Quality Problem & Trouble Shooting

Subject Models Condition

Quality problem Improvement No. Improve the sensor plate of material 1 4WD motor malfunction Noise from steering lower shaft Supplier changer ; 2 3 Battery discharge 4 5 6 7 8 9 From Korea spindle to Mando co. Separate fuses and battery terminal in shipping. Muffler corrosion Will change the material in new model Oil leak from clutch M/cylinder Change piston material from Zn to Poly Oil leak from upper timing cover 1. Change the gasket material to FPM 2. Add Loctite 5900 ECU malfunction on gasoline Improve the internal material; IC & rubber seal from rubber to silicon Idl RPM surging in cold start 1. Model change the thermo valve 2. Will change the Inj. Pump Develop the new model which is Water pump malfunction reinforced the bearing and grease Hard shifting of T/M gear 1. Change the lever type to 2 pivot type 2. Shifting type from cable to semi remote

International A/S & Parts Team 2001.08.10

Quality improvement of 4WD Musso & Korando

Date Dec.'97 Jul.'99 Jan.'98 Rmk Campaign

Oct.'97 Sep.'97 Apl.'97 Apl.'01 Oct.'99 Feb.'97 Jul.13.00 Musso May.12.00 Korando Dec.'97 Feb.11.00 Jun.5.00 Oct.'98 on test Dec.30.00 ISB2001014

10

11 T/C malfunction (oil leak & oil pump) 12 Noise of the brake pad, front

13 14 15

16 17

18

1. Improve the gasket surface 2. Improve the oil pump 1. Improve the friction specification ; of 0.41 to 0.49 for all range 2. Add the low temp lubrication Noise when to steer in corner Improve the steering wheel to prevent the latch to deviate Oil leak from T/M Change the oil seal dimension of input shaft Low efficient of park brake 1. Musso : Up the angle of front cable guide pipe to 10mm Extend the front cable end screw 2. Musso/Korando Reduce the return spring turns Impossible immobilize coding Service campaign for the new program of VDO model ; distributed the updated program by e-mail Warning lamp on of TOD & 4WD 1. Change the internal Micom 2. Improve the software 3. Identification : silver color A special lot damage Crack the towing hook ; Add a steel bar

Mar.'00 Jun.'00 Jul.'00 Musso Korando Iceland

ISB2001014

Quality Problem & Trouble Shooting

Subject Models Condition
Quality problem No. 19 Pressure leak and no start of fuel pump 20 Crack of the dust cover of windshield wiper link 21 Center lock malfunction Improvement Change the pressure O-ring

International A/S & Parts Team 2001.08.10

Quality improvement of 4WD Musso & Korando

Date Aug.'98 Rmk

22 Noise from catalytic convertor 23 Crack of the T/M housing 24 Shock and harsh gear shifting of BTRA 25 Stics unit malfunction 26 Rear seat vibration

27 Heat the battery

28 Oil leak from air breather 0f front axle

Change the model of dust cover Apl.'99 Musso model to Korando type 1. Change the avtuator rod angle Oct.'99 2. Change the actuator connector location to prevent water ingress 1. Change the model of dust cover for Musso Apl.'99 2. Change the model from clamsheel to toniquett Jul.'99 1. Improve tighten torque of plane damper plateFeb.'00 2. Improve the Rubber compound Change harness fixing point to prevent Dec.'98 inteference between main harness and T/C hous'g Add watch dog timer function May.'00 Add a damper under seat, 2 pcs Nov.'99 1. Add the heat protecter Apl.'98 2. Change the battery position Y170 raise up the height of air breather nipple Sep.'96

Campaign

Musso Korando

Musso

Quality Problem & Trouble Shooting

Subject Models Phenomenon
- The warning light for ABS does not go off

International A/S & Parts Team 2001.11.04

ABS/ABD warning lamp light on MUSSO '2000 M/Y

Main cause
- ABS wiring harness is damaged by interference with BRACKET-CTR SUPT.

Work procedure
- Check the damage of ABS wiring by interference with BRACKET-CTR SUPT. - Taping and re-routing the ABS wiring to the right side of BRACKET-CTR SUPT. <After> <Before>

ABS wiring

center support bracket

- Detail work procedure is attached. Refer to it.

