troubleshooting(musso & korando)

8/12/2019 Troubleshooting(Musso & Korando)

1/23

No.1 4WD motor malfunction Improve the sensor plate of material Dec.'97 Campaign2 Noise from steering lower shaft Supplier changer ; Jul.'99

From Korea spindle to Mando co.3 Battery discharge Separate fuses and battery terminal Jan.'98

in shipping.4 Muffler corrosion Will change the material in new model5 Oil leak from clutch M/cylinder Change piston material from Zn to Poly Oct.'976 Oil leak from upper timing cover 1. Change the gasket material to FPM Sep.'97

2. Add Loctite 59007 ECU malfunction on gasoline Improve the internal material; Apl.'97IC & rubber seal from rubber to silicon

8 Idl RPM surging in cold start 1. Model change the thermo valve Apl.'01 ISB20010142. Will change the Inj. Pump

9 Water pump malfunction Develop the new model which is Oct.'99reinforced the bearing and grease

10 Hard shifting of T/M gear 1. Change the lever type to 2 pivot type Feb.'972. Shifting type from cable to semi remote Jul.13.00 Musso

May.12.00 Korando11 T/C malfunction 1. Improve the gasket surface Dec.'97

(oil leak & oil pump) 2. Improve the oil pump12 Noise of the brake pad, front 1. Improve the friction specification Feb.11.00

; of 0.41 to 0.49 for all range2. Add the low temp lubrication Jun.5.00

13 Noise when to steer in corner Improve the steering wheel to prevent Oct.'98 the latch to deviate

14 Oil leak from T/M Change the oil seal dimension of input shaft on test15 Low efficient of park brake 1. Musso : Dec.30.00

Up the angle of front cable guide pipe to 10mmExtend the front cable end screw2. Musso/KorandoReduce the return spring turns

16 Impossible immobilize coding Service campaign for the new program Mar.'00of VDO model ; distributed the updated program by e-mail

17 Warning lamp on of TOD & 4WD 1. Change the internal Micom Jun.'00 Musso2. Improve the software Jul.'00 Korando3. Identification : silver color

18 Crack the towing hook A special lot damage Iceland ; Add a steel bar

Quality improvement of 4WD

Musso & Korando

Quality problem Improvement Date Rmk

International A/S & PartsTeam

2001.08.10

Condition

Quality Problem & Trouble Shooting

Subject

Models


2/23


3/23

No.19 Pressure leak and no start Change the pressure O-ring

of fuel pump20 Crack of the dust cover of Change the model of dust cover Apl.'99 Campaign

windshield wiper link Musso model to Korando type21 Center lock malfunction 1. Change the avtuator rod angle Oct.'99

2. Change the actuator connector locationto prevent water ingress

22 Noise from catalytic convertor 1. Change the model of dust cover for Musso Apl.'99 Musso

2. Change the model from clamsheel to toniqueJul.'99 Korando23 Crack of the T/M housing 1. Improve tighten torque of plane damper plateFeb.'002. Improve the Rubber compound

24 Shock and harsh gear shifting Change harness fixing point to prevent Dec.'98of BTRA inteference between main harness and T/C hous'g

25 Stics unit malfunction Add watch dog timer function May.'0026 Rear seat vibration Add a damper under seat, 2 pcs Nov.'9927 Heat the battery 1. Add the heat protecter Apl.'98 Musso

2. Change the battery position Y17028 Oil leak from air breather raise up the height of air breather nipple Sep.'96

0f front axle

Aug.'98Quality problem Improvement Date Rmk

International A/S & PartsTeam

2001.08.10

Condition


Subject

Models

Quality improvement of 4WD

Musso & Korando


4/23

- The warning light for ABS does not go off

- 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.

- Detail work procedure is attached. Refer to it.

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

International A/S & Parts Team

2001.11.04

Phenomenon

Main cause


Subject

Models

ABS/ABD warning lamp light on

MUSSO '2000 M/Y

center support bracket

BS wiring


5/23

- When driving you can hear a sound coming from the gear lever (in all gears but also in nutralabove 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.

- The improper clearance of Shift A-REMOTE

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


2001.08.10

Phenomenon

Main cause


Subject

Models

High vibrating sound coming from the gear shift lever (M/T)

MUSSO & KORANDO with the SHIFT A-SEMI REMOTE

improper clearance


6/23

- Noise will happen when vehicle drives the rough road.

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

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

Improvement history1. Change the type of the Stablizer bar mt'g nut ( Flange nut -> Lock nut ) : '98.08.182. Check and Control the tithening torque with T/Q control impact (6.0 ~ 8.0kgm) : '99.04.16


2001.11.04

Phenomenon

Main cause


Subject

Models

CHASSIS NOISE

Musso & Korando

LINK A-STABILIZER

STABILIZER LINK UPPERMT'G NUT

ARM A-FRT SUSP LWR


7/23

- Shifting is impossible in the P position

- 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.)


