 0.260
0.070 ~ 0.250
(0.0024 ~ 0.0102) (0.0028 ~ 0.0098)
Flywheel
Runout
Oil pump
mm (in.)
0.13 / 238
kPa
(kg/cm)
490.33 ~ 588.40
(5.0 ~ 6.0)
450 ~ 550
(4.59 ~ 5.61)
Cooling system
Cooling method
Coolant quantity
(lmp.qt)
Opening
C (F)
temperature
Thermostat
C (F)
Pull opening
Main valve
kPa
(kg/cm)
opening press.
Radiator cap
Vacuum valve
kPa
Type
k
20C (68F)
Resistance
k
80C (176F)
5 (4.4)

6.0 (5.28)
7.0 (6.1)
821.5
82 2(179.6
(179.62.7)
3.6)
95 (203)
85 (185)
100 (212.0)
107.9 14.7 (1.10.15)
93.16 ~ 122.58
(0.95 ~ 1.25)
107.9 14.7
(1.10.15)
-6.86 (-0.07)
0.98 ~ 4.90
(0.01 ~ 0.05)
-6.86 (-0.07)
Thermister type
2.45 0.14
0,3222
2.45 0.14
0,3222
KM-7

Engine
Main moving system
DSL D2.0 WGT
DSL D2.0 VGT
25 (2.5) +90
GSL 2.0
GSL 2.7
49.0 ~52.0
(5.0 ~5.3)
27.5~31.4
16~20 (1.6~2.0)
+ 90~94
Bolts
Crankshaft
main bearing cap
(2 8~3 2)+60~64
Long bolts (M10)
27~33 (2.7~3.0)
+ 90~94
Short bolts (M8)
13~19 (1.3~1.9)
+ 90~94
Cylinder head
26.5 ~ 29.5 (26.5 ~ 29.5)
Long bolts
50 (5.0) + 120 + 120
Short bolts
Cylinder head bolt
Lubrication system
Oil filter
Oil pan nuts
Oil pan drain plug
11.8 ~ 15.7 ( 1.2 ~ 1.6)

9.8 ~ 11.8 (1.0 ~ 1.2)
34.3 ~ 44.1 (3.5 ~ 4.5)
13.7 ~14.7
(1.4 ~1.5)
27.5 ~ 31.4
( 2.8 ~ 3.2)+
25 (2.5)+ 58~62
60~65 +
+ 43~47
60~65
22.6 ~ 26.5
(2.3 ~ 2.7) +
60~65+60~65
11.8 ~ 15.7 (1.2 ~ 1.6)
9.8 ~ 11.8 (1.0 ~ 1.2)
34.3 ~ 44.1 (3.5 ~ 4.5)
KM-8

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
Spark plugs
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
Secondary
k
12V, 2.0KW
11,5
Max. 120
4,000rpm, MIN
12V, 120A
1,000 ~ 12,000 rpm
I.C regulator built-in type
14.4 0.3V
MF 90 AH
12 V, 1.2 kW
11
Max. 90
3,000 rpm, MIN
13.5 V, 90A
12V, 120A
1,000 ~ 18,000 rpm
14.4 0.3V
14.55 0.2V
MF 60 AH
MF 68 AH
720 A
550 A
600 A
160 min
92 min
113 min
1.280 0.01
-
Unleaded (NGK)
0.58 10%
8.8 15%
0.74 10%
13.3 15%
IFR5G-11
BKR5ES-11
PFR5N-11
1.0 ~ 1.1 (0.0394 ~ 0.0433)
KM-9

Engine
DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Type
Driven by
MPa
(kgf/cm
)
kPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
Bosch
58 (51.03)
Return type
Siemens
58 (51.03)
65 (57.19)
Returnless type
High pressure type
Mechanical
Electrical
In-tank type
Camshaft
Electric motor
135 (1,377)
160 (1,632)
-
343 (3.5)
KM-10
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic type
15~22 (1.5~2.2)
25~35 (2.5~3.5)
12~16 (1.2~1.6)
25~35 (2.5~3.5)
mm (in.)
mm (in.)
150 (5.91)
6~13 (0.24~0.51)
Manual Transaxle
Type
Gear ratio
M/T oil quality

MT oil capacity
M5GF1
3,636
2,056
1,296
0,943
0,698
-
1st
2nd
3rd
4th
5th
6th
Rev.
FGR
3,455
4,333
(lmp.qt)
2.1 (1.8)
M6GF2
3,615
1,794
1,542
1,176
0,974
0,829
3,416
4.643 / 3.421
1.9 (1.67)
M5GF1
3,636
2,056
1,333
1,061
0,821
-
3,455
4,533
2.1 (1.8)
KM-11

Engine
DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7
Automatic Transaxle
Type
1st
2nd
3rd
4th
Rev.
Gear ratio
2WD
4WD
FGR
ATF quality
ATF capacity
F4A42
2,842
1,529
1,000
0,712
2,480
4,042
4,042
(lmp.qt)
F4A42
F4A51
2,842
2,842
1,495
1,529
1.000
1,000
0,731
0,712
2.720
2,480
3,735
4,626
3,735
4,626
7.8 (6.9)
2,842
1,529
1,000
0,712
2,480
4,042
4,407
Driveshaft
Front driveshaft
M/T
2WD
A/T
Joint type
M/T
4WD
A/T
Inner
Outer
Inner
Outer
Inner
Outer
Inner
Outer
Inner
Outer
UTJ-II#25
BJ#25
UTJ-II#24
BJ#24
UTJ-II#25
BJ#25
UTJ-II#24
BJ#24
UTJ-II#24
BJ#24
UTJ-II#24
BJ#24
UTJ-II#24
BJ#24
UTJ-II#24
BJ#24
UTJ-II#25
BJ#25
UTJ-II#25
BJ#25
46.5
23
KM-12
Rear driveshaft
Joint type
4WD
Inner
Outer
Inner
Outer
Rear differential carrier

Oil type
Oil capacity
Reduction gear type
Reduction gear ratio
Lubricants
Front driveshaft (2WD/4WD)
Joint type
Recommended grease
Quantity
Rear driveshaft (4WD)
Joint type
Recommended grease
Quantity
[NOTE]
Front hub
Wheel nut
Break caliper mounting bolt
TJ#22
BJ#22
46.5
23
Hypoid gear oil (GL-5, 80W/SAE90)
Approx. 0.75 ~ 0.80
Hypoid gear
3,091
BJ#24
BJ#25
UTJ-II#24
RBA
g
130 +10
UTJ-II#25
RTA-R
160 + 10
160 + 10
BJ#22
RBA
100 + 10
200 + 10
TJ#22
RTA-R
110 + 10
90 ~ 110 (9 ~ 11)
200 ~ 280 (20 ~ 28)
50 ~ 60 (6 ~ 6)
KM-13

Engine
Lower arm mounting bolt
Strut lower mounting blot
Tie rod end ball joint mounting nut
Rear
Wheel nut
Break disc(drum) mounting screw
Dust cover mounting bolt
Strut lower mounting nut
Trailing arm mounting bolt
Hub bearing flange nut
Suspension arm mounting nut
DSL D2.0 WGT
2WD
4WD
2WD
4WD
Propeller shaft
Front propeller shaft mounting bolt
propeller shaft center bearing bracket mounting
Rear propeller shaft mounting bolt
Differential
Rear differential mounting bolt
Differential cover mounting bolt
DSL D2.0 VGT

GSL 2.0
100 ~ 120 (10 ~ 12)
140 ~ 160 (14 ~ 16)
45 ~ 60 (4.5 ~ 6)
GSL 2.7
90 ~ 110 (9 ~ 11)
50 ~ 60 (5 ~ 6)
5 ~ 6 (0.5 ~ 0.6)
50 ~ 60 (5 ~ 6)
140 ~ 160 (14 ~ 16)
100 ~ 120 (10 ~ 12)
200 ~ 260 (20 ~ 26)
200 ~ 280 (20 ~ 28)
160 ~ 180 (16 ~ 18)
140 ~ 160 (14 ~ 16)
50 ~ 60 (5 ~ 6)
40 ~ 50 (4 ~ 5)
100 ~ 120 (10 ~ 12)
90 ~ 120 (9 ~ 12)
40 ~ 50 (4 ~ 5)
KM-14
Suspension System
Front
MacPherson strut
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
Tire size
Tire pressure
Camber
Caster
Wheel alignment
mm (in.)
Toe-in
King-pin
Hub nuts
Rear stabilizer link to rear strut assembly
Rear
Dual link
Gas pressurized
6.5J 16", 7.0J 17"
215/65 R16, 235/60 R16, 235/55 R17
2.1kgf/cm2, (30psi)
030'
336'30'
02 (00.079)
1246'30'
-55'30'
5.62 (0.2200.079)
-
90 ~ 110 (9.0 ~ 11.0)

45 ~ 60 (4.5 ~ 6.0)
140 ~ 160 (14.0 ~ 16.0)
60 ~ 70 (6.0 ~ 7.0)
FR: 140 ~ 160 (14.0 ~ 16.0), RR: 100 ~ 120 (10.0 ~ 120)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
45 ~ 55 (4.5 ~ 5.5)
30 ~ 40 (3.0 ~ 4.0)
140 ~ 160 (14.0 ~ 16.0)
40 ~ 55 (4.0 ~ 5.5)
100 ~ 120 (10.0 ~ 12.0)
KM-15

DSL D2.0 VGT
GSL 2.0
GSL 2.7
45 ~ 55 (4.5 ~ 5.5)
50 ~ 60 (5.0 ~ 6.0)
2WD: 160 ~ 180 (16.0 ~ 18.0), 4WD: 140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
Engine
DSL D2.0 WGT
Steering System
Type
Rack stroke
Quality
Quantity
(lmp.qt)
mm (in.)
Inner
Outer
kPa
Gasoline
Power steering pump
(kgf/cm
relief pressure
Diesel
)
Steering angle
Rack and Pinion

PSF-3 or PSF-4
0.75 ~ 0.8 (0.66 ~ 0.70)
140 (5.51)
36.77130'
31.74
8630 ~ 9120 (88 ~ 93)
9120 ~ 9611 (93 ~ 98)
35 ~ 45 (3.5 ~ 4.5)
13 ~ 18 (1.3 ~ 1.8)
15 ~ 20 (1.5 ~ 2.0)
15 ~ 20 (1.5 ~ 2.0)
45 ~ 60 (4.5 ~ 6.0)
DSL: 17 ~ 26 (1.7 ~ 2.6), GSL: 35 ~ 50 (3.5 ~ 5.0)
65 ~ 75 (6.5 ~ 7.5)
60 ~ 80 (6.0 ~ 8.0)
KM-16
Restraints
Type
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
Driver Airbag (DAB)
Passenger Airbag
Bolt
Side Airbag (SAB)
SRSCM Mounting Bolt
Depowered
1.6 ~ 5.7
1.6 ~ 5.7
1.6 ~ 5.7
1.6 ~ 5.7
1.6 ~ 5.7
7.84 ~ 10.79 (0.8 ~ 1.1)
18.63 ~ 26.48 (1.9 ~ 2.7)
6.86 ~ 8.83 (0.7 ~ 0.9)
5.88 ~ 9.8 (0.6 ~ 1.0)
39.22 ~ 53.94 (4.0 ~ 5.5)
6.86 ~ 8.83 (0.7 ~ 0.9)
8.83 ~ 10.79 (0.9 ~ 1.1)
8.83 ~ 10.79 (0.9 ~ 1.1)
KM-17

Engine
DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7
Brake System
Master cylinder
Type
I.D.
CBS
ABS
Piston stroke
Output port
Proportioning valve
Decompression ratio
Brake booster
Type
Effective diameter
Front brake(Disc)
Type
Disc O.D.
Disc O.D.
Disc thickness
Pad thickness
mm (in.)
mm (in.)
mm (in.)
MPa
(kg/cm)
2WD
4WD
Tandem type
23.8 (0.937)
25.4 (1.0)
30 ~ 32 (1.18 ~ 1.26)
4 port
Provided
1.47 (15)
0.27 : 1
0.32 : 1
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
vacuum
8 + 9 in
9:01
280 (11.02)
172 (6.77)
26 (1.02)
11 (0.43)
KM-18
Cylinder type
Cylinder I.D.
Rear brake(Drum)
Type
Drum I.D.
Rear brake(Disc)
Type
Disc O.D.
2WD
4WD
Parking Brake Drum I.D.

Disc thickness
Pad thickness
Cylinder type
Cylinder I.D
Parking brake
Type
Actuation
O.D=Outer Diameter
I.D=Inner Diameter
ABS : Anti-lock Brake System
mm (in.)
Single piston
60 (2.36)
mm (in.)
mm (in.)
mm (in.)
Leading trailing drum

228.6 (9.0)
4.5 (0.17)
Automatic
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)

262 (10.31)
284 (11.18)
190 (7.48)
10 (0.39)
10 (0.39)
Single piston
34 (1.34)
Lever
KM-19

DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
Engine
Anti-lock Brake System(ABS) / Electronic Stability Program(ESP)
HECU
System
0.2 ~ 1.3 (0.008 ~ 0.051)
mm(in.)
CBS
0.5 ~ 1.5 (0.019 ~ 0.059)
mm(in.)
Air gap ABS
Acitve wheel speed
0.5 ~ 1.5 (0.019 ~ 0.059)
sensor
mm(in.)
ESP
Tone
48
teeth
wheel(ABS)
Service standard
163 (6.42 )
mm (in.)
Brake pedal height
128 (5.04)
mm (in.)
3 ~ 8 (0.11 ~ 0.31)
mm (in.)
82 (3.23)
mm (in.)
Brake pedal floorboard clearance
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
stopper clearance
mm (in.)
piston clearance
7 ~ 8 clicks
11 (0.43)
mm (in.)
26 (1.02)
mm (in.)
4.5 (0.177)
mm (in.)
228.6 (9)
mm (in.)
Rear drum brake drum I.D.
10 (0.39)
mm (in.)
10 (0.39)
mm (in.)
GSL 2.7
KM-20

Brake booster vacuum hose fitting to surge tank
Bleeder screw
Push rod locking nut
Tightening torque [N.m (kgf-m)] (ABS & TCS)
Active wheel speed sensor mounting bolt Front
on the brake plate
Rear
HECU mounting bolt
Brake tubes nut
Air bleeder screw
Tightening torque [N.m (kgf-m)] (ESP)
Yaw rate lateral acceleration sensor nut
Steering wheel nut
35 ~ 55 (3.5 ~ 5.5)
8 ~ 12 (0.8 ~ 1.2)
13 ~ 16 (1.3 ~ 1.6)
15 ~ 18 (1.5 ~ 1.8)
7 ~ 13 (0.7 ~ 1.3)
13 ~ 17 (1.3 ~ 1.7)
85 ~ 100 (8.5 ~ 10)
25 ~ 30 (2.5 ~ 3.0)
200 ~ 260 (20 ~ 26)
16 ~ 22 (1.6 ~ 2.2)
22 ~ 32 (2.2 ~ 3.2)
8 ~ 9 (0.8 ~ 0.9)
8 ~ 9 (0.8 ~ 0.9)
8 ~ 10 (0.8 ~ 1.0)
17 ~ 26 (1.7 ~ 2.6)
12 ~ 16 (1.2 ~ 1.6)
7 ~ 13 (0.7 ~ 1.3)
4 ~ 6 (0.4 ~ 0.6)
40 ~ 50 (4.0 ~ 5.0)
22.4 ~ 26.5 (2.24 ~ 2.65)
KM-21

Engine
DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7

Hood
Type
Construction
Front door
Regulator system
Locking system
Construction
Rear door
Regulator system
Locking system
Tailgate
Type
mm (in.)
Windshield
mm (in.)
Front door
Glass thickness
mm (in.)
Rear window
Front
Seat belts
Rear
Door hinge to body
Door hinge to door
Tailgate
Tailgate latch to tailgate
Tailgate hinge to
Hood hinge to body
Hood
Hood hinge to hood
Hood latch to body

Wire drum type
Pin-fork system
Wire drum type
Pin-fork system
5 (0.1969)
3.2 (0.1260)
3.2 (0.1260)
3.2 (0.1260)
33.3~41.2 (3.4~4.2)
21.6~26.5 (2.2~2.7)
6.9~10.8 (0.7~1.1)
6.9~10.8 (0.7~1.1)
6.9~10.8 (0.7~1.1)
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.2~2.7)
6.9~8.8 (0.7~0.9)
KM-22
Seat
Seat belt
Front seat mounting

43.1~64.7 (4.4~6.6)
43.1~64.7 (4.4~6.6)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)

Audio
AM/FM/Cassette
(M420)
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
Frequency range /
Channel space
FM
AM
MW
LW
FM
AM
AM/FM/CD
AM/FM/Cassette/ AM/FM/Cassette/
(M445)
MP3 (M455)
6CDC (M465)
DC 14.4V
Max 43W x 4
Max 50W x 4
4 x 4
2 x 4
80PF 75
76.0~90.0 MHz/ 100KHz (Japan)
522~1629KHz/ 9KHz (Japan)
KM-23

Engine
Items
Life of battery
Button
DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7
Transmitter(TX)
10m or more
Door lock/unlock/Tailgate open/Panic(option)
433.92 MHz (EUROPE)
315.00 MHz (GENERAL)
Lighting system
Head lamp
Front position lamp
Front fog lamp
Rear tail/stop lamp
Back up lamp
License plate lamp
Side repeater
Room lamp
Glove box lamp
High
Low
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
60
55
21
5
35
21/5
16
21
21
5
5
10
10 x 2
LED
5
KM-24
Trunk room lamp

Door courtesy lamp
Other system
Immobilizer
5
5
W
W
Type
Manufacturer
SMARTRA system
Bosch