Improvement history
- The main wiring route was changed : Jan.31, 2001. vin No.: 244624 ~

Quality Problem & Trouble Shooting

Subject Models Phenomenon

International A/S & Parts Team 2001.08.10

High vibrating sound coming from the gear shift lever (M/T) MUSSO & KORANDO with the SHIFT A-SEMI REMOTE

- When driving you can hear a sound coming from the gear lever (in all gears but also in nutral above 1200 rpm), and when you carefully touch the lever knob you cal also feel it. But when you slightly push the lever to any side the sound disappears.

Main cause
- The improper clearance of Shift A-REMOTE

improper clearance

Work procedure
- Replace the SHIFT A SEMI REMOTE with new one.

Improvement history
- 1st. : Jul.15, 2001 Hole size of the shift rail is decreased (4.88 ~ 4.99 -> 4.75 ~ 4.88) Hole size of the U-joint is decreased (6.05 ~ 6.10 -> 6.01 ~ 6.06) - 2nd. : Aug.20, 2001 Metal Bush is deleted Length of the plastic insert on Lower rod is increased(1.5mm) - Part No. : TTEC1257

Quality Problem & Trouble Shooting

Subject Models Phenomenon
- Noise will happen when vehicle drives the rough road. CHASSIS NOISE Musso & Korando

International A/S & Parts Team 2001.11.04

Main cause
- The nut for stabilizer link upper mt'g are losing.

LINK A-STABILIZER STABILIZER LINK UPPER MT'G NUT

ARM A-FRT SUSP LWR

Work procedure
- Tighten all related bolts or nut under chassis.

Improvement history
1. Change the type of the Stablizer bar mt'g nut ( Flange nut -> Lock nut ) : '98.08.18 2. Check and Control the tithening torque with T/Q control impact (6.0 ~ 8.0kgm) : '99.04.16

Quality Problem & Trouble Shooting

Subject Models Phenomenon
- Shifting is impossible in the P position

International A/S & Parts Team 2001.11.04

Gear shift lever was locked in the P position Musso with the Auto Transmission

Main cause
- Brake fuse was blown for over voltage due to excessive accessories.

Work procedure
- A/T emergency shifting procedure Turn ignition off Remove the cover Push the shift lock release lever by inserting a proper stick. Then , with the brake pedal depressed, move the selector lever to N(neutral) Start engine and shift into the gear - Replace the FUSE(F6) with new one. - Remove the excessive accessories which is cause of over voltage.

Improvement history : 01.07.25 ~

- Brake fuse capacity increased ( 15A 20A) - Wire square increased ( 0.85 sq. 1.25 sq.)

Quality Problem & Trouble Shooting

Subject Models Phenomenon
- Accel pedal operating force is excessive.

International A/S & Parts Team 2001.11.04

Accel pedal operating force is excessive MUSSO with the BTR A/T

Main Cause
- Injection damper Function of the injection damper : Protecting the jucking
injection damper

Work procedure
- Remove the damper a-injection. - In case the manual transmission, do not remove it.

Improvement history :
- The injection damper was deleted : '01.05.24 (only A/T vehicle)

Quality Problem & Trouble Shooting

Subject Models Phenomenon

International A/S & Parts Team 2001.11.04

ECS warning lamp on and malfunction musso and korando

- When Ignitation switch is on, ECS warning lamp is on and ECS system is not operated.

Main Cause
- The ECS wiring of wheel - G sensor is cutted

Work procedure
- Refer to the enclosed

Improvement history :
- ECS wiring band'g clip was applied : 2000.09.26

T/shoot'g for replace the wheel-G sensor wiring

1. Remove the front right tire.

2. Remove the wheel-G sensor wiring.

cutted point

3. Remove the wheel-G sensor mt'g bolt.

4. Insert the clip-open-ct and Assemble the mt'g bolt.

FRONT MT'G BOLT

CLIP-OPEN-CT

5. Assemble the wiring

6. Hold the wiring with clip-open-ct. (The wiring length which is from connector to holding point is 70~80mm)

holding point

wiring length is 70~80mm

Required parts : 1. CLIP-OPEN-CT(M35) 1 EA (Part No.: 94427 - 35000) 2. Wheel-G sensor wiring 1 EA (Part No.: 82920 - 05620)

Quality Problem & Trouble Shooting

Subject Models Phenomenon

International A/S & Parts Team 2001.11.04

Noise and oil leakage of the S/ABS Musso & Korando

- Noise and oil leakage will be occurred in the ABSORBER A-SHOCK during the driving

Main cause
- OIL SEAL and ROD is damaged - OIL SEAL is loose or improperly connected.