2001.11.04

Phenomenon

Main cause


Subject

Models

Gear shift lever was locked in the P position

Musso with the Auto Transmission


8/23

- Accel pedal operating force is excessive.

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

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)


2001.11.04

Phenomenon

Main Cause


Subject

Models

Accel pedal operating force is excessive

MUSSO with the BTR A/T

injectiondamper


9/23

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

- 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


2001.11.04

Phenomenon

Main Cause


Subject

Models

ECS warning lamp on and malfunction

musso and korando


10/23

1. Remove the front right tire.

2. Remove the wheel-G sensor wiring.

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

4. Insert the clip-open-ct

and Assemble the 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)

Required parts : 1. CLIP-OPEN-CT(M35) 1 EA (Part No.: 94427 - 35000)

2. Wheel-G sensor wiring 1 EA (Part No.: 82920 - 05620)

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

FRONT MT'G BOLT

wiring length is70~80mm

cutted point

holding point


11/23

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

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

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)


2001.11.04

Phenomenon

Main cause


Subject

Models

Noise and oil leakage of the S/ABS

Musso & Korando

Rear shock absorber


12/23

- 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)

- 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

1. TCU label #1 and yellow sticker is attached. 1. TCU label #1 and red or blue sticker is attached. 2. TCU label #2

Before After


2001.11.04

Phenomenon

Main Cause


Subject

Models

Shift shock is occurred when the A/T is shifted form 1st to 2nd

musso and korando with BTR A/T


13/23

1. Condition

Statue - Vibration of safety lock knob of door - Light noise of inside handle and low side of door

Cause - Noise caused by clearance between - Friction noise between rod of inside handle and safety lock knob and rod. vinyl seal.- Friction noise of inner panel hole and - Friction noise caused by clearance between

knob rod of door. door trim and inner panel of door.- Noise of speaker of door.

Service - Increase coating thickness of rod screw. - Attached sponge to the friction portion.

work - Change to bending angle of knob rod. (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)

Item Contents

Quality Problem & Trouble Shooting International A/S & Parts Team

2001.08.10

Subject Noise of door trim

Models Musso

inner panel ofdoor

friction noisecaused by smallclearance betweenrod and inner panel

knob

rod

Occur a vibration noise of

door trim (SIZE:30 X 45 X 25T) (30 x 45 x 25t PAD)


14/23

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

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

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

Models Musso

Quality Problem & Trouble Shooting International A/S & PartsTeam

Subject Noise of tail gate

Door striker Height adjust shimSafety lock knob


15/23

1. Condition - 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.

3. Service work - Cutting of splash guard. (refer the above figure).

The splash guard placed inner side in natural.

Models Musso


Subject Interference of splash guard

Splash guard

Interferenceportion

Cutting portion


16/23

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.

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.


Subject Fault of key remind switch

Models Musso


17/23

Application table of Planar Dam er on the transfer case by vehicle descriptions- Model : Musso, Korando and Rexton Jan.04

After newBTRA A/T(Current)

Model Engine Transmission

32040 0500132040 05011

32040 0510032040 05110

M,K 662NA MB A/TM,K 662LA MB A/T

M 661LA BTRA A/T32040 05312 3A M,K,R E32 New BTRA A/T Add Rexton

R2TM R 662LA M/T Add Rexton2LBA M,K 662LA BTRA A/T

M,K 661LA M/TK 661LA BTRA A/T

M,K 661LA M/T

K 661LA New BTRA A/TM,K 661LA M/T

K 661LA BTRA A/TM,K 661LA M/T

K 661LA New BTRA A/T32040 05710 3A/T M,K E32 BTRA A/T

M,K 662LA New BTRA A/TK 662NA New BTRA A/TR 662LA New BTRA A/T Add RextonR 661LA M/T Add RextonM 661LA New BTRA A/T

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

Remarks

332040 05311

92AT,1LBA

M/T2

1LM,BA32040 05500

32040 05510

7

2M/2TM 2M/2TM M,K

32040 05210

32040 05610 2TA/2A

32040 05410

4

6 86

5 118

M1TA,R2TA,R1TM

83

96

1TMA

1LM,BA 1LM,BA

1TMA

Direct linktype M/T

transmission

1

Vehicle descriptions

73 MT M,K

Part number by supplier Identified indication

of plane damper

78662NA,662LA

Pyung-Hwa Kun-Hwa

Characteristicnumber of vibrations

Beforenew

BTRA A/T

662NA


18/23

Bulletin No. : OSB-2000046

Date : AUG 14, 2000 Component catagory :

09-BODY & ACCESSORIES

Bulletin Grou : TECHNICAL

Distribution : 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 unstabilityof STICS unit ground.