Air conditioner
Type
Compressor
Oil type & Capacity
Condeser
Pulley type
Displacement
Heat rejection
High
Triple switch
Low
Medium
Expansion valve
Refrigerant
Type
Type
Capacity
10PA17C (Swash plate)
10PA15C
(Swash plate)
10PA17C
(Swash plate)
ND-OIL8(PAG) 200~215cc
ND-OIL8(PAG)
120~135cc
ND-OIL8(PAG)
200~215cc
6PK - type
177.7 cc/rev
psi
(kg/cm
psi
(kg/cm
psi
(kg/cm
[oz.(g)]
4PK - type
155.3 cc/rev
13,500 5% Kcal/hr
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 : 220 11.4 (15.5 0.8)
OFF : 164 17.1 (11.5 1.2)
Block
R - 134a
18.0 0.88 (510 25)
6PK - type
177.7 cc/rev
KM-25

DSL D2.0 WGT
DSL D2.0 VGT
GSL 2.0
GSL 2.7
Engine
Blower unit
Actuator
Siroco
Type
Auto + 8speed (Autometic) , 9 speed (Manual)
Blower
Speed step
Speed control
Particle filter
Air filter
Type
Pin & Tube type
Type
4,500 5% Kcal/hr
Heating capacity
9000W +5% / -10%
PTC capccity
Heater
Actuator
Actuator
method
ON : 2.5 0.5 (36.5 32.9)
Evaporator
A/C ON/OFF
()
OFF : 0.5 0.5 (37.4 32.9)
KM-26
Sorento(BL)
F/L
BL-2
BL-9
BL-10
Fuel System..
BL-11
Clutch.
BL-11
Manual Transaxle.
BL-12
Automatic Transaxle
BL-13
Driveshaft..
BL-16
Suspension System.
Steering System BL-18
RestraintsBL-18
BL-19
Brake System
Body (Interior & Exterior). BL-22
BL-24
Heating, Ventilation & Air Conditioning..BL-26
BL-1
General specifications - Sorento F/L

Engine
DSL A2.5 WGT
DSL A2.5 VGT
GSL 3.3
GSL 3.8
Engine
Type
Number of cylinders
In-line, DOHC
4
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
mm (in.)
91 (3.58 ) x 96 (3.78 )
cc
2.497
17.7 : 1
1-3-4-2
800 100
800 100
800 100
800 100
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
V-type, DOHC
6
92 (3.6220)
x 83.8 (3.2992)
96 (3.7795)
x 87.0 (3.425)
3.342
3,778
10.4 : 1
1-2-3-4-5-6
BTDC 7 5
650 100
650 100
650 100
650 100
8.2 (7.21)
7.4 (6.51)
CH - 4
6.4 (5.63)
5.5 (4.84)
0.4 (0.35)
5.2 (4.58)
Above SJ or SL
130(1.32)
[at 1000rpm, 110C(230F)]
BL-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
Cylinder head
Intake
mounting surface
Exhaust
Camshaft
LH
Cam height
RH
8
38
52
8
mm (in.)
mm (in.)
mm (in.)
Intake mm (in.)
Exhaust mm (in.)
Intake mm (in.)
Exhaust mm (in.)
-14
66
52
0
-10
66
52
0
0.15 (0.0059)
0.15 (0.0059)
0.15 (0.0059)
Less than 0.05 (0.0019)

Less than 0.1(0.0039)
Less than 0.1(0.0039)
40.163 (1.5812)
40.043 (1.5765)
39.782 (1.5662)
40.456 (1.5928)
46.3 (1.8228)
46.8 (1.8425)
45.8 (1.8031)
46.3 (1.8228)
46.8(1.8425)
45.8 (1.8031)
No.1 : 27.964 ~ 27.978

(1.1009 ~ 1.1015)
No.2,3,4 : 23.954 ~ 23.970
(0.9430 ~ 0.9437)
mm (in.)
No.1: 0.027 ~ 0.057

(0.0011 ~ 0.0022)
No.2,3,4 : 0.030 ~ 0.067
(0.0012 ~ 0.0026)
End play
mm (in.)
0.10 ~ 0.20 (0.0039 ~ 0.0079)
0.02 ~ 0.18 (0.0008 ~ 0.0071)
BL-3

Engine
Valve
DSL A2.5 WGT
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Intake
Exhaust
Intake
Exhaust
DSL A2.5 VGT
GSL 3.3
GSL 3.8
mm (in.)
mm (in.)
mm (in.)
mm (in.)
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)
0.020 ~ 0.050 (0.0008 ~ 0.0020)
0.050 ~ 0.080 (0.0020 ~ 0.0031)
105.27 (4.1445)
105.50 (4.1535)
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)
1.73 ~ 2.03 (0.06811 ~ 0.07992)
0.020~0.047 (0.00078 ~0.00185)
0.030 ~ 0.054 (0.00118 ~0.00212)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
43.3 (1.705)
39.4 (1.551)
5.500 ~ 5.512 (0.2165 ~ 0.2170)

5.500 ~ 5.512 (0.2165 ~ 0.2170)
41.8 ~ 42.2 (1.6457 ~ 1.6614)
41.8 ~ 42.2 (1.6457 ~ 1.6614)
Intake
Exhaust
mm (in.)
mm (in.)
Seat angle
Valve spring
Free length
1.5 (0.059)
1.7 (0.067)
45
1.15 ~ 1.45 (0.05118~0.05709)

1.35 ~ 1.65 (0.05315~0.06496)
44.75 ~ 45.20
mm (in.)
48.2 (1.898)
43.86 (1.7267)
Load
mm (in.)
26.3 1.2 kg / 38
51.5 2.4 kg / 28.8
19.3 0.8kg / 34.0

42.3 1.3kg / 24.2
Less than 1.5
Valve length
Stem outer diameter
Face angle
(margin)
Valve stem to valve
guide clearance
Valve guide
Inner diameter
Length
Valve seat
Out of squareness
BL-4
MLA
MLA outer diameter
bore inner diameter
MLA to tappet bore
clearance
Valve clearance
Intake
Exhaust
Cylinder block
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
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)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
mm (in.)
mm (in.)
0.17 ~ 0.23 (0.0067 ~ 0.0090)

0.27 ~ 0.33 (0.0106 ~ 0.0129)
Cylinder bore
mm (in.) 91.000 ~ 91.030 (3.5827 ~ 3.5839)
mm (in.)
0.05 (0.0020)
92.00 ~ 92.03
96.00 ~ 96.03
(3.6220 ~ 3.6232) (3.7795 ~ 3.7807)
Less than 0.05 (0.0019)
[Less than 0.02 (0.0008) / 150x150]
Piston
mm (in.) 90.910 ~ 90.940 (3.5791 ~ 3.5803)
mm (in.)
Ring groove width
0.080 ~ 0.100 (0.0031 ~ 0.0039)

2.378 ~ 2.398 (0.0936 ~ 0.0944)
2.04 ~ 2.06 (0.0803 ~ 0.0811)
3.03 ~ 3.05 (0.1193 ~ 0.1201)
91.96 ~ 92.00
95.96 ~ 95.99
(3.6205 ~ 3.6220) (3.7779 ~ 3.7791)
0.03 ~ 0.05 (0.0012 ~ 0.0020)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
2.01 ~ 2.03 (0.0791 ~ 0.0799)
BL-5

Engine
Piston ring
Side clearance
End gap
DSL A2.5 WGT

Piston pin
Connecting rod
End play
Crankshaft
End play
DSL A2.5 VGT
0.05 ~ 0.09 (0.0020 ~ 0.0035)

0.04 ~ 0.08 (0.0016 ~ 0.0031)
0.25 ~ 0.40 (0.0098 ~ 0.0157)
0.50 ~ 0.70 (0.0197 ~ 0.0276)
0.20 ~ 0.40 (0.0079 ~ 0.0157)
GSL 3.3
GSL 3.8
0.03 ~ 0.07 (0.0012 ~ 0.0027)

0.03 ~ 0.07 (0.0012 ~ 0.0027)
0.06 ~ 0.15 (0.0024 ~ 0.0059)
0.17 ~ 0.32 (0.0067 ~ 0.0126)
0.32 ~ 0.47 (0.0126 ~ 0.0185)
0.20 ~ 0.70 (0.0078 ~ 0.0275)
mm (in.) 32.993 ~ 32.998 (1.2989 ~ 1.2991)

mm (in.) 33.014 ~ 33.019 (12.998 ~ 1.3000)
mm (in.) 0.016 ~ 0.026 (0.0006 ~ 0.0010)
mm (in.) 33.020 ~ 33.033 (1.3000 ~ 1.3005)
mm (in.) 0.022 ~ 0.040 (0.0009 ~ 0.0016)
23.001 ~ 23.006 (0.9055 ~ 0.9057)

23.016 ~ 23.021 (0.9061 ~ 0.9063)
0.01 ~ 0.02 (0.0039 ~ 0.0078)
22.974 ~ 22.985 (0.9045 ~ 0.9049)
-0.032 ~ -0.016 (-0.0012~0.0006)
mm (in.) 60.000 ~ 60.018 (2.3622 ~ 2.3629)

mm (in.) 0.024 ~ 0.042 (0.0009 ~ 0.0016)
mm (in.)
58.000 ~ 58.018 (2.2834 ~2.2842)

0.038 ~ 0.056 (0.0015 ~ 0.0022)
0.1 ~ 0.25 (0.0039 ~ 0.0098)
mm (in.) 66.982 ~ 67.000 (2.6371 ~ 2.6378)

mm (in.) 56.982 ~ 57.000 (2.2434 ~ 2.2441)
mm (in.) 0.030 ~ 0.054 (0.0012 ~ 0.0021)
0.05 ~ 0.25 (0.0020 ~ 0.0098)
mm (in.)
68.942 ~ 68.960 (2.7142 ~ 2.7149)

54.954 ~ 54.972 (2.1635 ~ 2.1642)
0.022 ~ 0.040 (0.0008 ~ 0.0016)
0.10 ~ 0.28 (0.0039 ~ 0.0110)
BL-6
Oil pump
kPa
(kg/cm)
Cooling system
Cooling method
Coolant quantity
(lmp.qt)
C (F)
C (F)
mm (in.)
Opening
Thermostat
Full opening
Full lift
Main valve
kPa
(kg/cm)
opening press.
Radiator cap
Vacuum valve
kPa
Type
k
20C (68F)
Resistance
k
80C (176F)
784.5 78.4 (8 0.8)
450 ~ 550 (4.59 ~ 5.61)
10 (8.80)
9.0 (7.83)
82 (180)
95 (203)
-
82 2 (179.6 35.6)
95 (203)
10 (0.3937)
93.16 ~ 122.58 (0.95 ~ 1.25 )
0.98 ~ 4.90 (0.01 ~ 0.05)
Thermister type
2.31 ~ 2.59
0,3222
BL-7

Engine
Main moving system
Bolts
Inner bolt (M11)
Crankshaft
main bearing cap
Out bolt (M8)
Side bolt (M8)
Cylinder head
Long bolts
Cylinder head bolt
Short bolts
Lubrication system
Oil filter
Oil filter cap
Oil pan drain plug
Lower oil pan bolt
DSL A2.5 WGT
DSL A2.5 VGT
GSL 3.3
GSL 3.8
58.8 + 34.3 (6.0 + 3.5) + 60 ~ 64

127.5 ~ 137.3 (13 ~ 14)
-
19.60 (2.0) + 90
49.00 (5.0) + 90
19.60 (2.0) + 120
29.40 ~ 31.36 (3.0 ~ 3.2)
13.7 ~ 14.7 (1.4 ~ 1.6)
9.80 ~ 11.76 (1.0 ~ 1.2)

39.2 (4.0) + 120 + 90
18.62 ~ 23.52 (1.9 ~ 2.4)
49.0 (5.0) +120+90

21.6 ~ 24.5 (2.2 ~ 2.5)
29.8 ~ 11.8 (1.0 ~ 1.2)
34.3 ~ 44.1 (3.5 ~ 4.5)
-
24.5 (2.5)
34.3 ~ 44.1 (3.5 ~ 4.5)
9.80 ~ 11.76 (1.0 ~ 1.2)
BL-8

Rated voltage
Starter No-load
charasteristics
Generator
Battery
Ignition coil
Spark plugs
V
Voltage
A
Amperage
Speed
Type
Rated voltage
Speed in use
Regulator setting
Type
Cold cranking
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
Unleaded (NGK)
Leaded (CHAMPION)
mm(in.)
Gap
12V, 2.2KW
11
130, MAX
4,500rpm, MIN
13.5V, 110A
14.4 0.3V
MF 100 AH
850A
182min
12 V, 1.4 kW
11,5
85, MAX
2,600 rpm, MIN
13.5 V, 130A
1,000 ~ 18,000 rpm
14.2 ~ 14.8 V (500 RPM, 10A, 25C)
CMF 70AH
CMF 80AH
600 A
660 A
120 min
145 min
1.280 0.01
0.62 10 %
7.0 15 %
IFR5G-11
BKR5ES
1.0 ~ 1.1 (0.0394 ~ 0.0433)
BL-9

Engine
DSL A2.5 WGT
DSL A2.5 VGT
GSL 3.3
GSL 3.8
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Type
Driven by
MPa
(kgf/cm
)
KPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
Bosch
Delphi
80 (70.39)
Return type
Returnless type
High pressure type

Mechanical
Electrical
In-tank type
Drive Belt
Electric motor
135 (1,377)
160 (1,632)
-
375 ~ 385 (3.82 ~ 3.92)
BL-10
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic type
15~22 (1.5~2.2)
25~35 (2.5~3.5)
18~27 ( 1.8~2.7)
19~26 (1.9~2.6)
mm (in.)
mm (in.)
150 (5.91)
7.3~13.9 (0.28~0.55)
Manual Transaxle
Type
Gear ratio
M5UR1
3,749
2,044
1,289
1,000
1st
2nd
3rd
4th
5th
Rev.
0,794
3,453
SAE 75W-90
(Fill-for-life)
M/T oil quality

MT oil capacity
2WD
4WD
(lmp.qt)
3.2 (2.8)
2.7 (2.38)
M5SR1
4,393
2,306
1,452
1,000
0,825
4,632
SAE 75W/85 or
API GL - 4
3.5 (3.07)
BL-11

Engine
DSL A2.5 WGT
DSL A2.5 VGT
GSL 3.3
GSL 3.8
Automatic Transaxle
Type
Gear ratio
ATF quality
ATF capacity
A5SR1
3,827
2,368
1,520
1,000
0,834
2,613
1st
2nd
3rd
4th
5th
Rev.
(lmp.qt)
A5SR2
A5SR1
4,497
3,827
2,442
2,368
1,686
1,520
1,233
1,000
0,868
0,834
4,586
2,613
APOLLOIL ATF RED-1
10 (8.8)
A5SR2
4,497
2,442
1,686
1,233
0,868
4,586
BL-12
Driveshaft
Propeller shaft
Front
Rear
Joint type
Front
(4WD)
UJ + UJ
UJ + UJ
M/T
mm (in.)
A/T
mm (in.)
M/T
mm (in.)
A/T
mm (in.)
M/T
mm (in.)
1496 76.2
(58.90 3.00)
A/T
mm (in.)
1476 76.2
(58.11 3.00)
660.4 63.5
(26.00 2.50)
Length O.D.
Rear
(4WD)
Rear
(2WD)
Run-out
[NOTE]
UJ : Universal Joint
O.D. : Outer Diameter
mm (in.)
1137 76.2
(44.76 3.00)
640.8 63.5
(25.23 2.50)
675 63.5
(26.57 2.50)
625.5 63.5
(24.63 2.52)
1156 76.2
(45.51 3.00)
1123 76.2
(44.21 3.00)
1172 76.2
(46.14 3.00)
1462.8 76.2
(57.59 3.00)
0.3 (0.01)
1531.6 76.2
(60.30 3.00)
BL-13

Engine
Front axle and driveshaft
Front axle hub bearing type
DSL A2.5 WGT
DSL A2.5 VGT
Double taper roller bearing

TSJ
BJ
Hypoid gear
3,727
Inner
Outer
Driveshaft Joint type
Reduction gear type

Differential (4WD)
Reduction ratio
M/T
A/T
Rear axle and axle shaft

Axle housing type
Axle shaft supporting type
Reduction gear type
M/T
Differential
Reduction ratio
A/T
GSL 3.3
4,181
3,333
Banjo type
Semi-floating type
Hypoid gear
3,727
4,181
3,333
GSL 3.8
3,333
3,333
BJ : Birfield Joint
TSJ : Three Spherical Joint
BL-14
Lubricants
Driveshaft
Joint type
Recommended grease
g
Quantity
LSD Oii
Quantity
RBA
210
150
SAE90, API GL-5 (MOBIL : MOBIL LUBE HD,

SHELL : SHELL SPIRRAX HD)
hypoid gear oil

Differential
TSJ
BJ
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
[NOTE]
BL-15

Suspension System
Front
Double wishbone
Suspension type
Shock absorber type
Wheel size
Gas pressurized
7.0JJ 16", 7.0JJ 17"
245/70 R16, 245/65 R17
Steel
Aluminum
Tire size
Tire pressure
Wheel alignment
Rear
5 link coil spring
2.4kgf/cm2 (35psi)
Camber
Caster
Toe-in
King-pin
mm (in.)
0.000.5
3.890.5
02 (00.079)
12.13
030'
02 (00.079)
-
BL-16

Hub nuts
Front strut assembly to frame
Front strut assembly to lower arm
Front stabilizer link to lower arm
Front lower arm to frame
Front upper arm to knuckle
Front upper arm to frame
Rear shock absorber to frame
Rear shock absorber to rear axle
Rear upper arm to rear axle
Rear upper arm to frame
Rear lower arm to rear axle
Rear lower arm to frame
Rear stabilizer link to frame
Lateral rod to rear axle
90 ~ 120 (9.0 ~ 12.0)