Rear shock absorber

Work procedure
- Replace the SHOCK ABSORBER with new one.

Improvement history
- Length of o/sheet is extended (10mm up) 01.07.28 - Thickness of oil seal washer is increased ( 0.8T -> 1.0T). '01.08.30 - Improvement the seal inserting equipment '01.03.02 (jig diameter : 23 ->23.3, jig height : 3.7mm -> 3.0mm)

Quality Problem & Trouble Shooting

Subject Models Phenomenon

International A/S & Parts Team 2001.11.04

Shift shock is occurred when the A/T is shifted form 1st to 2nd musso and korando with BTR A/T

- When engien is cold, excessive shift shock is occurred in the shifting from 2nd to 1st (It is occurred only A/T is in the cold condition)

Main Cause
- The operating time of B1 brake is short.

Work procedure
- Replace the TCU - Replace the valve body

Improvement history :
[TCU]

- The TCU Program is changed : Dec.22,1999 ( MUSSO : 189293 ~, KORANDO : 73155) - The part number is not changed - Distinguishing point Before After 1. TCU label #1 and yellow sticker is attached. 1. TCU label #1 and red or blue sticker is attached. 2. TCU label #2

Quality Problem & Trouble Shooting

Subject Models 1. Condition
Item Statue Cause Contents - Vibration of safety lock knob of door - Noise caused by clearance between safety lock knob and rod. - Friction noise of inner panel hole and knob rod of door. - Increase coating thickness of rod screw. - Change to bending angle of knob rod.

International A/S & Parts Team 2001.08.10

Noise of door trim Musso

- Light noise of inside handle and low side of door - Friction noise between rod of inside handle and vinyl seal. - Friction noise caused by clearance between door trim and inner panel of door. - Noise of speaker of door. - Attached sponge to the friction portion. (size ; 30*45*25T) - Attached pad to the center portion of door trim. (size : 15*200*5T) - Attached pad to the speaker. (size : 30*45*25T)

Service

work

knob

inner panel of door

rod

friction noise caused by small clearance between rod and inner panel

Occur a vibration noise of door trim(SIZE:30 X 45 X 25T) (30 x 45 x 25t PAD)

Quality Problem & Trouble Shooting

Subject Models 1. Condition
- Occur the noise of tail gate door during driving.

International A/S & Parts Team

Noise of tail gate Musso

2. Cause
- Interference between door latch and striker caused by improper assembly tail gate door to the body. - Interference between door latch and striker while the door closed. - Vibration of safety knob of door latch.

3. Service work
- Adjust to the door striker inner direction. - Adjust height of door striker by height adjust shim.

- Attached pad to the door safety lock knob trim. *Figure

Door striker

Height adjust shim

Safety lock knob

* Reference - Tight torque of door striker : 1.1~1.4kgfm

Quality Problem & Trouble Shooting

Subject Models 1. Condition
Interference of splash guard Musso

International A/S & Parts Team

- The light noise occurred under body when handle is full steering during driving. - The noise disappear or characteristic noise change at sometimes. - This status has mainly left side steering. There is misunderstanding caused by suspension or steering system problem.

2. Cause
- Interference between splash guard and tire when steers.

Cutting portion Splash guard

Interference portion

3. Service work
- Cutting of splash guard. (refer the above figure). The splash guard placed inner side in natural.

Quality Problem & Trouble Shooting

Subject Models 1. Condition
1) Fault of auto door locking during driving. 2) Fault of setting REKES. - Not operate combi lamp when set REKES. (STICKS controls combi lamp.) - Not operate combi lamp when remoter set when key remind switch is "ON". - Not operate combi lamp when key remind terminal no.4 removed.

International A/S & Parts Team

Fault of key remind switch Musso

2. Cause
1) Fault of auto door lock during driving. - Doesn't recognize ignition key caused by broken to inner plastic of key remind switch. 2) Fault of setting REKES. - Impossible setting of REKES caused by the key remind switch recognized key all the time.