CORRECTION :

To get rid of the above condition, DWMC/SYMC have improved the STICS unit and add the groundpoint. Therefore, in case of STICS failure on KORANDO model, STICS unit should be replacedwith a improved one, of which part number is '87110-06810'. And additional rework is necessaryfor 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 compa-tible 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 Unit1. 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 TeamTel: 82-32-509-7320Fax: 82-32-509-7205E-mail:[email protected]

Printed in KoreaDAEWOO MOTORS CO., LTD

OSB-2000046Page No:18 of 5


19/23

Classification of Korando Model According to the Part Number of STICS

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

Extension Wire for Rework

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



MODEL K100( ~ MY 98) K110(MY 99)

BREAK POINT Before 034404 After 034405

W/O BUGLAR ALARM 87110 - 06802

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

KORANDO 2000(MY 00)

After 81430

PART NUMBER 87110 - 06000 87110 - 06801

PART NO 87110 - 06860 87110 - 06870

SPECIFICATION K100 W/REKES, W/O B/ALARM(TYPE A & C) K100 : W/REKES, W B/ALARM(TYPE B & C)

K100 W/o REKES, W/IMMOBILIZER(TYPE A & C) K110 : ONLY TYPE B NEEDED

TYPE

TYPE A(BLACK) TYPE B(BLACK)

TYPE C(YELLOW) TYPE C(YELLOW)

Terminal a(small)

Terminal b(big)

W2





20/23

- Extension Wiring Harness

- Rework Procedure

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




Work No. Pin No. Description If not reworked Remark

W1 53 If there is a wire inserted to pin no. 53, remove andcut the wire off and tape i t.

W2 39, 53 Remove the wire of pin no. 39and insert to the connector pin hole of no 53.

Key hole illumination lamp does not go on.Internal failure of STICS

W3 11, 29 Splice the Type C extension wire with the wire of pinno. 29 and then insert its terminal to the connector pin hole of no. 11.

Unlock impossible & continuous lock.

W4 44 Splice the stripped terminal of Type A extension wirewith the wire of pin no. 44.

Malfunction may be caused becauseSTICS ground is unstable.

W5 20, 33 Insert the other terminal of the Type Aextension wire to the connector at pinno.20(small) and pin no. 33(large) respect

Malfunction may be caused because STICSground is unstable.Interference between the buglar alarm and theimmobilizer.

W6 Tighten the type A extn wire (Ring terminal) at the

ground point, STICS mounting point, when assemblinthe new STICS unit.

Malfunction may be caused because

STICS ground is unstable.

W2

Mounting point to which the ringterminalis to be tightened.

W3 : Splice with No. 29 wire

W3 :Insert to pin hole no 11

W4 : Splice with No.44 wire

W5 :Insert the terminalb

W6 : Tighten with a STICSmounting bolt.




W5 :Insert the terminala

W4 : Splice withNo. 44 wire

W5 :Insert topin hole no 20

Overseas Technical Service TeamTel: 82-32-509-7320Fax: 82-32-509-7205 Printed in Korea

DAEWOO MOTORS CO LTDOSB-200004


21/23

- Rework Procedure

C. Rework procedure for K110 - Connectors


- Rework Procedure

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.




W1 53 If there is a wire inserted to pin no. 53, remove andcut the wire off and tape it.

W2 39, 53 Remove the wire from pin hole of no. 39and insert to the connector at pin hole of no 53.

Key hole illumination lamp does not go on.Internal failure of STICS

W3 11, 29 Splice the Type C extension wire withthe wire of pin no. 29 and then

insert to the connector at pin hole of no. 11.

Unlock impossible & continuous lock.

W4 44 Splice the Type B extension wire withthe wire of pin no. 44.

Malfunction may be caused because STICSground is unstable.

W5 20 Insert the remaining terminal of the Type B extnwire to the connector at pin hole of no.20(small).

Malfunction may be caused because STICSground is unstable.Interference between the buglar alarm and theimmobilizer.

W6 Tighten the type A extn wire (Ring terminal) at theground point, STICS mounting point, when assemblinthe new STICS unit.



W1 20, 44 Splice the Type B extension wire withthe wire of pin no. 44 and theninsert to the connector at pin hole of no. 20.


W2 Tighten the type B extn wire at the groundpoint, STICS mounting point, installing the new STICunit.









22/23

PART INFORMATION:

WARRANTY INFORMATION:

Nature Code : N92 Cause Code : R16



Operation Code Operation Description Operation Time

T091032 UNIT-STICS, Replacement and Rework(K100) 0.8 M/Hour

T091033 UNIT-STICS, Replacement and Rework(K110) 0.7 M/Hour

Part Number Part Description Q'TY REMARK87110-06810 UNIT-STICS 1 EA

87110-06860 WIRING- EXTN STICS 1 EA K100 W/REKES &W/O B/ALARM W/O REKES, W/IMMO.(MED/MET

87110-06870 WIRING- EXTN STICS 1 EAK100 W/REKES &W B/ALARMK110





23/23

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 th - Not operate combi lamp when set REKES. (STICKS controls combi lamp.)

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.

Models Musso, Korando


Subject Noise from the Front Door (Left or Right)

troubleshooting(musso & korando)

Documents