44 ~ 55 (4.4 ~ 5.5)
122 ~ 140 (12.2 ~ 14.0)
100 ~ 120 (10.0 ~ 12.0)
160 ~ 200 (16.0 ~ 20.0)
145 ~ 165 (14.5 ~ 16.5)
44 ~ 55 (4.4 ~ 5.5)
76 ~ 95 (7.6 ~ 9.5)
100 ~ 120 (10.0 ~ 12.0)
44 ~ 55 (4.4 ~ 5.5)
70 ~ 85 (7.0 ~ 8.5)
122 ~ 140 (12.2 ~ 14.0)
122 ~ 140 (12.2 ~ 14.0)
122 ~ 140 (12.2 ~ 14.0)
140 ~ 160 (14.0 ~ 16.0)
140 ~ 160 (14.0 ~ 16.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
45 ~ 55 (4.5 ~ 5.5)
187 ~ 225 (18.7 ~ 22.5)
187 ~ 225 (18.7 ~ 22.5)
BL-17

Engine
DSL A2.5 WGT
DSL A2.5 VGT
GSL 3.3
GSL 3.8
Steering System
Type
Rack stroke
mm (in.)
kPa
(kgf/cm
)

Steering gear box mounting bolt
Steering gear box mounting clamp bolt and nut
Rack and Pinion

PSF-3
162 (6.38)
8336 ~ 9002 (85 ~ 92)
40 ~ 50 (4.0 ~ 5.0)
16 ~ 23 (1.6 ~ 2.3)
22 ~ 27 (2.2 ~ 2.7)
22 ~ 27 (2.2 ~ 2.7)
60 ~ 80 (6.0 ~ 8.0)
DSL: 20 ~ 30 (2.0 ~ 3.0), GSL: 35 ~ 50 (3.0 ~ 5.0)
55 ~ 65 (5.5 ~ 6.5)
122 ~ 158 (12.2 ~ 15.8)
85 ~ 110 (8.5 ~ 11.0)
Restraints
Type
Resistance
Driver Airbag (DAB)
Depowered
1.6 ~ 6.4
1.8 ~ 6.4
1.8 ~ 4.8
1.8 ~ 6.4
BL-18

Driver Airbag (DAB)
Bolt
Passenger Airbag
(PAB)
Nut
SRSCM Mounting Bolt
7.9 ~ 10.8 (0.8 ~ 1.1)

18.6 ~ 26.5 (1.9 ~ 2.7)
8.8 ~ 13.7 (0.9 ~ 1.4)
7.8 ~ 11.8 (0.8 ~ 1.2)
39.2 ~ 53.9 (4.0 ~ 5.5)
10.2 ~ 13.8 (1.0 ~ 1.4)
10.2 ~ 13.8 (1.0 ~ 1.4)
10.2 ~ 13.8 (1.0 ~ 1.4)
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
Brake booster
Type
Effective diameter
Boosting ratio
DOT 3 or equivalent
As required
mm (in.)
Tandem type
26.99 (1.06)
Provided
mm (in.)
Vacuum type with tandem booster

8 + 9 in
7.5 : 1
BL-19

Engine
Front brake
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
Rear brake(Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D
Parking brake
Type
Actuation
Drum I.D.
Lining thickness
O.D=Outer Diameter
I.D=Inner Diameter
DSL A2.5 WGT
mm (in.)
mm (in.)
mm (in.)
mm (in.)
DSL A2.5 VGT
GSL 3.3

302 (11.89)
28 (1.10)
10.5 (0.41)
Double piston
46 (1.81)
mm (in.)

315 (12.4)
20 (0.787)
10 (0.39)
Single piston
42.9 (1.69)
mm (in.)
mm (in.)
DIH(Drum in hat) type

lever
190 (7.48)
4 (0.157)
mm (in.)
mm (in.)
mm (in.)
GSL 3.8
BL-20

HECU
System
0.15 ~ 1.5 (0.006 ~ 0.059)
Front mm(in.)
Air gap
Acitve wheel speed
0.2 ~ 1.2 (0.008 ~ 0.047)
Rear mm(in.)
sensor
48
teeth
Tone wheel
Service standard
200 (7.87 )
mm (in.)
Brake pedal height
Clearance between stop lamp switch
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
outer case and pedal arm
4 ~ 7 (0.157 ~ 0.275)
mm (in.)
4 ~ 6 clicke (When lever assembly is pulled with 10kgf)
Parking brake lever stroke
2.0 (0.0787)
mm (in.)
26 (1.02)
mm (in.)
0.03 (0.0012)
mm (in.)
Front disc runout
0.005 (0.0002)
mm (in.)
Front disc thickness variation
2.0 (0.079)
mm (in.)
18.4 (0.724)
mm (in.)
Rear disc thickness
191 (7.52)
mm (in.)
Parking brake drum I.D.
1.5 (0.059)
mm (in.)
Parking brake liner thickness
7 ~ 10 (0.7 ~ 1.0)
Sensor mounting bolt on Front
7 ~ 10 (0.7 ~ 1.0)
the brake plate
Rear
8 ~ 12 (0.8 ~ 1.2)
HECU mounting nut
19 ~ 26 (1.9 ~ 2.6)
13 ~ 22 (1.3 ~ 2.2)
Six brake tubes on the hydraulic unit
BL-21

Engine
DSL A2.5 WGT
DSL A2.5 VGT
GSL 3.3
GSL 3.8

Hood
Front door
Tailgate
Glass thickness
Seat belts
Type
Construction
Regulator system
Locking system
Type
mm (in.)
Windshield
mm (in.)
Front door
Quarter window mm (in.)
Tailgate glass mm (in.)
Front
Rear

X-arm type
Pin-fork system
5 (0.1969)
3.5 (0.1378)
3.5 (0.1378)
3.5 (0.1378)
3.5 (0.1378)
BL-22

Front fender
Mounting bolts
Checker (Body side)
Checker (Door side)
Hinge (Body side)
Hinge (Door side)
Glass grip bolt
Glass guide
Front door
Regulator assembly
Latch assembly
Outside handle
Striker
Outside rearview mirror
Checker (Body side)
Checker (Door side)
Hinge (Body side)
Hinge (Door side)
Rear door
Glass grip bolt
Regulator assembly
Latch assembly
Outside handle
Striker
Crash pad
Cross bar mounting
Seat
Seat mounting bolt/nut
Hinge
Hood
Latch assembly
7~9 (0.7 ~ 0.9)

22~27 (2.2~2.7)
9~13 (0.9~1.3)
35~42 (3.5~4.2)
18~30 (1.8~3.0)
8~12 (0.8~1.2)
8~12 (0.8~1.2)
4~6 (0.4~0.6)
4~6 (0.4~0.6)
7~11 (0.7~1.1)
18~26 (1.8~2.6)
5~7 (0.5~0.7)
22~27 (2.2~2.7)
9~13 (0.9~1.3)
35~42 (3.5~4.2)
18~30 (1.8~3.0)
8~12 (0.8~1.2)
4~6 (0.4~0.6)
4~6 (0.4~0.6)
7~11 (0.7~1.1)
18~26 (1.8~2.6)
17~26 (1.7~2.6)
39 (3.9)
22~27 (2.2~2.7)
7~11 (0.7~1.1)
BL-23

Engine
Seat belt
DSL A2.5 WGT

mounting bolt
DSL A2.5 VGT

GSL 3.3
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
GSL 3.8
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
Frequency range /
Channel space
FM
AM
MW
LW
RADIO/TAPE/CD/MP3 (M455)
RADIO/TAPE/6CDC (M465)
DC 14.4V
Max 43W x 4
3.2Vrms
4 x 4
10
80PF 75
87.5~108 MHz / 100KHz (General), 50KHz(Europe)
531~1602 KHz / 9KHz (General)
522~1620 KHz / 9KHz (Europe)
BL-24

Items
Life of battery
Button
Transmitter(TX)
5m or more
Door lock / unlock, rear hatch glass open, panic
433MHz 250MHz (Except Middle east)
315MHz 250 MHz (Middle east)
Lighting system
Head lamp
Front position lamp
Front fog lamp
Rear tail/stop lamp
Back up lamp
License plate lamp
Room lamp
Luggage lamp
Door courtesy lamp
High
Low
W
W
W
W
W
W
W
W
W
W
W
W
W
55
55
21
5
27
21/5
16
21
5
10 x 2
10 x 2
5
5
BL-25

Engine
Other system
DSL A2.5 WGT
Type
Manufacturer
Type
SMART KEY
Manufacturer
Immobilizer
DSL A2.5 VGT
GSL 3.3
GSL 3.8
SMARTRA system
Bosch
4 channel
Button type (Front door)
SIEMENS

Air conditioner
Compressor
Condeser
APT
(A/C pressure
Expansion valve
Refrigerant
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
the pressure
Type
Type
Capacity [oz.(g)]
HS - 18 (Swash plate)
FD46XG (PAG) , 150 10cc
4PK - TYPE
110 cc/rev
8,500 10% Kcal/hr
Voltage = 5 * (0.025 * pressure + 0.1) [Kgf/]
Voltage = 5 * (0.001758 * pressure + 0.074612) [PSIA]
Block
R - 134a
18.25 0.88 (540 25)
BL-26
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
Type
Evaporator
A/C ON/OFF C (F)
Actuator
Siroco fan
Power mosfet
Particle filter
Pin & Tube type
5,000 5% Kcal/hr
Actuator
Actuator
Drawn cup
Thermistor
Off : 0 0.5 (32 32.9)
ON : 2.5 0.5 (36.5 32.9)
BL-27
Mohave
/Borrego(HM)
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
HM-26
Heating, Ventilation & Air Conditioning
BL-1
General specifications -MOHAVE / HM

Engine
D 3.0 TCI
G 3.8 DOHC
G 4.6 DOHC
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
Oil pressure (Idle)
kPa
(kg/cm)
V-type, DOHC
6
84.0mm (3.3071in) x 89.0mm
(3.5039in)
2.959
17.3 0.5 : 1
1-2-3-4-5-6
-
680rpm
7.8L(8.24US qt,6.86imp qt)

6.4L(6.76US qt, 5.63imp qt)
7.4L(7.82US qt,6.51imp qt)
API CH - 4 , ACEA B4
0.8kg/(7.85kpa , 1.14psi)
V-type, DOHC
8
96 (3.7795)
92 (3.6220)
x 87 (3.4252)
x 87 (3.4252)
3.778
4,627
10.4 : 1
1-2-3-4-5-6
1-2-7-8-4-5-63
BTDC 11 5
720 100
570 100
720 100
630 100
6.0L(5.28)
5.5 (4.84)
0.4 (0.35)
5.2 (4.58)
Above SJ or SL,SAE5w-20
130(1.32)
[at 1000rpm, 110C(230F)]
BL-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
Cylinder head
Intake
mounting surface
Exhaust
Camshaft
13
34
55
15
10
66
52
0
8
74
62
4
0.05 (0.0020in)
0.016 (0.0006in)
0.016 (0.0006in)
Less than 0.05mm

0.02mm
Less than 0.1(0.0039)
Less than 0.1(0.0039)
Intake mm (in.)
Exhaustmm (in.)
Intake mm (in.)
Exhaustmm (in.)
36.000~40.152mm
36.000~40.477mm
36.000~40.152mm
36.000~40.477mm
46.3 (1.8228)
41.6mm(15.4in)
45.8 (1.8031)
41 5mm(16 3in)
46.3 (1.8228)
41.6mm(15.4in)
45.8 (1.8031)
41 5mm(16 3in)
No1:
No1
24.947 ~ 24.960mm
LH
Cam height
RH
mm (in.)
mm (in.)
mm (in.)
mm (in.)
0.040~0.074mm
End play
mm (in.)
0.05 ~ 0.15mm
27.964 ~27.978
35.964~35.980mm
No.2,3,4:
No.2,3,4
23.954~23.970
No.1:
0.027 ~ 0.057
No.2,3,4 :
0.030 ~ 0.067
0.02 ~ 0.18mm (0.0008 ~
0 0071in )
BL-3
General specifications - MOHAVE/HM

Engine
D 3.0 TCI
G6DA 3.8DOHC
GSL 3.8
Valve
Valve length
Stem outer diameter
Face angle
Thickness of valve
head (margin)
Valve stem to valve
guide clearance
Valve guide
Inner diameter
Length
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
99.3mm
99.3mm
5.960 ~ 5.975mm
5.960 ~ 5.970mm
45.00 ~ 45.25
1.5mm
1.5mm
0.025 ~ 0.052mm
0.030 ~ 0.057mm
105.27 (4.1445)
105.50 (4.1535)
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)
1.73 ~ 2.03 (0.06811 ~ 0.07992)
0.020~0.047 (0.00078 ~0.00185)
0.030 ~ 0.054 (0.00118 ~0.00212)
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
mm (in.)
mm (in.)
6.000 ~ 6.012mm
6.000 ~ 6.012mm
36.25 ~ 36.75mm
36.25 ~ 36.75mm
5.500 ~ 5.512 (0.2165 ~ 0.2170)

5.500 ~ 5.512 (0.2165 ~ 0.2170)
41.8 ~ 42.2 (1.6457 ~ 1.6614)
41.8 ~ 42.2 (1.6457 ~ 1.6614)
Intake
Exhaust
mm (in.)
mm (in.)
1.39 ~ 1.43mm
1.39 ~ 1.43mm
44.5 ~ 45
1.15 ~ 1.45 (0.05118~0.05709)

1.35 ~ 1.65 (0.05315~0.06496)
44.75 ~ 45.20
mm (in.)
48.2 (1.898)
43.86 (1.7267)
Valve seat
Seat angle
Valve spring
Free length
BL-4
175 8N/33.5mm
278 20N/24.8mm
1.5or less
19.3 0.8kg / 34.0

41.5 1.3kg / 24.2
Less than 1.5
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
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)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
0.020 ~ 0.061 (0.0008 ~ 0.0024)
mm (in.)
mm (in.)
0.17 ~ 0.23 (0.0067 ~ 0.0090)

0.27 ~ 0.33 (0.0106 ~ 0.0129)
Cylinder bore
mm (in.)
84.000 ~ 84.030mm
Less than 0.42mm (W), 0.096mm

(L)
mm (in.)
Less than 0 012(50mm x 50mm)
Load
mm (in.)
Out of squareness
MLA
MLA outer diameter
bore inner diameter
MLA to tappet bore
clearance
Valve clearance
Intake
Exhaust
Cylinder block
Piston
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
mm (in.)
mm (in.)
Ring groove width
83.926 ~ 83.956mm
0.064 ~ 0.084 mm
2.434 ~ 2.454mm
1.82 ~ 1.84mm
3.02 ~ 3.04 mm
92.00 ~ 92.03
96.00 ~ 96.03
Less than 0.05 (0.0019)
[Less than 0.02 (0.0008) / 150x150]
91.96 ~ 91.99
95.96 ~ 95.99
0.03 ~ 0.05 (0.0012 ~ 0.0020)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
2.01 ~ 2.03 (0.0791 ~ 0.0799)
BL-5
General specifications -MOHAVE/HM

Engine
Piston ring
Side clearance
End gap
D3.0TCI

Piston pin
mm (in.)
mm (in.)
mm (in.)
Connecting rod small end hole clearancemm (in.)
Connecting rod
Connecting rod big end inner diameter mm (in.)
mm (in.)
mm (in.)
End play
Crankshaft
mm (in.)
mm (in.)
mm (in.)
mm (in.)
End play
0.102 ~ 0.146mm
0.08 ~ 0.12mm
0.03 ~ 0.35mm
0.20 ~ 0.35mm
0.40 ~ 0.60 mm
0.25 ~ 0.50 mm
30.994 ~ 31.000 mm
31.014 ~ 31.021mm
0.014 ~ 0.027mm
31.020 ~ 31.031mm
0.020 ~ 0.037mm
G6DA 3.8DOHC
0.03 ~ 0.07
0 080.03 ~ 0.07
0 080.06 ~ 0.15
0 150.17 ~ 0.32
0 320.32 ~ 0.47
0 520.20 ~ 0.70
0 70
G8BA4.6DOHC
0.04 ~
0.04 ~
0.06 ~
0.17 ~
0.37 ~
0.20 ~
23.001 ~ 23.006
21.995 ~
22 000 ~ 23.021
23.016
22.004 ~
22 010
0.01 ~ 0.02
0.004 ~ 0.015
22.974 ~ 22.985
22.007 ~
22 018
0.032 ~ 0.016 0.007 ~ 0.023
66.500 ~ 66.518 mm
0.024 ~ 0.058mm
0.007 ~ 0.024mm
58.000 ~ 58.018 (2.2834 ~2.2842)

0.038 ~ 0.056 (0.0015 ~ 0.0022)
0.1 ~ 0.25 (0.0039 ~ 0.0098)
75.982 ~ 76.000mm
63.482 ~ 63.500mm
0.030 ~ 0.048mm
01 ~ 0.3mm
68.942 ~ 68.960 (2.7142 ~ 2.7149)

54.954 ~ 54.972 (2.1635 ~ 2.1642)
0.022 ~ 0.040 (0.0008 ~ 0.0016)
0.10 ~ 0.28 (0.0039 ~ 0.0110)
BL-6
Oil pump
kPa
(kg/cm)
Cooling system
Cooling method
450 ~ 550 (4.59 ~ 5.61)

(lmp.qt)
Coolant quantity
Type
Opening
Thermostat
Full opening
Full lift
Main valve
opening press.
Radiator cap
Vacuum valve
opening press.
Type
20C (68F)
Resistance
80C (176F)
C (F)
C (F)
mm (in.)
kPa
(kg/cm)
kPa
(kg/cm)
k
k
14.7L
Wax pellet type
82 2 C
95 (203)
-
Forced circulation with water pump