3. Service work
1) Replace the inner plastic of key remind switch when doesn't operate auto door lock. 2) Replace the key remind switch when REKES doesn't set.

 Application table of Planar

- Model : Musso, Korando and Rexton Part number by supplier Pyung-Hwa Kun-Hwa

Damper on the transfer case by vehicle descriptions

Jan.04,2002 Identified indication of plane damper Before new BTRA A/T MT 2M/2TM 2M/2TM After new BTRA A/T (Current) Vehicle descriptions Remarks

Characteristic number of vibrations

Model

Engine

Transmission

M,K M,K M,K M,K M M,K,R R M,K M,K K M,K K M,K K M,K K M,K M,K K R R M

662NA 662NA, 662LA 662NA 662LA 661LA E32 662LA 662LA 661LA 661LA 661LA 661LA 661LA 661LA 661LA 661LA E32 662LA 662NA 662LA 661LA 661LA

Direct link type M/T M/T MB A/T MB A/T BTRA A/T New BTRA A/T M/T BTRA A/T M/T BTRA A/T M/T New BTRA A/T M/T BTRA A/T M/T New BTRA A/T BTRA A/T New BTRA A/T New BTRA A/T New BTRA A/T M/T New BTRA A/T

1 2

32040 05001 32040 05011 32040 05100 32040 05110 32040 05311 32040 05312

73 78

Old type manual transmission (Before cable link type)

Model out

92

AT,1LBA 3A R2TM 2LBA 1LM,BA

Model out Model out Model out Add Rexton Add Rexton Model out Model out

32040 05210

83

32040 05500 1TMA 5 32040 05510 1TMA 32040 05710 6 32040 05610 86 3A/T 2TA/2A M1TA,R2TA, R1TM 118 1LM,BA 1LM,BA

Model out

32040 05410

96

Add Rexton Add Rexton

Annotations A : A/T (Automatic transmission), M : M/T (Manual transmission), T : Turbo intercooler M : Musso, K : Korando, R : Rexton (New vehicle of Ssangyong motor co.) 662NA : 5-cylinder non-turbo, 661LA : 4-cylinder turbo intercooler, 662LA : 5-cylinder turbo intercooler, E32 : Gasoline 3.2L (Inline-6) BTRA A/T : 4-shift automatic transmission of BTR automotive (M74 ; Electronic type) MB A/T : 4-shift automatic transmission of Mercedes Benz (DaimlerChrysler) (W4A040 ; Hydraulic type) M/T : 5-shift manual transmission of Tremec (BorgWarner) (T5 WC) New BTRA A/T : Bell shape type, BTRA A/T (Before new BTRA A/T) : T-rib type

Bulletin No. Date Component catagory Distribution

: : :

OSB-2000046 AUG 14, 2000

09-BODY & ACCESSORIES

Bulletin Group: :

TECHNICAL WORLD WIDE

SUBJECT : INFORMATION OF NEW STICS UNIT (REPLACEMENT AND REWORK OF STICS UNIT) MODELS : KORANDO CONDITION:
STICS in Korando model may not function properly, and this condition may be caused by unstability of STICS unit ground.

CORRECTION :
To get rid of the above condition, DWMC/SYMC have improved the STICS unit and add the ground point. Therefore, in case of STICS failure on KORANDO model, STICS unit should be replaced with a improved one, of which part number is '87110-06810'. And additional rework is necessary for STICS unit to be compatible regardless of model year.(Refer to the following rework procedure) Along with the improvement, some function of STICS unit were added or deleted to be compatible inevitably. * Added - WIPER INT MIST :Operated by operating the windshield wiper switch within 0.6 second. - AUTO DOOR LOCK : When vehicle speed is over 50km/h. - BRAKE SYSTEM WARNING LIGHT : Comes on for 4 seconds with ignition on and goes off, in case of the parking brake is not applied. - ROOM LAMP WARNING CHIME : Chime will sound and the mark lamp comes on with the ignition key being withdrawn when the co-driver side door as well as the driver side door is opened. * Deleted - DIAGNOSIS : To enable the new STICS to be compatible.