11.4 (12.0)
82 2 (179.6 35.6)
95 (203)
10 (0.3937)
93.16 ~ 122.58 (0.95 ~ 1.25 )
0 ~ 6.86kpa (0 ~ 0.07)
Thermister type
2.31 ~ 2.59
0,3222
BL-7

Engine
Main moving system
LH
Intake
Camshaft
Exhaust
Cam height
RH
Intake
Camshaft
Exhaust
Cylinder head
Camshaft bearing ladder bolts
long bolt(LH/RH)
Cylinder head bolt
flange bolt(LH/RH)
Lubrication system
Oil gauge bracket
Oil filter cap
Upper Oil pan nuts or bolts1
Upper Oil pan nuts or bolts2
Lower oil pan bolt
D3.0TCI
27.5 ~31.4 + 120 ~ 124

36.000 ~
40 152mm(1
4173~1
36.000
~ 5808in )
40 477mm(1
4173~1
36.000
~ 5936in )
40 152mm(1
4173~1
36.000
~ 5808in )
40 477mm(1 4173~1 5936in )
9.8~11.8
58.8+88~92+118~122
9.8 ~ 11.8
24,5
9.8 ~ 11.8
29.4 ~ 33.3
9.8 ~11.8
G6DA 3.8DOHC
G8BA4.6DOHC
19.60 (2.0) + 90
46.3mm(1.8228in.) /
46 8mm(1 8425in )
45.8mm (1.8031in.)
46.3mm(1.8228in.) /
46 8mm(1 8425in )
45.8mm (1.8031in.)
9.8~11.8
13.7 ~ 14.7
39.2+120+90
32.4~36.3
24.5 (2.5)
34.3 ~ 44.1 (3.5 ~ 4.5)
7.2 ~ 8.7
BL-8

Rated voltage
V
Voltage
Starter No-load
A
Amperage
charasteristics
Speed
Type
Rated voltage
Generator
Speed in use
Regulator setting
Type
Cold cranking
Battery
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Ignition coil
Secondary
k
Unleaded (NGK)
Leaded (CHAMPION)
Spark plugs
mm(in.)
Gap
12V, 2.2KW
11
130, MAX
2.000rpm, MIN
12V, 150A
1000~18000rpm
14.55 0.2V
80-23FL
900A
182min
12 V, 1.4 kW
11,5
85A, MAX
2,600 rpm, MIN
2660rpm MIN
13.5 V, 130A
13.5V ,180A
1,000 ~ 18,000 rpm
12.4 ~ 14.8 V
13.2V ~
14 0V
64-27AH
CMF 80AH
660 A
900 A
145 min
182 min
1.280 0.01
-
0.62 10 %
7.0 15 %
IFR5G-11
T40246P
1.0 ~ 1.1
1.0 ~1.1
BL-9

Engine
D3.0TCI
G6DA 3.8DOHC
G8BA4.6DOHC
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Fuel Pressure
(Maximum)
Fuel Pressure
Regulator
Bosch
Manufacturer
(lmp.qt
82 (21.6U.S.gal,86.6U.S.qt,72.1lmp.qt)
Capacity
)
Return type
Type
High pressure type
Type
Mechanical Plunger Pumping Type
Electrical In-tank type
Type (High Pessere)
Timing chain
Electric motor
Driven by
Type (Low Pessere)
Electrical In-tank type
Electric motor
Driven by
Pressure
MPa
(kgf/cm
)
KPa
Regulated Fuel
(kgf/cm
Pressure
1600ber
-
380kpa(3.87kgf/ 55.0psi)
Engine
D 3.0 TCI
G6DA 3.8DOHC
G8BA4.6DOHC
A5SR2
6HP26 (ZF)
Automatic Transaxle
Type
6HP26 (ZF)
Shift position
Gear ratio
Solenoid
ATF capacity
P
R
N
D
1st
2nd
3rd
4th
5th
6th.
Rev
3-way
Linear
Fix output axle (Engine start allowed)
Reverse
Neutral (Engine start allowed)
12345
4,171
3,827
4,171
2,340
2,368
2,340
1,521
1,520
1,521
1,143
1,000
1,143
0,864
0,834
0,864
0,691
0,691
3.403
2.613
3.403
1ea [MV1]
1ea [MV1]
D3.0 G4.6 6ea[EDS1,EDS2,EDS3,EDS4,EDS5,EDS6]
APOLLOIL ATF RED-1
Shell M-1375.4 10 (8
(lmp.qt)hell M-1375.4 10 (8.8)
BL-10
Driveshaft
Propeller shaft
Joint type
Joint type
Front driveshaft
Rear driveshaft
Oil type
Oil capacity (L)
Reduction gear type
Final drive gear
Differential gear
Oil type
Oil capacity (L)
Reduction gear type
Final drive gear
Differential gear
Front differential
Rear differential
Inner side
TSJ#25
Outer side BJ#25
20
43
Inner side TSJ#25
Outer side BJ#25
20
43
Hypoid gear oil(API GL-5, SAE 90)
About1.3~1.4
Hypoid gear
3,357
0.13 ~ 0.18
Max : 0.1 (0.0039)
ypoid gear oil(API GL-5, SAE 75W/90
About1.7~1.9
Hypoid gear
3,357
0.13 ~ 0.18
Max : 0.1 (0.0039)
Lubricants
Items
Front driveshaft
Rear driveshaft
BJ
TSJ
BJ
TSJ
Lubricants
Quantity
RBA
RBA
RBA
RBA
145g
130g
210g
150g
[NOTE]
BL-11
General specifications -MOHAVE/HM

Suspension System
Front
Double wishbone
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
Tire size
Tire pressure
Camber
Caster
Toe-in
King-pin
Front Wheel nut
Driveshaft Lock nut
Strut assembly lower mounting bolt
Inner shaft bearing housing bolt
Break disc mounting screw
Lower arm assembly mounting bolt
Wheel alignment
mm (in.)
Rear
Multi-link
Gas pressurized
7.5JJ 17", 7.5JJ 18"
245/70 R16, 245/65 R17
2.2kg/cm(32psi)
02mm (00.079in.)
2.12mm (0.0820.079in.)
0.500.5
1.000.5
3.800.5
02 (00.079)
13.92
88.3~107.9Nm
(9~11Kgf.m)
240.2~269.6Nm (24.5~27.5Kgf.m)
152.0~171.6Nm (15.5~17.5Kgf.m)
69.6~93.1Nm
(7.1~9.5Kgf.m)
88.3~98.1Nm
(8.5~10Kgf.m)
6.9~10.8 Nm
(0.7~1.1Kgf.m)
4.9~5.9 Nm
(0.5~0.6Kgf.m)
137.2~156.9 Nm (14~16Kgf.m)
BL-12
Lower arm ball joint mounting bolt

Tie rod end ball joint mounting nut
Driveshaft lock nut
Shock absorber upper mounting bolt
Shock absorber upper mounting nut
Break disc mounting screw
Hub assembly mounting bolt
Upper arm ball joint mounting nut
Lower arm mounting bolt
Assist arm ball joint mounting nut
Trailing arm mounting bolt
98.1~117.7 Nm
(10~12Kgf.m)
58.8~78.4 Nm
(6.0~8.0Kgf.m)
240.2~269.6Nm (24.5~27.5Kgf.m)
137.3~156.9 Nm (14~16Kgf.m)
98.1~117.7 Nm
(10~12Kgf.m)
63.7~73.5 Nm
(6.5~7.5Kgf.m)
6.9~10.8 Nm
(0.7~1.1Kgf.m)
4.9~5.9 Nm
(0.5~0.6Kgf.m)
78.5~88.3 Nm
(8~9Kgf.m)
78.5~88.3 Nm
(8~9Kgf.m)
137.3~156.9 Nm (14~16Kgf.m)
98.1~117.7 Nm
(10~12Kgf.m)
137.3~156.9 Nm (14~16Kgf.m)
BL-13
Engine
D 3.0 TCI
G6DA 3.8DOHC
G8BA4.6DOHC
Steering System
Type
Rack stroke
mm (in.)
kPa
(kgf/cm
)

Drive shaft nuts
Steering wheel and column shaft
Steering column assembly mounting bolts and nu
Steering column assembly & universal joint
Bolt connecting universal joint to steering gear pi
Tie-rod end andknuckle
Power steering gear box and frame
Pressure tube eye bolt and Power steering pump
Power steering pump and Pump bracket
Rack & Pinion

PSF-3
168mm
90 ~ 95kgf/cm(1280 ~ 1351 psi, 8.8 ~ 9.3MPa)
245 ~ 275
40 ~ 50
13 ~ 18
22 ~ 27 (2.2 ~ 2.7)
30 ~ 35
60 ~ 80
LH122 ~ 158 RH90 ~ 110
55 ~ 65
20 ~ 27
Restraints
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
1.5 ~ 5.7
1.5 ~ 5.7
1.5 ~ 5.7
1.5 ~ 5.7
1.5 ~ 5.7
BL-14

Driver Airbag (DAB)
Bolt
Passenger Airbag
(PAB)
Nut
SRSCM Mounting Bolt
7.8 ~ 10.8
18.6 ~ 26.5
5.9 ~ 6.9
6.9 ~ 8.8
39.2 ~ 53.9
6.9 ~ 8.8
6.9 ~ 8.8
4.9 ~ 6.9
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
Brake booster
Type
Effective diameter
Boosting ratio
mm (in.)
DOT 3 or DOT 4
As required
Tandem type
26.99 mm (1.063 in)
Provided
9" + 9" Tandem
mm (in.)
9:01
BL-15

D 3.0 TCI
G6DA 3.8DOHC G8BA4.6DOHC
Engine
Front brake
Ventilated disc
Type
328 mm (12.91 in)
mm (in.)
Disc O.D.
28 mm (1.10 in)
mm (in.)
Disc thickness
mm (in.)
Pad thickness
Double
Cylinder type
48mm(1.89 in) X 2
mm (in.)
Cylinder I.D.
Rear brake(Disc)
Solid disc
Type
324 mm (12.76 in)
mm (in.)
Disc O.D.
13 mm (0.51 in)
mm (in.)
Disc thickness
mm (in.)
Pad thickness
Single piston
Cylinder type
mm (in.)
Cylinder I.D
Parking brake
DIH(Drum in hat) type
Type
Actuation
210 mm (7.48 in)
mm (in.)
Drum I.D.
mm (in.)
Lining thickness
O.D=Outer Diameter
I.D=Inner Diameter
HECU
System
0.5 ~ 1.5 mm
Front mm(in.)
Air gap
Acitve wheel speed
0.5 ~ 1.5 mm
Rear mm(in.)
sensor
48
teeth
Tone wheel
BL-16
Service standard
Hub nut
Brake tube flare nuts
mm (in.)
ABS
ESP
mm (in.)
mm (in.)
Brake booster mounting nuts
mm (in.)
mm (in.)
mm (in.)
Master cylinder to brake booster
mm (in.)
Air bleeding screw
mm (in.)
mm (in.)
Rear disc thickness
mm (in.)
Brake hose to caliper
mm (in.)
Brake pedal member bracket bolts
Stop lamp switch lock Common pedal
nut
Adjustable pedal
HECU bracket mounting bolt and nut
Yaw rate&G sensor mounting bolts
88.3 ~ 107.9
12.7 ~ 16.7
18.6 ~ 22.6
3 ~ 8 mm (0.12 ~ 0.31 in)
12.7 ~ 15.7
10.5 mm (0.41 in)
28 mm (1.10 in)
12.7 ~ 16.7
6.9 ~ 12.7
10.5 mm (0.41 in)
13 mm (0.51 in)
16.7 ~ 25.5
16.7 ~ 25.5
7.8 ~ 9.8
11.8 ~ 14.7
16.7 ~ 25.5
4.9 ~ 6.7
BL-17

Engine
D 3.0 TCI
G6DA 3.8DOHC
G8BA4.6DOHC

Hood
Front door
Tailgate
Rear Door
Glass Thicknes
Seat belts
Type
Construction
Regulator system
Locking system
Type
Construction
Regulator system
Locking system
Front door glass
Rear door glass
Front
Rear

Wire drum type
Pin-fork system
Inner hinged, gas lifter
Wire drum type
Pin-fork system
3.56mm (0.1402in.)
3.56mm (0.1402in.)
BL-18

Checker (Body side)
Checker (Door side)
Front door
Hinge (Body side)
Hinge (Door side)
Striker
Checker (Body side)
Checker (Door side)
Rear door
Hinge (Body side)
Hinge (Door side)
Striker
Seat
Seat mounting bolt/nut
Hood hinge to body
Hood
Hood hinge to hood
Hood latch to body
16.7~21.6
6.9~10.8
34.3~41.2
34.3~41.2
16.7~21.6
16.7~21.6
6.9~10.8
34.3~41.2
34.3~41.2
16.7~21.6
39.2~53.9
21.6~26.5
21.6~26.5
6.9~8.8
BL-19

Engine
Seat belt
D 3.0 TCI

mounting bolt
G6DA 3.8DOHC
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
G8BA4.6DOHC
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)

Audio
Type
Power supply
Rated output
Speaker impedance()
Front
Antenna
Tuning type
FM
Frequency range /
Channel space
LW
Items
Life of battery
(General key ,
Smart key)
Button
Radio/MP3/CD(PA710) Radio/MP3/CDC(PA760)
Radio/MP3/6CDC(PA760 RSE)
DC 14.4V
Max 43W x 4 (Power IC)
3.2Vrms
4 0.6
4 0.6
Min 1.6
80PF 75
87.5~108.0 MHz / 100KHz
531~1602 KHz / 9KHz
Transmitter(TX)
5m or more
2 year (10 times / day), 2 year (Active 20 times / day + Passive 10 times
/ day)
Door lock / unlock, Panic, Tailgate unlock (for China)
433MHz 250MHz (General and Middle east)
315MHz 250 MHz (China)
BL-20
Lighting system
Head lamp
Front position lamp
Front fog lamp
Rear tail/stop lamp
Back up lamp
License plate lamp
Room lamp
Luggage lamp
Front Side marker
High
Low
W
W
W
W
W
W
W
W
W
W
W
W
W
55
55
28
8
27
27/8 or LED
16
21
5
10 x 2
6x2
5
5
BL-21

Engine
Other system
D 3.0 TCI
Type
Manufacturer
Type
SMART KEY
Manufacturer
G6DA 3.8DOHC
G8BA4.6DOHC
SMARTRA 3system
Bosch
4 channel
Button type (Front door)
Continental
Immobilizer

Air conditioner
Compressor
Condeser
APT
(A/C pressure
Expansion valve
Refrigerant
Type
Oil type & Capacity
Pulley type
Displacement
Heat rejection
The method to
measure
Type
Type
Capacity [oz.(g)]
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
Type
Evaporator
A/C ON/OFF C (F)
10PA17
PAG 20015CC
200 + 15CC
7PK-TYPE
178cc/rev
15,000-5% kcal/hr
PAG
17,000 kcal/hr
Voltage= 0.00878835 * Pressure (psig) + 0.5

Block type
R-134a
60025(21.10.88)
75025(26.40.88)
Actuator
Sirocco
Auto + 8 speed (Automatic), 1~8speed (Manual)
Power mosfet
Particle filter
Pin & Tube type
4,700 - 5% kcal/hr
Actuator
Actuator
Thermistor
OFF: 1.0 0.3 (33.8 32.5)
ON : 2.1 0.3 (34.7 32.5),
BL-22
Carnival /
Sedona(VQ)
VQ-2
VQ-11
VQ-13
Fuel System..
VQ-13
Clutch.
VQ-14
Manual Transaxle.
VQ-14
Automatic Transaxle
VQ-15
Driveshaft..
VQ-17
Suspension System.
Steering System VQ-18
RestraintsVQ-19
VQ-20
Brake System
Body (Interior & Exterior). VQ-23
VQ-25
Heating, Ventilation & Air Conditioning..VQ-27
VQ-1
General specifications - Carnival/Sedona

Engine
DSL J2.9 WGT
DSL J2.9 VGT
GSL 2.7
GSL 3.8
V-type, DOHC
6
V-type, DOHC
6
86.7(3.4134)
x 75 (2.9528)
96(3.7795)
x 87.0 (3.425)
2.656
3,778
Engine
Type
Number of cylinders
Bore x Stroke
Total displacement
Compression ratio
Firing order
Ignition Timing
A/C
OFF
Idle Speed
A/C
ON
Engine oil
Oil quantity
mm (in.)
cc
2.902
2.902
18,4
1-3-4-2
Neutral,N,PD-range
Neutral,N,PD-range
Total
Oil pan
Oil filter
Drain and refill
rpm
rpm
rpm
rpm
(lmp.qt)
(lmp.qt)
(lmp.qt)
(lmp.qt)
Oil quality
Oil pressure (Idle)
In-line, DOHC
In-line, DOHC
4
4
101.5~101.526 (3.9961~3.9971)
x 98 (8.8583)
kPa
(kg/cm)
10,4
-
800100
800100
800100
800100
8.0 (7.0392)
5.4 (4.75)
6.0 (5.28)
0.6 (0.53)
6.0 (5.28)
6.6 (5.81)
2-3-4-5-6-1
1-2-3-4-5-6
BTDC 7 10
BTDC 10 5
650 100
650 100
650 100
650 100
4.5 (3.96)
4.2 (3.70)
0.3 (0.26)
-
6.4 (5.63)
5.5 (4.84)
0.4 (0.35)
5.2 (4.58)
Above API CH-4
Above API CH-4

or ACEA B4
Above SJ or SL
78.45 (0.8)
78.4 (0.8)
130 (1.32)
[at 1000rpm, 110C(230F)]
VQ-2
Valve timing
Intake valve
Exhaust valve
Opens (ATDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
26
50
72
32
4 ~ -56
60 ~ 0
46
10
10
62
42
6
mm (in.)
Less than 0.05 (0.0020)
0.03 (0.0012)
or less
Less than 0.05

(0.0019)
Intake
mm (in.)
Less than
0.15 (0.0059)
0.15 (0.0059)
or less
Less than 0.1

(0.0039)
Exhaust
mm (in.)
Less than 0.15 (0.0059)
0.15 (0.0059)
or less
Less than 0.1

(0.0039)
Intake
Exhaust
mm (in.) 39.397 ~ 39.597 (1.5511 ~ 1.5589)

39.4932 ~ 39.6932 (1.5548 ~
mm (in.)
1 5627)
44.5 (1.7520)
46.8 (1.8425)
45.8 (1.8031)
Cylinder head
mounting surface
Camshaft
Cam height
No.1:
27.964 ~ 27.980
27.964 ~ 27.980 (1.1009 ~ 1.1016)
(1.1009 ~ 1.1016)
No.2,3,4:
23.954 ~ 23.970
(0.9430 ~ 0.9437)
VQ-3

Engine
DSL J2.9 WGT
DSL J2.9 VGT
GSL 2.7
GSL 3.8
mm (in.)
0.040 ~ 0.080 (0.0016 ~ 0.0031)
No.1:
0.020 ~ 0.057
0.020 ~ 0.057 (0.0008 ~ 0.0022)
(0.0008 ~ 0.0022)
No.2,3,4:
0.030 ~ 0.067
(0.0012 ~ 0.0026)
End play
mm (in.)
0.08 ~ 0.17
(0.0031 ~ 0.0067)
0.05 ~ 0.15
0.02 ~ 0.18
(0.0020 ~ 0.0059) (0.0008 ~ 0.0071)
Intake
Exhaust
mm (in.)
mm (in.)
126.24 (4.9701)
126.24 (4.9701)
Intake
mm (in.)
6.965 ~ 6.980 (0.2742~0.2748)
5.965 ~ 5.980
5.465 ~ 5.480
(0.2348 ~ 0.2354) (0.2151 ~ 0.2157)
Exhaust
mm (in.)
6.945 ~ 6.960 (0.2734 ~ 0.2740)
5.950 ~ 5.965
5.458 ~ 5.470
(0.2343 ~ 0.2348) (0.2149 ~ 0.2153)
Valve
Valve length
Stem outer diameter

Face angle
45
110.1 (4.3346)
111.1 (4.3740)
105.27 (4.1445)
105.50 (4.1535)
45 ~ 45.5
45.25 ~ 45.75
Intake
mm (in.)
1.7 (0.0669)
1.0 (0.0394)
1.56 ~ 1.86
(0.06142 ~
0.07323)
Exhaust
mm (in.)
1.6 (0.0630)
1.3 (0.0512)
1.73 ~ 2.03
(0.06811 ~
0.07992)

(margin)
VQ-4
mm (in.)
0.030 ~ 0.065 (0.0012 ~ 0.0026)
0.020 ~ 0.050
(0.0008 ~ 0.0020)
0.020~0.047
(0.00078
~0.00185)
Exhaust
mm (in.)
0.050 ~ 0.085
( 0.0020~ 0.0033)
0.035 ~ 0.065
(0.0014 ~ 0.0026)
0.030 ~ 0.054
(0.00118
~0.00212)
Intake
mm (in.)
6.000 ~ 6.015
5.500 ~ 5.512
(2.2362 ~ 2.2368) (0.2165 ~ 0.2170)
Exhaust
mm (in.)
6.000 ~ 6.015
5.500 ~ 5.512
(2.2362 ~ 2.2368) (0.2165 ~ 0.2170)
Intake
mm (in.)
52.5 (2.0669)
45.8 ~ 46.2
41.8 ~ 42.2
(1.8031 ~ 1.8189) (1.6457 ~ 1.6614)
Exhaust
mm (in.)
52.5 (2.0669)
46.8 ~ 47.2
41.8 ~ 42.2
(1.8425 ~ 1.8583) (1.6457 ~ 1.6614)
Intake
mm (in.)
1.4 ~ 2.0
(0.0551 ~ 0.0787)
Exhaust
mm (in.)
0.9 ~ 1.5
(0.0354 ~ 0.0591 )
45
Intake
Valve stem to valve
guide clearance
Valve guide
Inner diameter
Length
Valve seat
Seat angle
1.15 ~ 1.45
(0.05118~0.0570
1.35 9)
~ 1.65
(0.05315~0.0649
6)
44.75 ~ 45.20
VQ-5

Engine
Valve spring
Free length
Load(Intake)
DSL J2.9 WGT
Installed
Valve opened
Installed
Load(Exhaust)
Valve opened
Out of squareness
MLA
DSL J2.9 VGT
GSL 3.8
mm (in.) 52.477 (2.0660) 52.477 (2.0660)

46.8 (1.8425)
43.86 (1.7267)
23.451.87kg/40.0
mm (in.)
180.5 ~ 199.5N
39.153.13kg/31.65
mm (in.)
(18.4 ~ 20.3Kgf) 19.30.8kg/34.0
Height:35
23.451.87kg/40.0
mm (in.)
42.31.3kg/24.2
342 ~ 378N
(34.9 ~ 38.6Kgf) 39.433.15kg/31.50
mm (in.)
Height: 26.5
Less than 2
mm (in.) 20.000 ~ 20.027 (0.7874 ~ 0.7885)
mm (in.) 19.959 ~ 19.980 (0.7858 ~ 0.7866)
1.5 or less
Less than 1.5
Intake
mm (in.)
29.964 ~ 29.980 34.964 ~ 34.980

(1.1797 ~ 1.1803) (1.3765 ~ 1.3772)
Exhaust
mm (in.)
29.964 ~ 29.980 34.964 ~ 34.980

(1.1797 ~ 1.1803) (1.3765 ~ 1.3772)
Intake
mm (in.)
30.000 ~ 30.025 35.000 ~ 35.025

(1.1811 ~ 1.1821) (1.3779 ~ 1.3789)
Exhaust
mm (in.)
30.000 ~ 30.025 35.000 ~ 35.025

(1.1811 ~ 1.1821) (1.3779 ~ 1.3789)
MLA outer diameter

bore inner diameter
GSL 2.7
VQ-6
MLA to tappet bore

clearance
Intake
mm (in.)
Exhaust
mm (in.)
0.020 ~ 0.061
0.020 ~ 0.061
(0.0008 ~ 0.0024) (0.0008 ~ 0.0024)
0.020 ~ 0.061
0.020 ~ 0.061
(0.0008 ~ 0.0024) (0.0008 ~ 0.0024)
0.17 ~ 0.23
0.17 ~ 0.23
(0.0067 ~ 0.0090) (0.0067 ~ 0.0090)
0.27 ~ 0.33
0.27 ~ 0.33
(0.0106 ~ 0.0129) (0.0106 ~ 0.0129)
Valve clearance
Intake
mm (in.)
Exhaust
mm (in.)
Cylinder block
Cylinder bore
mm (in.) 101.500~101.526 (3.9961~3.9971 )
Liner inner diameter
mm (in.)
97.100 ~ 97.126
(3.8228~ 3.8239)
Liner outer diameter
mm (in.)
101.480~101.526
(3.9953~3.9971)
mm (in.)
Less than 0.05 (0.0020)
Piston
mm (in.) 97.015 ~ 97.030 ( 3.8195~ 3.8201)
mm (in.) 0.070 ~ 0.098 (0.0028 ~ 0.0039)
No. 1 ring groovemm (in.) 2.397 ~ 2.417 ( 0.0944~0.0952 )
2.05 ~ 2.07 ( 0.0807~ 0.0815)
Ring groove width
3.02 ~ 3.04 (0.1189 ~ 0.1197)
Piston OS
96.00 ~ 96.03 (3.7795 ~ 3.7807)
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)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
1.22 ~ 1.24 (0.0480 ~ 0.0488)
2.01 ~ 2.03 (0.0791 ~ 0.0799)
0.25 (0.0098)
-
VQ-7

Engine
Piston ring
Side clearance
End gap
DSL J2.9 WGT
DSL J2.9 VGT
0.104 ~ 0.128
(0.0041~0.0050 )

0.06 ~ 0.10 (0.0024~0.0039)

0.03 ~ 0.07 (0.0012~0.0028)
0.25 ~ 0.40 (0.0098~ 0.0157)
0.40 ~ 0.55 (0.0157~0.0217)
Oil ring groove
0.20 ~ 0.40 (0.0079 ~ 0.0157)
mm (in.)
GSL 2.7
GSL 3.8
0.04 ~ 0.08
0.03 ~ 0.07
(0.0016 ~ 0.0031) (0.0012 ~ 0.0027)
0.03 ~ 0.07 (0.0012 ~ 0.0027)
0.06 ~ 0.15 (0.0024 ~ 0.0059)
0.15 ~ 0.30
0.17 ~ 0.32
(0.0059 ~ 0.0118) (0.0067 ~ 0.0126)
0.30 ~ 0.45
0.32 ~ 0.47
(0.0118 ~ 0.0177) (0.0126 ~ 0.0185)
0.20 ~ 0.70 (0.0078 ~ 0.0275)
Piston pin
mm (in.) 31.994 ~ 32.000 (1.2596 ~ 1.2598)
21.001 ~ 21.007 23.001 ~ 23.006

(0.8268 ~ 0.8270) (0.9055 ~ 0.9057)
mm (in.) 32.015 ~ 32.025 (1.2604 ~ 1.2608)
21.014 ~ 21.023 23.016 ~ 23.021

(0.8273 ~ 0.8277) (0.9061 ~ 0.9063)
mm (in.)
0.015 ~ 0.031 (0.0006 ~ 0.0012)
0.007 ~ 0.022
0.01 ~ 0.02
(0.0003 ~ 0.0009) (0.0039 ~ 0.0078)
Connecting rod small end inner diameter mm (in.) 32.012 ~ 32.033 (1.2603 ~ 1.2611)
20.974 ~ 20.985 22.974 ~ 22.985

(0.8257 ~ 0.8262) (0.9045 ~ 0.9049)
0.016 ~ 0.033
-0.032 ~ -0.016
(0.0006 ~ 0.0013) (-0.0012~0.0006)
0.012 ~ -0.039 (0.0005 ~ 0.0015)
VQ-8
Connecting rod
mm (in.) 60.833 ~ 60.846 (2.3950 ~ 2.3955)
mm (in.)
0.043 ~ 0.077 (0.0017 ~ 0.0030)
End play
Crankshaft
Main journal outer
diameter
mm (in.)
0.239~0.39 (0.0094 ~ 0.0154)
NO 1, 2, 4, 5
NO 3
51.000 ~ 51.018 58.000 ~ 58.018

(2.0079 ~ 2.0086) (2.2834 ~2.2842)
0.018 ~ 0.036
0.038 ~ 0.056
(0.0007 ~ 0.0014) (0.0015 ~ 0.0022)
0.1 ~ 0.25 (0.0039 ~ 0.0098)
mm (in.) 69.995 ~ 70.015 (2.7557 ~2.7565 ) 61.982 ~ 62.000 68.942 ~ 68.960

mm (in.) 69.973~69.993 (2.7548 ~2.7556 ) (2.4402 ~ 2.4409) (2.7142 ~ 2.7149)
mm (in.)
57.106~57.124 (2.2483~2.2490 )
47.982 ~ 48.000 54.954 ~ 54.972

(1.8891 ~ 1.8898) (2.1635 ~ 2.1642)
mm (in.)
mm (in.)
0.045 ~ 0.079 (0.0018 ~0.0031 )

0.067~0.101 (0.0026 ~0.0040 )
0.004 ~ 0.022
0.022 ~ 0.040
(0.0002 ~ 0.0009) (0.0008 ~ 0.0016)
End play
mm (in.)
0.14 ~ 0.39
(0.0055 ~0.0154 )
0.07 ~ 0.25
0.10 ~ 0.28
(0.0028 ~ 0.0098) (0.0039 ~ 0.0110)
Flywheel
Runout
Oil pump
mm (in.)
kPa
(kg/cm)

Main bearing oil
clearance
NO 1, 2, 4, 5
NO 3
Cooling system
Cooling method
Coolant quantity
0.10 (0.0039)
0.10 (0.0039)
588.4049.0
(6.00.5)
(lmp.qt)
9.7~10 (8.54 ~
8.8)
490.33 ~ 588.40
(5.0 ~ 6.0)
450 ~ 550
(4.59 ~ 5.61)

8.2~8.3
(7.22~7.30)
8.6 (7.57)
VQ-9

Engine
Thermostat
Opening
Pull opening
Full lift
C (F)
C (F)
mm (in.)
DSL J2.9 WGT

DSL J2.9 VGT
88 1.5 (190.4 34.7 )
100 (212.0)
-
GSL 2.7
GSL 3.8
82 2 (179.6 35.6)
95 (203)
10 (0.3937)
or more
10 (0.3937)
Main valve
93.16 ~ 122.58
kPa
Relief valve
93.16 ~ 122.58
(0.95 ~ 1.25)
opening press. (kg/cm) opening pressure (0.95 ~ 1.25)
Radiator cap
Vacuum valve
0.98 ~ 4.90
kPa
(0.01
~ 0.05)
(kg/cm)
opening press.
Thermister type
Type
k
2.27 ~ 2.64
2.27 ~ 2.64
2.31 ~ 2.59
2.31 ~ 2.59
20C (68F)
Resistance
0.31 ~ 0.33
0,3222
k
80C (176F)
Main moving system
68.6(7.0)Unfasten bolts29.4+90
19.60(2.0) + 90
69.6~79.4(7.1~8.1)
+
55~65
Bolts
Inner bolt (M11)
49.00(5.0) + 90
Out bolt (M8)
19.60(2.0) + 120
Crankshaft
29.40 ~ 31.36
main bearing cap
Side bolt (M8)
(3.0 ~ 3.2)
Long bolts (M10)

Short bolts (M8)
29.4(3.0) + 90
15.7(1.6) + 90
VQ-10
Cylinder head
17.7 ~ 26.5 (1.8 ~ 2.7)
Long bolts
39.2(4.0) + 90 + 120
22.6~26.5(2.3~2.
7)
+(602)+(452
Short bolts
39.2(4.0) + 90+ 90
18.62 ~ 23.52
(1.9 ~ 2.4)
Lubrication system
Oil filter
Oil pan nuts
21.6 ~ 24.5 (2.2 ~ 2.5)

15.7 ~ 22.6 (1.6 ~ 2.3)
Oil pan drain plug
34.3 ~ 44.1 (3.5 ~ 4.5)
34.3 ~ 44.1
(3.5 ~ 4.5)
9.8 ~ 11.8
(1.0 ~ 1.2)
9.80 ~ 11.76
(1.0 ~ 1.2)
Cylinder head bolt
Lower oil pan bolt
39.2(4.0) +
120 + 90

Rated voltage
Starter No-load
charasteristics
12V, 2.0KW
Voltage
Amperage
Speed
V
A
12 V, 1.2 kW
11,5
Max. 190
3,000rpm, MIN
Max. 90
Max. 85
2,600 rpm, MIN
VQ-11

Engine
DSL J2.9 WGT
Type
Generator
Rated voltage
Speed in use
Regulator setting
voltage
Battery
Ignition coil
Spark plugs
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
Primary
resistance
Secondary
k
resistance
Unleaded (NGK)
DSL J2.9 VGT
Battery voltage
sensing
12V, 120A
14.4 0.3V
GSL 2.7
GSL 3.8

13.5 V, 110A
13.5V, 130A
1,000 ~ 18,000 rpm
14.2 ~ 14.8V
(5000rpm, 10A,
25C)
14.2 ~ 14.8V
14.2 ~ 14.8V
1) CMF 100 AH, 2) CMF 80 AH
MF 68AH
MF 80AH
1) 900A - CMF 100 AH

2) 660A - CMF 80 AH
600 A
630 A
1) 182min - CMF 100 AH

2) 145min - CMF 80 AH
110 min
130 min
1.280 0.01
-
0.715 0.015
0.62 10 %
7.0 15 %
ILFR5B11
IFR5G-11
1.0 ~ 1.1 (0.0394 ~ 0.0433)
VQ-12
Fuel System
Engine Management
Fuel Tank
Fuel Return System
Fuel Filter
Fuel Pump
Manufacturer
(lmp.qt
Capacity
)
Type
Type
Type
Driven by
MPa
(kgf/cm
)
kPa
Fuel Pressure
(Maximum)
Pressure
Regulated Fuel
(kgf/cm
Pressure
)
Delphi
80 (70.39)
Return type
Returnless type
High pressure type

Mechanical
Electrical
Volume Metric-Blade Type
In-tank type
Drive Belt
Electric motor
160 (1,632)
-
375 ~ 385 (3.82 ~ 3.92)
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic type
Self Adjusting Clutch
25~36 (2.5~3.6)
19~26 (1.9~2.6)
12~16 (1.2~1.6)
25~34 (2.5~3.4)
mm (in.)
mm (in.)
150 (5.91)
6~13 (0.24~0.51)
VQ-13

Engine
DSL J2.9 WGT
DSL J2.9 VGT
GSL 2.7
GSL 3.8
M5GF2
3,615
1,931
1,969
1,273
0,974
3,416
5.071 / 3.737
Manual Transaxle
Type
Gear ratio
M5HF2
3,600
1,875
1,205
0,818
0,768
4,320
4.500/3.706
1st
2nd
3rd
4th
5th
Rev.
FGR
M/T oil quality

MT oil capacity

(lmp.qt)
1.85 (1.63)
1.9 (1.67)
A5HF1
4,497
2,442
1,686
1,233
0,868
4,586
3,333
F4A51
2,842
1,495
1.000
0,731
2.720
4.520
A5HF1
4,497
2,442
1,686
1,233
0,868
4,586
3,333
Automatic Transaxle
Type
Gear ratio
ATF quality
ATF capacity
1st
2nd
3rd
4th
5th
Rev.
FGR