Work Procedure for Replacement of STICS Unit

1. Remove the STICS unit referring to the removal and installation procedure(Service Manual 9U-10) 2. Check the part number of STICS unit to clarify the model referring to the following table.

This service bulletin is intended for internal use only. All information, illustrations and specifications contained in this bulletin are based on the latest product information available at the time of issue.

Overseas Technical Service Team Tel: 82-32-509-7320 Fax: 82-32-509-7205 E-mail:[email protected]

Printed in Korea DAEWOO MOTORS CO., LTD

OSB-2000046 Page No:18 of 5

Classification of Korando Model According to the Part Number of STICS

MODEL BREAK POINT PART NUMBER REWORK K100( ~ MY 98) Before 034404 87110 - 06000 NEED K110(MY 99) After 034405 87110 - 06801 NEED KORANDO 2000(MY 00) After 81430 W/O BUGLAR ALARM 87110 - 06802

WITH BUGLAR ALARM 87110 - 06810 NO NEED(Only replace the part)

3. Rework the STICS wiring harness using extension wires of the table and referring to the following rework procedure.

Extension Wire for Rework

PART NO 87110 - 06860 K100 W/o REKES, W/IMMOBILIZER(TYPE A & C) 87110 - 06870 K100 : W/REKES, W B/ALARM(TYPE B & C) K110 : ONLY TYPE B NEEDED SPECIFICATION K100 W/REKES, W/O B/ALARM(TYPE A & C)

TYPE A(BLACK)

Terminal a(small) Terminal b(big)

TYPE B(BLACK)

TYPE

TYPE C(YELLOW)

TYPE C(YELLOW)

Rework Procedure of STICS Wiring Harness

A. Rework procedure for K100- W/REKES & W/O B/ALARM or W/O REKES & W/IMMOBILIZER (MED, META) - Connectors

W2

This service bulletin is intended for internal use only. All information, illustrations and specifications contained in this bulletin are based on the latest product information available at the time of issue.

Overseas Technical Service Team Tel: 82-32-509-7320 Fax: 82-32-509-7205 E-mail:[email protected]

Printed in Korea DAEWOO MOTORS CO., LTD

OSB-2000046 Page No:19 of 5

- Extension Wiring Harness

W6 : Tighten with a STICS mounting bolt. W4 : Splice with No. 44 wire

W3 : Splice with No. 29 wire

W5 :Insert the terminal b

W5 :Insert the terminal a

W3 :Insert to pin hole no 11

Mounting point to which the ring terminal is to be tightened.

- Rework Procedure
Work No. W1 W2 W3 53 39, 53 11, 29 Pin No. Description If there is a wire inserted to pin no. 53, remove and cut the wire off and tape it. Remove the wire of pin no. 39 and insert to the connector pin hole of no 53. Splice the Type C extension wire with the wire of pin no. 29 and then insert its terminal to the connector pin hole of no. 11. Splice the stripped terminal of Type A extension wire with the wire of pin no. 44. Insert the other terminal of the Type A extension wire to the connector at pin no.20(small) and pin no. 33(large) respect If not reworked Remark

Key hole illumination lamp does not go on. Internal failure of STICS Unlock impossible & continuous lock.

W4 W5

44 20, 33

W6

Malfunction may be caused because STICS ground is unstable. Malfunction may be caused because STICS ground is unstable. Interference between the buglar alarm and the immobilizer. Tighten the type A extn wire (Ring terminal) at the Malfunction may be caused because ground point, STICS mounting point, when assemblingSTICS ground is unstable. the new STICS unit.

B. Rework procedure for K100 - W/REKES, W B/ALARM - Connectors

W2

- Extension Wiring Harness

W3 : Splice with No. 29 wire

W6 : Tighten with a STICS mounting bolt.

W4 : Splice with No. 44 wire

W5 :Insert to pin hole no 20

W3 :Insert to pin hole no 11

This service bulletin is intended for internal use only. All information, illustrations and specifications contained in this bulletin are based on the latest product information available at the time of issue.