(lmp.qt)
10.7 (9.4)
8.5 (7.5)
10.9 (9.6)
VQ-14
Driveshaft
M/T
Joint type
A/T
M/T
A/T
Lubricants
Joint type
Recommended grease
Quantity
Front hub bearing assembly
[NOTE]
Inner
Outer
Inner
Outer
Inner
Outer
Inner
Outer
TSJ#26
BJ#28
TSJ#26
BJ#26
46.5
23
UTJ-II#25
CK-2
220
TSJ#26
RBA
150
UTJ-II#25
BJ#26
46.5
23
46.5
23
BJ#26
BJ#28
RBA
210
250
1.97 (0.2)
1.97 (0.2)
VQ-15

Engine
Hub nut
Driveshaft lock nut
Front lower arm to knuckle bolt nut
Inner shaft bearing bracket assembly bolts
Front hub bearing assembly to knuckle bolts
Rear lower arm to carrier bolt nut
Rear hub lock nut
Rear brake assembly to carrier assembly bolts
Carrier assembly to assist arm bolt
Carrier assembly to upper arm bolt
Carrier assembly to upper arm bolt
DSL J2.9 WGT
DSL J2.9 VGT
GSL 2.7
GSL 3.8
90 ~ 110 (9.0 ~ 11.0)

245 ~ 275 (24.5 ~ 27.5)
60 ~ 80 (6.0 ~ 8.0)
90 ~ 120 (9.0 ~ 12.0)
43 ~ 63 (4.3 ~ 6.3)
50 ~ 65 (5.0 ~ 6.5)
85 ~ 100 (8.5 ~ 10.0)
100 ~ 120 (10.0 ~ 12.0)
160 ~ 180 (16.0 ~ 18.0)
160 ~ 180 (16.0 ~ 18.0)
50 ~ 60 (5.0 ~ 6.0)
200 ~ 260 (20.0 ~ 26.0)
50 ~ 60 (5.0 ~ 6.0)
90 ~ 100 (9.0 ~ 10.0)
90 ~ 100 (9.0 ~ 10.0)
90 ~ 100 (9.0 ~ 10.0)
VQ-16
Suspension System
Front
MacPherson strut
Suspension type
Shock absorber type
Wheel size
Steel
Aluminum
Tire size
Tire pressure
Gas pressurized
6.5J 16"
6.5J 16", 6.5J 17"
225/70 R16, 235/60 R17
2.4kgf.m/cm2, (35psi)
Camber
Wheel alignment
Rear
Multi link
Long body
Short body
mm (in.)
Toe-in
Caster
King-pin
Hub nuts
Rear shock absorber to bracket
030'
346'30'
354'30'
02 (00.079)
1227'30'
-6'30'
2.62 (0.1020.079)
90 ~ 110 (9.0 ~ 11.0)
100 ~ 120 (10.0 ~ 12.0)
60 ~ 70 (6.0 ~ 7.0)
160 ~ 180 (16.0 ~ 18.0)
90 ~ 120 (9.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
39 ~ 60 (3.9 ~ 6.0)
160 ~ 180 (16.0 ~ 18.0)
140 ~ 160 (14.0 ~ 16.0)
90 ~ 110 (9.0 ~ 11.0)
160 ~ 180 (16.0 ~ 18.0)
160 ~ 180 (16.0 ~ 18.0)
VQ-17

Engine
DSL J2.9 WGT
DSL J2.9 VGT

GSL 2.7
200 ~ 270 (20.0 ~ 27.0)
90 ~ 110 (9.0 ~ 11.0)
90 ~ 120 (9.0 ~ 12.0)
160 ~ 180 (16.0 ~ 18.0)
80 ~ 100 (8.0 ~ 10.0)
50 ~ 65 (5.0 ~ 6.5)
39 ~ 60 (3.9 ~ 6.0)
GSL 3.8
Steering System
Type
Rack stroke
Quality
Quantity
VRS on
VRS off
VRS on
Steering angle
VRS off
Power steering pump
relief pressure
Gasoline
Diesel
(lmp.qt)
mm (in.)
mm (in.)
Inner
Outer
Inner
Outer
kPa
(kgf/cm
)
Rack and Pinion, VRS (Variable Rack Stroke) System

PSF-3
1.1 (0.97)
148 (5.67)
156 (6.14)
38.64
31.78
41.91
33.54
8630 ~ 9120 (88 ~ 93)
9611 ~ 10101 (98 ~ 103)
VQ-18

40 ~ 50 (4.0 ~ 5.0)
13 ~ 18 (1.3 ~ 1.8)
13 ~ 18 (1.3 ~ 1.8)
15 ~ 20 (1.5 ~ 2.0)
35 ~ 45 (3.5 ~ 4.5)
60 ~ 80 (6.0 ~ 8.0)
Restraints
Type
Resistance
Driver Airbag (DAB)
Side Airbag (SAB)
Seat Belt Buckle Pretensioner (BUPT)
Driver Airbag (DAB)
Passenger Airbag
Bolt
Nut
(PAB)
Side Airbag (SAB)
Buckle Pretensioner (BUPT)
SRSCM Mounting Bolt
Depowered
1.6 ~ 4.7
1.6 ~ 4.7
1.6 ~ 4.7
1.6 ~ 4.7
1.6 ~ 4.7
1.6 ~ 4.7
7.9 ~ 10.8 (0.8 ~ 1.1)
12.0 ~ 13.0 (1.2 ~ 1.3)
7.0 ~ 8.0 (0.7 ~ 0.9)
18.6 ~ 26.5 (1.9 ~ 2.7)
18.6 ~ 26.5 (1.9 ~ 2.7)
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)
9.5 ~ 13.6 (1.0 ~ 1.4)
VQ-19

Engine
DSL J2.9 WGT
DSL J2.9 VGT
GSL 2.7
GSL 3.8
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
Piston stroke
Brake booster
Type
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder type
Cylinder I.D.
Rear brake(Disc)
Type
Disc O.D.
Disc thickness
Pad thickness
mm (in.)
mm (in.)
DOT 3 or DOT 4
As required
Tandem type
26.99 (1.063)
30(1.18)
Provided
8 + 9 in Tandem
9
mm (in.)

298 (11.73)
28 (1.10)
10.5 (0.41)
Double piston
48 (1.89)
mm (in.)
mm (in.)
mm (in.)

302 (11.89)
12 (0.47)
10 (0.39)
mm (in.)
mm (in.)
mm (in.)
VQ-20
Single piston
Cylinder type
42.9 (1.69)
mm (in.)
Cylinder I.D
Parking brake
DIH(Drum in hat)
Type
Foot brake
Actuation
190 (7.48)
mm (in.)
Drum
O.D=Outer Diameter
I.D=Inner Diameter
HECU
System
0.15 ~ 1.5 (0.006 ~ 0.059)
Front mm(in.)
Air gap
Acitve wheel speed
0.2 ~ 1.2 (0.008 ~ 0.047)
Rear mm(in.)
sensor
48
teeth
Tone wheel
Service standard
192.4 (7.57 )
mm (in.)
Brake pedal height
122 (4.8)
mm (in.)
60 (2.36)
mm (in.)
3 ~ 8 (0.11 ~ 0.31)
mm (in.)
1.0 ~ 1.5 (0.04 ~ 0.06)
mm (in.)
stopper clearance
0.6 ~ 1.7 (0.02 ~ 0.07)(at 500 mmHg)
mm (in.)
piston clearance
Parking brake pedal stroke when pedal
above 145 (5.71)
assembly is depressed with 294N (30kgf, mm (in.)
66lb force)
VQ-21

DSL J2.9 WGT
Engine
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Bleeder screw
Front
Rear
Front
Caliper assembly
to knuckle
Rear
brake plate
HECU mounting nut
DSL J2.9 VGT

GSL 2.7
10.5 (0.41)
28 (1.10)
10 (0.39)
12 (0.47)
4 (0.16)
GSL 3.8
8 ~ 12 (0.8 ~ 1.2)
13 ~ 16 (1.3 ~ 1.6)
7 ~ 13 (0.7 ~ 1.3)
13 ~ 17 (1.3 ~ 1.7)
22 ~ 32 (2.2 ~ 3.2)
22 ~ 32 (2.2 ~ 3.2)
85 ~ 100 (8.5 ~ 10)
50 ~ 60 (5.0 ~ 6.0)
25 ~ 30 (2.5 ~ 3.0)
10 ~ 15 (1.0 ~ 1.5)
13 ~ 16 (1.3 ~ 1.6)
8 ~ 10 (0.8 ~ 1.0)
7 ~ 10 (0.7 ~ 1.0)
17 ~ 26 (1.7 ~ 2.6)
6 ~ 10 (0.6 ~ 1.0)
5 ~ 8 (0.5 ~ 0.8)
VQ-22

Hood
Type
Construction
Front door
Regulator system
Locking system
Construction
Rear door
Regulator system
Locking system
Tailgate
Type
mm (in.)
Windshield
mm (in.)
Front door
Glass thickness
mm (in.)
Rear window
Front
Seat belts
Rear
Door hinge to body
Door hinge to door
Striker
Glass mounting bolt
Outside handle
Rear channel

X-ARM type
Pin-fork system
Sliding door construction
Wire drum type
Pin-fork system
5 (0.1969)
4 (0.1575)
4 (0.1575)
3.5 (0.1378)
33.3~41.2 (3.4~4.2)
21.6~26.5 (2.2~2.7)
6.9~10.8 (0.7~1.1)
7.8~11.8 (0.8~1.2)
6.9~10.8 (0.7~1.1)
7.8~11.8 (0.8~1.2)
VQ-23

Engine
Tailgate
Hood
Seat
Seat belt
DSL J2.9 WGT

Tailgate hinge to
Tailgate lift mounting
Key cylinder mounting
Hood hinge to body
Hood hinge to hood
Hood latch to body
Front seat mounting
Rear seat mounting
DSL J2.9 VGT

GSL 2.7
6.9~8.8 (0.7~0.9)
6.9~8.8 (0.7~0.9)
6.9~8.8 (0.7~0.9)
6.9~10.8 (0.7~1.1)
21.6~26.5 (2.2~2.7)
21.6~26.5 (2.2~2.7)
6.9~10.8 (0.7~1.1)
43.1~64.7 (4.4~6.6)
43.1~64.7 (4.4~6.6)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
39.2~53.9 (4.0~5.5)
GSL 3.8
VQ-24

Audio
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
Frequency range /
Channel space
FM
AM
Items
Life of battery
Button
RADIO/Cassette/
RADIO/Cassette/EQ/CDC/MP3(M46
EQ/CD/MP3
5)
(M455)
DC 14.4V
3.2Vrms
Max 43W x 4
4 x 4
10
80PF 75
87.5~108 MHz / 50KHz (Europe)
RADIO/EQ/CD
(M445)
Type
Transmitter(TX)
30m or more
Door lock/unlock
PSD(Power Sliding Door) open/close (option)
PTG(Power Tail Gate) open/close (option)
Panic
Tailgate open (option)
447 MHz (Europe, Austrailia, Middle east)
315.00 MHZ (General)
VQ-25

Engine
Lighting system
Head lamp
Front position lamp
Front side marker lamp
Front fog lamp
Rear stop/tail lamp
Back up lamp
Rear fog lamp
License plate lamp
Side repeater
Room lamp
Glove box lamp
Luggage room lamp
Door courtesy lamp
DSL J2.9 WGT
High
Low
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
DSL J2.9 VGT
GSL 2.7
GSL 3.8
55
55
28
8
5
35
12/5
16
27
21
5
5
10
10 x 2
LED
5
5
5
VQ-26
Other system
Type
Manufacturer
Body Network Communication type
Power tailgate
Power sliding door
SMARTRA system
Bosch
CAN
4 channel
Electric type
Electric type
Immobilizer
Heating, Ventilation & Air Conditioning

Air conditioner
Compressor
Condenser
APT(A/C pressue
transducer)
Type
Oil type Capacity
Pulley type
Displacement
Heat rejection
Method to measure
pressure
High
Dual pressure switch

Low
Expansion valve
Refrigerant
Type
Type
Capacity
Kpa
(kg/)
Kpa
(kg/)
VS18 (Variable capacity)

FD46XG(PAG), 180 10cc
4PK-TYPE
180cc/rev
14,000 5% kcal/hr
Fixed type (Swash plate)

FD46XG(PAG), 210 10cc
6PK-TYPE
214cc/rev
19,500 5% kcal/hr
Vout = 0.00878835 * pa + 0.37081095
ON : 26.0 2.0, OFF : 32.0 2.0

(ON:2549.7196.1,
OFF:3138.1196.1)
ON : 2.0 2.55, OFF : 2.0 0.2
(ON: 196.1250.1, OFF:

196 119 6)
Block(L-TYPE)
R-134a
800 25
900 25
VQ-27

Engine
Blower unit
Type
Blower
Speed step
Speed control
Air filter
Type
Type
Heating capacity
Heater
Mode operating
Temperature control
Evaporator
C (F)
A/C ON/OFF
DSL J2.9 WGT
DSL J2.9 VGT
GSL 2.7
GSL 3.8
Actuator
Sirocco
Auto + 8 speed (Automatic)
1~8 speed (Manual)
Power mosfet
Particle filter
Pin Tube type
4,700 5% kcal/hr
Actuator
Actuator
ON : 2.3 0.5 (36.14 0.9)
ON : 2.6 0.5 (36.7 0.9)
OFF: 1.3 0.5 (34.34 0.9)
OFF: 1.1 0.5 (34.0 0.9)
VQ-28
K2500 /
K2700 /
PU-2
PU-8
PU-9
Fuel System..
PU-9
Clutch.
PU-10
Manual Transaxle.
PU-11
Driveshaft..
PU-13
Suspension System.
Steering System PU-14
PU-15
Brake System
Body (Interior & Exterior). PU-18
PU-20
Heating, Ventilation & Air Conditioning..PU-21
PU-1
General specifications - K2500 / K2700 / K3000

Engine
DSL 4D56-2.5
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0
In-line, OHC
4
In-line, Longitudinal
4
91.1 (3.5866)
x 95 (3.7401)
94.5 (3.7204)
95 (3.7401)
2.467
20.5:1
2.665
21.5:1
Engine
Type
Number of cylinders
Bore x Stroke
mm (in.)
Total displacement
Compression ratio
Firing order
Ignition Timing
Idle Speed
cc
2.957
22:1
1-3-4-2
M/T
A/T
rpm
rpm
98 (3.8583) 98 (3.8583)
ATDC 7
-
ATDC 7
750 ~ 790
700 ~ 750
6.1 (5.3)
4.9 (4.2)
-
7.4 (6.5)
5.7 (5.0)
21.5:1
1-3-4-2
ATDC 7
700 ~ 750
700 ~ 750
Engine oil
Oil quantity
Total
Oil pan
(lmp.qt)
(lmp.qt)
Oil quality
kPa
(kg/cm)
Oil pressure
7.9 (6.9)
6.2 (5.4)
API Service CF-4 or CG-4
353~432 (3.6~4.4) / 3000rpm
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
20
48
54
22
12
48
50
12
19
47
52
14
PU-2
Cylinder head
mm (in.)
0.05 (0.002)
0.25 (0.0098) / Longitudinal

0.10 (0.0039) / Lateral
Intake
mm (in.)
0.15 (0.0059)
or less
0.15 (0.0059) or less
Exhaust
mm (in.)
0.15 (0.0059)
or less
0.15 (0.0059) or less
Intake
Exhaust
mm (in.)
mm (in.)
37.05 (1.4587)
37.05 (1.4587)

mounting surface
Camshaft
Cam height
44.116 (1.7369)
44.116 (1.7369)
44.133 (1.7375)
44.133 (1.7375)
29.94 ~ 29.95
(1.1787 ~ 1.1791)
mm (in.)
0.05 ~ 0.08
(0.002 ~ 0.0031)
0.06~0.12 (0.0024~0.0047)
End play
mm (in.)
0.10 ~ 0.20
(0.0039 ~ 0.0079)
0.02~0.18 (0.0008~0.0070)
Valve
Valve length
Intake
Exhaust
mm (in.) 130.15 (5.1240)

mm (in.) 129.85 (5.1122)
Intake
mm (in.)
7.96 ~ 7.975
(0.3133~0.3140)
8.466~8.491 (0.3333~0.3343)
Exhaust
mm (in.)
7.93 ~ 7.975
(0.3122 ~ 0.3130)
8.440~8.463 (0.3323~0.3332)
Stem outer diameter