Overseas Technical Service Team Tel: 82-32-509-7320 Fax: 82-32-509-7205 E-mail:[email protected]

Printed in Korea DAEWOO MOTORS CO., LTD

OSB-2000046 Page No:20 of 5

- Rework Procedure
Work No. W1 W2 W3 53 39, 53 11, 29 Pin No. Description If there is a wire inserted to pin no. 53, remove and cut the wire off and tape it. Remove the wire from pin hole of no. 39 and insert to the connector at pin hole of no 53. Splice the Type C extension wire with the wire of pin no. 29 and then insert to the connector at pin hole of no. 11. Splice the Type B extension wire with the wire of pin no. 44. Insert the remaining terminal of the Type B extn wire to the connector at pin hole of no.20(small). If not reworked Remark

Key hole illumination lamp does not go on. Internal failure of STICS Unlock impossible & continuous lock.

W4 W5

44 20

W6

Malfunction may be caused because STICS ground is unstable. Malfunction may be caused because STICS ground is unstable. Interference between the buglar alarm and the immobilizer. Tighten the type A extn wire (Ring terminal) at the Malfunction may be caused because ground point, STICS mounting point, when assemblingSTICS ground is unstable. the new STICS unit.

C. Rework procedure for K110 - Connectors

- Extension Wiring Harness

W2 : Tighten with a STICS mounting bolt.

W1 : Splice with No. 44 wire

W1 :Insert to pin hole no 20

- Rework Procedure
Work No. W1 Pin No. 20, 44 Description If not reworked Remark Splice the Type B extension wire with Malfunction may be caused because the wire of pin no. 44 and then STICS ground is unstable. insert to the connector at pin hole of no. 20. Tighten the type B extn wire at the ground Malfunction may be caused because point, STICS mounting point, installing the new STICSSTICS ground is unstable. unit.

W2

D. Rework procedure for KORANDO 2000 Only replace the STICS unit. Notice : All the connectors of the above figures are wiring harness side. After splicing the extension wiring harness, insulate it with a heat shrinkage tube. 4. Connect the STICS wiring harness connectors to the new STICS unit(part no. : 87110-06810). 5. Tighten the STICS unit mounting bolt. 6. Check if the STICS unit functions properly.
This service bulletin is intended for internal use only. All information, illustrations and specifications contained in this bulletin are based on the latest product information available at the time of issue.

Overseas Technical Service Team Tel: 82-32-509-7320 Fax: 82-32-509-7205 E-mail:[email protected]

Printed in Korea DAEWOO MOTORS CO., LTD

OSB-2000046 Page No:21 of 5

PART INFORMATION:
Part Number 87110-06810 87110-06860 87110-06870 Part Description UNIT-STICS WIRING- EXTN STICS WIRING- EXTN STICS Q'TY 1 EA 1 EA 1 EA REMARK
K100 W/REKES &W/O B/ALARM W/O REKES, W/IMMO.(MED/META) K100 W/REKES &W B/ALARM K110

WARRANTY INFORMATION:
Operation Code T091032 T091033 Operation Description UNIT-STICS, Replacement and Rework(K100) UNIT-STICS, Replacement and Rework(K110) Operation Time 0.8 M/Hour 0.7 M/Hour

Nature Code : N92 Cause Code : R16

This service bulletin is intended for internal use only. All information, illustrations and specifications contained in this bulletin are based on the latest product information available at the time of issue.

Overseas Technical Service Team Tel: 82-32-509-7320 Fax: 82-32-509-7205 E-mail:[email protected]

Printed in Korea DAEWOO MOTORS CO., LTD

OSB-2000046 Page No:22 of 5

Quality Problem & Trouble Shooting

Subject Models 1. Phenomenon
- Noise comes from the Front Door trim inside when you drive the rough road. - When the vehicle is drove at low speed, if you operate the brake repearedly - Not operate combi lamp when set REKES. (STICKS controls combi lamp.) the noise is occurred.

International A/S & Parts Team

Noise from the Front Door (Left or Right) Musso, Korando

2. Main Cause
When the Front Door is closed, the Door Contact Switch which is installed to the 'B' pillar panel is operated slightly. And this operating noise is propagated through the 'B' pillar panel.

3. Service work
1. Check the above phenomenon. 2. Remove the Dor Contact Switch of noisy door side - If the noise does not come from, install the Door Contact Switch and then re-check the noise - If the noise is recurred, Replace the Door Contact Switch. - In case of the noise going on, Adjust the clearance between Door and Body panel.