Face angle
45 ~ 45.5
PU-3

Engine
(margin)
Exhaust
Valve stem to valve
guide clearance
Valve guide
Inner diameter
Length
mm (in.)
mm (in.)
DSL 4D56-2.5
2.0 (0.0787)
2.0 (0.0787)
DSL J2-2.7
1.35 (0.05)
DSL JT-3.0
DSL JTA-3.0
1.5 (0.06)
1.5 (0.06)
Intake
mm (in.)
0.03 ~ 0.06
(0.0012 ~ 0.0024)
0.027 ~ 0.074 (0.0010 ~ 0.0029)
Exhaust
mm (in.)
0.05 ~ 0.09
( 0.0020~ 0.0035)
0.055 ~ 0.10 (0.0021 ~ 0.0039)
Intake
mm (in.)
8.0 ~ 8.02
(0.3150 - 0.3157)
Exhaust
8.0 - 8.02
mm (in.)
(0.3150 - 0.3157)
Intake
Exhaust
mm (in.)
mm (in.)
71 (2.7953)
74 (2.9134)
Intake
mm (in.)
0.9 ~ 1.3
(0.0354 ~ 0.0512)
2.41(0.095)
1.05~1.25 (0.041~0.049)
Exhaust
mm (in.)
0.9 ~ 1.3
(0.0354 ~ 0.0512)
1.98 (0.078)
0.90~1.10 (0.035~0.043)
8.518~8.540 (0.3354~0.3362)
-
Valve seat
Seat angle
Valve spring
Free length
45
45
mm (in.)
47.9 (1.5585)
49.5 (1.95)
Load
mm (in.)
27.6 kg /
39.5 (1.5157)
Out of squareness
mm (in.)
Max. 2
1.63 (0.0641)
PU-4

mm (in.)
18.910 ~ 18.928
(0.7445 ~ 0.7455)
19.000~19.021 (0.748~0.749)
mm (in.)
18.878 ~ 18.898
(0.7432 ~ 0.7440)
18.959~18.980 (0.746~0.747)
Valve clearance
Intake
Exhaust
Cylinder block
mm (in.)
mm (in.)
0.15 (0.0059)
0.15 (0.0059)
0.30 (0.0118)
0.38 (0.0149)
Cylinder bore
X:97.513~97.526
X: 101.5 ~ 101.513 (3.9960~3.9965)
91.10 ~ 91.13 (3.8390 ~ 3.8396)
Y: 101.513~101.526
mm (in.)
(3.5866 ~ 3.5877) Y:97.500~97.513
(3.9966~3.9971)
(3.8385 ~ 3.8390)

Piston
mm (in.)
mm (in.)
Piston OS
91.05 ~ 91.08
94.468 ~ 94.488
(3.5846 ~ 3.5858) (3.7192 ~ 3.7200)
0.04 ~ 0.06
0.047 ~ 0.072
(0.0016 ~ 0.0023) (0.0019 ~ 0.0028)
2.61 ~ 2.63
(0.1027 ~
0 1035)
2.10 ~ 2.12
(0.0827 ~ 0.0835)
4.01 ~ 4.035
(0.1579 ~
0 1589)
0.25, 0.50,
0.75, 1.00
Ring groove width
0.05 (0.0020)
mm (in.)
97.942~97.968 (3.8560~3.8570)
0.045~0.071 (0.0018~0.0028)
PU-5

Engine
Piston ring
Side clearance
End gap
DSL 4D56-2.5
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0
0.056 ~ 0.076
(0.0022 ~ 0.0030)
0.06 ~ 0.10 (0.0023 ~0.0039)
0.046 ~ 0.066
(0.0018 ~ 0.0026)
0.04 ~ 0.08 (0.0015 ~ 0.0031)
Oil ring groove
mm (in.)
0.02 ~ 0.065
(0.0008 ~ 0.0026)
0.03 ~ 0.07 (0.0012 ~ 0.0027)
0.30 ~ 0.43
(0.0118 ~ 0.0169)
0.26 ~ 0.36 (0.0102 ~ 0.0142)
0.41 ~ 0.54
(0.0161 ~ 0.0212)
0.30 ~ 0.45 (0.0118 ~ 0.0177)
Oil ring groove
0.25 ~ 0.45
(0.0098 ~ 0.0177)
0.20 ~ 0.40 (0.0078 ~ 0.0157)
Piston pin
Connecting rod
End play
Crankshaft
mm (in.)
28.994 ~ 29.000
mm (in.) (1.1415 ~ 1.1417
)
29.994 ~ 30.000 (1.1809 ~ 1.1811)
mm (in.)
mm (in.)
mm (in.)
30.012 ~ 30.033 (1.1816 ~ 1.1824)

0.012 ~ 0.039 (0.0005 ~ 0.0015)
0.239 ~ 0.390 (0.0094 ~ 0.0153)
mm (in.)
mm (in.)
66 (2.5984)
53 (2.0866)
PU-6
mm (in.)
0.02 ~ 0.05
(0.0008 ~ 0.0020)
0.038 ~ 0.071 (0.3726 ~ 0.6962)

No 3 : 0.060 ~ 0.093 (0.5883 ~ 0.9120)
End play
mm (in.)
0.05 ~ 0.18
(0.0020 ~ 0.0071)
0.14 ~ 0.30 (0.0055 ~ 0.0118)
mm (in.)
0.13 (0.0051)
Flywheel
Runout
Cooling system
Cooling method
Forced circulation system
Coolant quantity
Opening
Pull opening
Type
20C (68F)
Resistance
80C (176F)
Main moving system
Thermostat

Crankshaft
main bearing cap
Cylinder head
bolts

Cylinder head bolt
(lmp.qt)
C (F)
C (F)
k
k
9.5 (8.2) Without heater 8.5 (7.3)
8 (6.9)
82 (179)
95 (203)
95 (203)
82 1.5 (179.6 27)

95 (203)
Thermister type
2.45 0.14
0,3222
2.45 0.14
0,3222
45 ~ 48 ( 4.5
~4.8)
68.6 (7.0) + 29.4 (3.0) + 90
75 ~85 (7.5 ~ 8.5)
78.4 (8.0) + 44.1 (4.5) + 90
19 ~ 21 (1.9 ~
2.1)
102.96 ~ 1152.77
(10.5 ~ 11.5)
44 ~ 74 (4.5 ~7.5) + 90 + 90
PU-7

Engine
Lubrication system
DSL 4D56-2.5
DSL J2-2.7
11.8~15.7(1.2~1.
6)
9.8 ~ 11.8 (1 ~
1 2)
Oil filter
Oil pan bolts
Oil pan drain plug
DSL JT-3.0
DSL JTA-3.0
21.5 ~ 24.5 (2.2 ~ 2.5)

15.7 ~ 22.5 (1.6 ~ 2.3)
34.3 ~ 44.1 (3.5 ~ 4.5)
34.3~44.1(3.5~4.5
)

Rated voltage
Starter No-load
charasteristics
Generator
Voltage
Amperage
Speed
Type
Rated voltage
Speed in use
V
A
Battery
Regulator setting
Type
Cold cranking
amperage
at -18C (-0 4F)
Reserve capacity
Specific gravity at
25C (77F)
12V, 2.0KW
11,5
130
3600rpm
12V / 75A
12V /95A
2.800
12 V, 2.2 kW
12
130
4500 rpm
12V / 95A
12V / 95A
-
Electronic built in type
14.4 0.3V
MF 100 AH
14.4 0.3V
PT80-33HL MF 100 AH
850A
900A
122 min.
182 min
1.280 0.01
PU-8
Fuel System
Engine Management
System
Fuel Tank
Fuel Return System
Manufacturer
Capacity
Type
ZEXEL
(lmp.qt
)
Mechanical Injection Pump
Electrical Injection
Pump
70 (61.59)
Return type
Clutch
Clutch operation
Clutch disc
Service standard
Clutch pedal stroke
Hydraulic System
Dry, single plate
Diaphragm spring type
15~22 (1.5~2.2)
20~30 (2.0~3.0)
10~15 (1.0~1.5)
23~27 (2.3~2.7)
mm (in.)
mm (in.)
145~150(5.7~5.9)
6~13 (0.24~0.51)
PU-9

Engine
DSL 4D56-2.5
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0
M5ZR1
4,270
2,282
1,414
1,000
0,813
3,814
3,727
With PTO/Standard
RT-10
Manual Transaxle
Type
Gear ratio
1st
2nd
3rd
4th
5th
Rev.
FGR
M/T oil quality

MT oil capacity
(lmp.qt)
2WD
4WD
2.4 (2.16)
4.186/4.117
2.371/2.272
1.432/1.425
1,000
0.806/0.871
4.130/3.958
4,444
SAE 75W-85, API GL-4
2.4(2.1)/2.2(1.9)
3.5(3.1)/3.3(2.9)
5,192
2,621
1,536
1,000
0,865
4,432
4,111
2.2(1.9)
3.3(2.9)
PU-10
Driveshaft
Propeller shaft
total length
Long wheelbase
High long wheelbase
Front (4WD)
1.4TON (2WD)
Run-out
Outer diameter
Rear axle
Differential
Lubricants
Rear axle housing type

Supporting type
Reduction gear type
Quality
Quantity (g)
Quality
Outer bearing
Quantity (g)
Quality
Oil seal
Quantity (g)
Quality
Hub inner
Quantity (g)
Quality
Grease cap inne
Quantity (g)
Inner bearing
Front hub
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
725.5 (28.56)
924 (36.38)
-
888.6 (34.98)
888.6 (34.98)
1052.1 (41.42)
888.6 (34.98)
0.3 (0.12)
63.5 (2.5)
Banjo type
Full-floating type
Hypoid gear
888.6 (34.98)
Li-COMPLEX(WBG-2)
About 10
Li-COMPLEX(WBG-2)
About 7
Li-COMPLEX(WBG-2)
About 2
Li-COMPLEX(WBG-2)
About 45
Li-COMPLEX(WBG-2)
About 7
PU-11

Engine
DSL 4D56-2.5
Quality
Quantity (g)
Quality
Rear hub
Outer bearing
Quantity (g)
Quality
Inner/Outer oil se
Quantity (g)
Quality
Universal joint
Quantity (g)
Quality
Differential carrier
Quantity (g)
Quality
Quantity (g)
Gear oil
Quality
Quantity (g)
Yoke flange mounting nut
Disc brake mounting nut
Knuckle to tie rod end mounting
Knuckle to upper arm ball joint mounting
Knuckle to lower arm ball joint mounting
Brake tube flare nut
Inner bearing
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0
Li-COMPLEX(WBG-2)
Required
Li-COMPLEX(WBG-2)
Required
Li-COMPLEX(WBG-2)
Required
ALVANIA EP #2
About 3.5
General zone(-30~30C): API GL-#4, GS 90(SAE 90)
Fill the reservoir to the plug hold (About 1.7)
Severe heat zone(30C Min.): API GL-#4, GS 90(SAE 140)
Severe frigid zone(-30C Max.): API GL-#5, GH 90(SAE 80)
50 ~ 60 (5 ~ 6)
120 ~ 140 ( 12 ~ 14)
65 ~ 87 (6.5 ~ 8.7)
34 ~ 45 (3.5 ~ 4.5)
140 ~ 180 (14 ~ 18)
140 ~ 180 (14 ~ 18)
22 ~ 30 (2.2 ~ 3)
PU-12
Knuckle to dust cover mounting

Rear axle shaft mounting bolt
Rear axle housing mounting nut
Differential carrier gear oil supply plug
Differential carrier gear oil drain plug
Differential carrier to rear axle housing mounting
Wheel sensor mounting
Front wheel nut
Rear wheel nut
16 ~ 23 (1.6 ~ 2.3)
60 ~ 75 (6 ~ 7.5)
80 ~ 110 (8 ~ 11)
40 ~ 55 (4 ~ 5.5)
40 ~ 55 (4 ~ 5.5)
23 ~ 27 (2.3 ~ 2.7)
8 ~ 10 (0.8 ~ 1)
190 ~ 220 (19 ~ 22)
190 ~ 220 (19 ~ 22)
Suspension System
Suspension type
Front
Torsion bar spring
Torsion bar spring
Leaf spring
1ton 2WD
1ton 4WD
1.4ton
Shock absorber type

Wheel size
1ton 2WD
1ton 4WD
1.4ton
5.0J 14"
5.0J 14"
5.5J 16"
Rear
Leaf spring
Leaf spring
Leaf spring
Gas pressurized
3.5J 12" 4.0J 13", 5.0J 14"
5.0J 14"
4.0J 13"
1ton 2WD
kgf/cm 2
(psi)
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/cm 2
(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)]
1.4ton
kgf/cm 2
(psi)
6.50R16-10P [4.7 (67)]
5.50R13-8P [3.6 (52)]

5.50R13-10P [5.4 (77)]
PU-13

1ton 2WD
Wheel alignment
1ton 4WD
1.4ton
Camber
Caster
Toe-in
King-pin
Camber
Caster
Toe-in
King-pin
Camber
Caster
Toe-in
King-pin
Front
00.5
3.00.5
03mm (00.118in.)
922'
00.5
3.70.5
02mm (00.079in.)
953'
0.670.5
1.50.5
32mm (0.1180.079in.)
7.85
Rear
-
Steering System
Type
Rack stroke
Steering angle
Inner
Outer
1ton
Rack and Pinion
PSF-3
mm (in.) 2WD: 176 (6.93) 4WD: 148 (5.83)
2WD: 38.72
4WD: 34.11
2WD: 35.35
4WD: 31.00
kPa
8826 ~ 9316 (90 ~ 95)
(kgf/cm
)
1.4ton
Ball & nut
39.00
30.00
PU-14

Bolt connecting universal joint to bevel gear
Pitman arm to drag link (1.4ton)
Drag link to knuckle arm (1.4ton)
Knuckle arm to center link (1.4ton)
Tie rod end to knuckle nut
Steering gear box to frame
35 ~ 45 (3.5 ~ 4.5)
17 ~ 26 (1.7 ~ 2.6)
22 ~ 27 (2.2 ~ 2.7)
22 ~ 27 (2.2 ~ 2.7)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
100 ~ 120 (10.0 ~ 12.0)
60 ~ 80 (6.0 ~ 8.0)
90 ~ 110 (9.0 ~ 11.0)
Brake System
Brake fluid
Quantity
Master cylinder
Type
I.D.
mm (in.)
mm (in.)
Tandem type
26.99 (1.06)
28.57 (1.12)
Provided
Without load
MPa
(kg/cm)
0.98 (10)
With load
MPa
(kg/cm)
5.49 (56)
K2500, K2700
K3000S

LSPV
Cut-in pressure
(Split point)
Decompression ratio
DOT 3 or DOT 4
As required
0.2 : 1
PU-15

Engine
Brake booster
Type
Effective diameter
DSL 4D56-2.5
Disc thickness
Pad thickness
K2500, K2700
K3000S
K2500, K2700
K3000S
K2500, K2700
K3000S
K2500, K2700
K3000S
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
K2500, K2700
K3000S
mm (in.)
mm (in.)
Cylinder type
Cylinder I.D.
Rear brake(Drum)
Type
Drum I.D.
2WD
4WD, K3000S
DSL JT-3.0
DSL JTA-3.0
Vacuum
8.0 : 1
Boosting ratio
Front brake(Disc)
Type
Disc O.D.
DSL J2-2.7
mm (in.)
mm (in.)
mm (in.)

278 (10.94)
294 (11.57)
26 (1.02)
35 (1.38)
11 (0.43)
17.4 (0.69)
Double piston
46 (1.81) 2
60.6 (2.39) 2
Dual servo
220 (0.87)
260 (1.02)
4.5 (0.18)
Automatic
PU-16
Parking brake
Type
Actuation
O.D=Outer Diameter
I.D=Inner Diameter
Service standard
Brake pedal height
Brake pedal stroke
stopper clearance
piston clearance
Parking brake lever stroke when lever
assembly is pulled with 196N (20kgf,
44lb force)
K2500, K2700
Front disc brake pad
K3000S
thickness (minimum)
K2500, K2700
K3000S
(minimum)
Front disc run out
K2500, K2700
Rear drum brake
K3000S
drum I.D. (maximum)

Lever
mm (in.)
mm (in.)
185 (7.28)
143 ~ 147 (5.63 ~ 5.79)
mm (in.)
0.5 ~ 1.0 (0.02 ~ 0.04)
mm (in.)
0 ~ 3 (0 ~ 0.11)
mm (in.)
0.6 ~ 1.4 (0.023 ~ 0.055) (at 500 mmHg vacuum)
mm (in.)
5 ~ 7 clicke
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)
2.0 (0.079)
1.0 (0.039)
24 (0.945)
33 (1.299)
0.02 (0.0008)
0.02 (0.0008)
1.0 (0.039)
221.5 (8.72)
261.5 (10.30)
PU-17

Engine
Bleeder screw
Front
Rear
Front
Caliper assembly
to knuckle
Rear
DSL 4D56-2.5
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0
9.8 ~ 15.7 (1.0 ~ 1.6)

12.7 ~ 15.7 (1.3 ~ 1.6)
6.8 ~ 8.8 (0.7 ~ 0.9)
12.7 ~ 16.7 (1.3 ~ 1.7)
21.6 ~ 31.4 (2.2 ~ 3.2)
117.7 ~ 137.3 (12 ~ 14)
24.5 ~ 29.4 (2.5 ~ 3.0)
10 ~ 15 (1.0 ~ 1.5)
13.7~ 19.6 (1.4 ~ 2.0)
7.8 ~ 9.8 (0.8 ~ 1.0)
4.9 ~ 10.8 (0.5 ~ 1.1)

Hood
Front door
Glass thickness
Seat belts
Type
Construction
Regulator system
mm (in.)
Windshield
mm (in.)
Front door
Driver's seat
Passenger's seat

X-ARM type
5.0 (0.1969)
3.2 (0.1260)
3 point type
3 point type
PU-18

Front fender
Mounting bolts
Hinge bolt(door side)
Hinge bolt(body side)
Checker bolt(door side)
Checker bolt(body side)
Latch screw
Front door
Striker screw
Outside handle bolt
Door channel nut
Door window regulator
Door glass screw
Cowl cross bar side
Crash pad
Cowl cross bar center
Mounting bolts
Front seat
Shutter lever mounting
Anchor mounting bolt
Seat belt
Buckle mounting bolt
7~9 (0.7~0.9)
22~26 (2.2~2.7)
33~41 (3.4~4.2)
7~11 (0.7~1.1)
17~26 (1.7~2.6)
8~11 (0.8~1.1)
17~22 (1.7~2.2)
7~11 (0.7~1.1)
8~12 (0.8~1.2)
4~6 (0.4~0.6)
8~12 (0.8~1.2)
7~11 (0.7~1.1)
19~26 (1.9~2.6)
19~26 (1.9~2.6)
34~54 (3.5~5.5)
7~11 (0.7~1.1)
39~54 (4.0~5.5)
39~54 (4.0~5.5)
39~54 (4.0~5.5)
PU-19

Engine
DSL 4D56-2.5
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0

Audio
Type
Power supply
Rated output
Speaker impedance
Antenna
Tuning type
Frequency range /
Channel space
AM/FM/Cassette (Logic deck)

DC 13.2V
Max 25W x 2
Max 41W x 4
4 x 2
4 x 4
80PF 75
87.5~108 MHz / 100KHz (General), 50KHz(Europe)
AM/FM/ Cassette
FM
AM
MW
Lighting system
Head lamp
Front position lamp
Front fog lamp
Rear tail/stop lamp
Back up lamp
License plate lamp
Room lamp
Rear fog lamp
High
Low
W
W
W
W
W
W
W
W
W
W
W
W
60
55
28/8
28/8
27
27/8
27
27
10
10
10 x 2
21
PU-20

Air conditioner
Type
Compressor
Oil type & Capacity
Condeser
Pulley type
Displacement
Heat rejection
High
Dual pressure switch

Low
Expansion valve
Refrigerant
Type
Type
Capacity
[psi
(kg/cm)
]
[psi
(kg/cm)
]
[oz.(g)]
Blower unit
Type
Blower
Speed step
Speed control
HS - 18
(Swash plate)
FD46XG(PAG)15
0
100cc
5PK - TYPE
10PA17C (Swash plate)

FD46XG(PAG)210 100cc
1PK - TYPE
180 cc/rev
10,000 10% Kcal/hr
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)
Block
R - 134a
15.87 0.88(450 25)
Actuator
Siroco fan
4 speed
Resistor
PU-21

DSL 4D56-2.5
Engine
Type
Heating capacity
Heater
method
Type
Cooling capacity
Evaporator
A/C ON/OFF
[C (F)]
DSL J2-2.7
DSL JT-3.0
DSL JTA-3.0
Pin & Tube type

4,550 - 5% Kcal/hr
Actuator
Cable
Drawn cup
4,000 -10% Kcal/hr
Thermistor
Off : 1.0 0.5 (33.8 32.9)
ON : 4.0 0.5 (39.2 32.9)
PU-22
General
Information
GI-1
Diagnosis Plug
4
12 11 10
2
9
1
6
20 19 18 17 16 15 14 13
Feature
Terminal
Ground
1
MELCO TCU
2
3
B+
4
Ground
4
CAN - Hi
6
FLASH
7
P/T K-Line
8
CAN - Hi
9
10
Feature
Terminal
11
Memory Power
12
13
CAN - Low
14
ON/START Input
15
16
CAN - Low
17
Chassis K-Line
18
Body K-Line
19
20
GI-2
OBD-II Plug
8
16 15 14 13 12 11 10
Terminal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Feature
Chassis K-Line
P/T K-Line
CAN - Hi
Ground
Ground
Vehicle Speed Sensor
J1850
Memory Power
L-Line
CAN - Low
Door Remote
Body K-Line
J1850
-
GI-3
Error Code (Pending Code)
(P 0 1 3 0)
XXXXX
Error Number (00-99)
1 - Fuel and Intake Air
2 - Fuel and Exhaust Air (Injection Cycle)
3 - Ignition System
4 - Additional Emission Control
5 - Speed and Idle System
6 - ECU Output Side
7 - Transmission
8 - Transmission
0 - ISO
1 - Manufacturer
B - Body
C - Chassis
P - Driveline
U - Network
GI-4
GI-1
GI-2
GI-3
GI-4
Chassis Number
Manufacturer
1
2
3
Model
Chassis
Manufacturer
K
N
Korea
KIA
E
A
C
D
Europe all
PKW
USA
LKW
MPV
Model Code
8
Motor
Transmission
Model
SA
JB
LD
MG
GH
UN
KM
BL
VQ
PU
Picanto
Rio
Cerato F/L
Magentis / Optima
Opirus F/L
Carens
Sportage
Sorento F/L
Carnival / Sedona
K2500 / K2700 / K3000
10
Model
Year
Y
11
Production
Location
5
Series Number
12
13
14
15
16
17
Consecutive Number
1
Chassis
22
24
52
55
13
23
01
03
06
21
26
91
96
4 door Sendan
5 door Hatchback
5 door Station Wagon
5 door SUV
Coach
Long Coach
Ultra long cargo box, Low deck, Standard cabin
Ultra long cargo box, Low deck, Super cabin
Ultra long cargo box, Low deck, Double cabin
Standard cargo box, High deck, Standard cabin
Standard cargo box, High deck, Double cabin
Standard cargo box, Low deck, Standard cabin
Standard cargo box, Low deck, Double cabin
GI-5
Motor
1
6
7
1.4 Gasoline (JB)

2.0 Gasoline (UN)
2.0 Diesel (KM)
2.5 Diesel (BL)
2.7 Diesel (PU)
2.9 Diesel (VQ)
1.6 Gasoline (JB, LD)
2.0 Gasoline (MG, KM)
2.4 Gasoline (BL)
2.0 Diesel (UN)
3.0 Diesel (PU)
1.1 Gasoline (SA)
2.0 Gasoline (LD)
2.7 Gasoline (KM)
3.5 Gasoline (BL)
2.5 Diesel (PU)
3.8 Gasoline (VQ)
1.5 Diesel (JB)
2.0 Diesel (LD)
2.7 Gasoline (MG)
3.5 Gasoline (GH)
2.5 Diesel (BL)
1.1 Diesel (SA)
1.5 Diesel (LD)
3.8 Gasoline (GH)
1.6 Diesel (LD)
1.6 Gasoline (LD)
Transmission
2
3
5
8
Manual (2WD)
Automatic (2WD)
5 Speed Manual (4WD)
4 Speed Automatic (4WD)
Model year
S
T
V
W
X
Y
1
2
3
4
5
6
7
8
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
Production plant
5
6
7
T
Whasung
Soha
Kwang Ju
Donghee Auto
GI-6
GI-1
GI-2
GI-3
GI-4
GI-5
GI-6
Abbreviation Explanation
Abbreviation
2WD
4WD
A.P.I.
A/C
A/T
AAS
ABDC
ABS
ACC
ACL
ACU
ADM
AFM
ALDL
AP
APS
AQS
AT(X)
ATDC
ATF
ATT
B+
BAC
BARO
BBDC
BCM
BDC
BPT
BS
BTDC
BTS
BUPT
English
2 Wheel Drive
4 Wheel Drive
A
American Petroleum Institute
Air Conditioning
Automatic Transmission
Air Adjust Screw
After Bottom Dead Center
Antilock Brake System
Accessories
Air Cleaner
Airbag Control Module
Assist Door Module
Air Flow Meter
Assembly Line Diagnostic Link
Accelerator Pedal
Accelerator Position Sensor
Air Quality Sensor
Automatic Transaxle
After Top Dead Center
Automatic Transaxle Fluid
Active Torque Transfer
B
Battery Positive Voltage
Bypass Air Control
Barometric Pressure
Before Bottom Dead Center
Body Control Module
Bottom Dead Center
Seat Belt Pretensioner
Seat Belt Buckle Switch
Before Top Dead Center
Seat Belt Tension Sensor
Seat Belt Buckle Pretensioner
GI-7
Abbreviation
English
C
CAB
CAC
CAN
CAS
CBS
CFI
CKPS
CLS
CM
CMPS
CO
CO2
CPP
CPU
CSP
CSS
CTP
CVVT
D.O.T.
DAB
DBV
DCC
DCL
DCV
DDM
DI
DIS
DLC
DLI
DRL
DOHC
DTC
DTM
DVC
Curtain Air Bag

Charge Air Cooler
Controller Area Network
Crank Angle Sensor
Conventional Brake System
Central Fuel Injection
Crankshaft Position Sensor
Closed Loop System
Control Module
Camshaft Position Sensor
Carbon Monoxide
Carbon Dioxide
Clutch Pedal Position
Central Processing Unit
Control Sleeve Position Sensor
Control Sleeve Sensor
Closed Throttle Position
Continuously Variable Valve Timing
D
Department of Transport
Driver Airbag
Diagonal Bracked Vehicle
Damper Clutch Control
Data Communication Link
Double Check Valve
Driver Door Module
Distributer Ignition
Driving Information System
Data Link Connector
Distributorless Ignition
Daytime Running Light
Double Overhead Camshaft
Diagnostic Trouble Code
Diagnostic Test Mode
Driving Circle
GI-8
Abbreviation
English
E
E/L
EBD
EC-AT
ECM
ECS
ECTS
ECU
EEC
EEPROM
EFI
EGR
ELR
EPS
ESC
ESP
EST
ETACS
ETS
EVAP
EX
FAM
FC
FCV
FIP
FIS
GEN
GND
HC
HCU
HECU
HFM
HIVEC
HO2S
Electric Load
Electronic Brakeforce Distribution
Electronically Controlled Automatic Transaxle
Engine Control Module
Electronic Control Suspension
Engine Coolant Temperature Sensor
Electronic Control Unit
Electronic Engine Control
Electrically Eraseable Programable Read Only Memory
Electronic Fuel Injection
Exhaust Gas Recirculation
Emergency Locking Retractor
Electric Power Steering
Electronic Stability Control
Electronic Stability Program
Electric Shift Transfer
Electronic Time & Alarm Control System
Electronic Throttle System
Evaporative Emission
Exhaust
F
Front Area Module
Fan Control
Fuel Cut Valve
Fuel Injection Pump
Front Impact Sensor
G
Generator
Ground
H
Hydrocarbons
Hydraulic Control Module
Hydraulic & Electric Control Unit
Hot Film Meter
Hyundai Intelligent VehicleElectronic Control
Heated Oxygen Sensor
GI-9
Abbreviation
English
I
IAC
IATS
ICM
IG
IMS
IN
INT
IPM
ISCA
KS
LED
LF
LH
LHD
LIN
LO
LR
LSD
M/S
MAFS
MAPS
MAT
MCC
MFL
MIL
MLA
MT(X)
NC
NO
NOX
NTC
Idle Air Control

Intake Air Temperature Sensor
Intergrated Circuit Module
Ignition
Integrated Memory System
Intake
Intermittent
In-Panel Module
Idle Speed Control Actuator
J
K
Knock Sensor
L
Light Emitting Diode
Links Front
Left Hand
Left Hand Drive
Local Interconnect Network
Low
Left Rear
Limited Slip Differential
M
Manual Steering
Mass Air Flow Sensor
Manifold Absolute Pressure Sensor
Manifold Air Temperature
Manifold Catalytic Converter
Multipoint Fuel Injection
Malfunction Indicator Lamp
Mechanical Lash Adjuster
Manual Transaxle
N
Normal Closed
Normal Open
Nitrogen of Oxide
Negative Temperature Coefficient
GI-10
Abbreviation
English
O
OBD
OC
OCV
OD
OHC
OL
OTS
P/S
P/W
PAB
PAD LAMP
PCM
PCSV
PCV
PID
PNP
PRC
PSD
PSP
PTC
PTC
PTG
QTY
RAM
RF
RH
RHD
RKE
ROZ
RPM
RR
RSE
On Board Diagnosis
Oxidation Catalytic Converter
Oil Control Valve
Overdrive
Overhead Camshaft
Open Loop
CVVT Oil Temperature Sensor
P
Power Steering
Power Window
Passenger Air Bag
Passenger Air Bag Deactivation Lamp
Powertrain Control Module
Purge Control Solenoid Valve
Positive Crankcase Ventilation
Parameter Identification Data
Park / Neutral Position
Pressure Regulator Control
Power Sliding Door
Power Steering Pressure
Positive Temperature Coefficient
Pending Trouble Code
Power Tail Gate
Q
Quantity
R
Rear Area Module
Right Front
Right Hand
Right Hand Drive
Remote Keyless Entry
Research Octan value
Rounds Per Minute
Right Rear
Rear Seat Entertainment
GI-11
Abbreviation
English
S
SAB
SAE
SAS
SAS
SFI
SIS
SRS
SRSCM
SST
ST
STPS
SW
TAS
TB
TBI
TC
TCC
TCC
TCI
TCM
TCS
TCV
TDC
TFT
TNS
TOD
TPMS
TPS
TPS
TR
TWC
UCC
Side Airbag
Society of Automotive Engineers
Sophisticated Air Bag Sensor
Start Adjust Screw
Sequential Fuel Injection
Side Impact Sensor
Supplemental Restraint System
Supplemental Restraint System Control Module
Special Service Tool
Start
Seat Track Position Sensor
Switch
T
Throttle Adjusting Screw
Throttle Body
Throttle Body Injection
Turbocharger
Torque Converter Clutch
Torque Converter Control
Turbo Charger Intercooler
Transmission Control Module
Traction Control System
Timer Control Valve
Top Dead Center
Transaxle Fluid Temperature
Tail Number Side
Torque On Demmand
Tire Pressure Monitoring System
Throttle Position Sensor
Timing Position Sensor
Transmission Range
Three Way Catalytic Converter
U
Underfloor Catalytic Converter
GI-12
Abbreviation
English
V
V/P
VAC
VAF
VAS
VCM
VDC
VFS
VICS
VIM
VIN
VR
VREF
VSS
VSS
WCC
WOT
WSS
Vacuum Pump
Vacuum
Volume Air Flow
Voice Alarm System
Vehicle Control Module
Vehicle Dynamic Control
Variable Force Solenoid
Variable Inertia Charging System
Vehicle Immobilizer Module
Vehicle Identification Number
Voltage Regulator
Reference Voltage
W
Warm-up Catalytic Converter
Wide Open Throttle
Wheel Speed Sensor
X
Y
Z
GI-13
Unit Conversion
Unit
in
ft
Yard
Meile
in2
ft2
Yard
in3
qt
Gallone
Yard
lb
Ton
kg
kp
oz
lb
mph
Multiplier
Length
25,4
0,3048
0,9144
1,609
Surface
645,2
0,0929
0,8361
Volume
16387
0,9464
3,7854
0,7646
Weight
0,4536
907,18
Force
9,807
9,807
0,278
4,448
Speed
1,6093
Unit
Unit
mm
m
m
km
ft/sec2
in/sec2
mm2
m2
m2
in-lb
ft-lb
mkp
kg.m
mm3
l
l
m3
PS
kg
kg
psi
kp/cm2
bar
mmHg
N
N
N
N
ft-lb
kWh
km/h
Multiplier
Acceleration
0,3048
0,0254
Torque
0,11298
1,3558
9,807
9,807
Power
0,746
Pressure
6,895
9,807
100000
1,333
Energy
1,3558
3600000
Unit
m/s2
m/s2
Nm
Nm
Nm
Nm
Kw
kPa
bar
Pa
mbar
J
J
Fuel consumption
mpg
0,4251
km/l
C = 5/9 (F - 32), F = 9/5 (C + 32)
GI-1

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2010

All New Cerato / Forte*

K2500 / K2700 / K3000

General Specifications - Picanto

147.1 (1.5) [at

Less than 0.03 (0.0012)

Less than 0.05 (0.0020)

mm (in.) 33.941 ~ 34.141 (1.3363 ~ 1.3441)

mm (in.) 34.055 ~ 34.255 (1.3407 ~ 1.3486)

LH: 35.452 ~ 35.652 (1.3957 ~

Bearing oil clearance

0.045 ~ 0.085 (0.0018 ~ 0.0033)

0.07 ~ 0.19 (0.0028 ~ 0.0075)

General Specifications - Picanto

5.465 ~ 5.480 (0.2152 ~ 0.2157)

5.430 ~ 5.450 (0.2138 ~ 0.2146)

0.020 ~ 0.047 (0.0008 ~ 0.0019)

0.050 ~ 0.082 (0.0020 ~ 0.0032)

Stem outer diameter

0.9 ~ 1.3 (0.0354 ~ 0.0512)

15.60.9kg / 32.0 (1.2598)

Less than 1.5

Less than 1.5

Width of seat contact

mm (in.) 17.010 ~ 17.028 (0.6697 ~ 0.6704)

mm (in.) 67.000 ~ 67.030 (2.6378 ~ 2.6390)

Flatness of gasket surface

Less than 0.05 (0.002)

Less than 0.05 (0.0020)

Piston outer diameter

66.000 ~ 67.030 66.970 ~ 67.000

Piston to cylinder clearance

0.020 ~ 0.040 (0.0008 ~ 0.0016)

No. 1 ring groovemm (in.)

1.22 ~ 1.24 (0.0480 ~ 0.0488)

No. 2 ring groovemm (in.)

1.21 ~ 1.23 (0.0476 ~ 0.0484)

Ring groove width

Oil ring groove

General Specifications - Picanto

No. 1 ring groovemm (in.)

0.03 ~ 0.07 (0.0012 ~ 0.0028)

No. 2 ring groovemm (in.)

0.02 ~ 0.06 (0.0008 ~ 0.0024)

Oil ring groove

No. 1 ring groovemm (in.)

0.15 ~ 0.30 (0.0059 ~ 0.0118)

No. 2 ring groovemm (in.)

0.20 ~ 0.70 (0.0079 ~ 0.0276)

Oil ring groove

mm (in.) 17.000 ~ 17.003 (0.6693 ~ 0.6694)

Piston pin hole inner diameter

mm (in.) 17.011 ~ 17.015 (0.6697 ~ 0.6699)

Piston pin hole clearance

Connecting rod big end inner diameter

mm (in.) 41.000 ~ 41.015 (1.6142 ~ 1.6148)

Connecting rod bearing oil clearance

0.012 ~ 0.041 (0.0005 ~ 0.0016)

0.10 ~ 0.25 (0.0039 ~ 0.0098)

mm (in.) 41.982 ~ 42.000 (1.6528 ~ 1.6535)

Pin journal outer diameter

mm (in.) 37.980 ~ 38.000 (1.4953 ~ 1.4961)